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MINNESOTA STATE, MANKATO’S PLUG-IN HYBRID VEHICLE PROJECT Minnesota Plug-In Hybrid (PHEV) Task Force Meeting 11/17/2006 Dr. Bruce Jones & Dr. Vince Winstead Minnesota Center for Automotive Research (MnCAR) Minnesota State University, Mankato
MINNESOTA CENTER FOR AUTOMOTIVE RESEARCH • To provide industry and government with technical expertise in automotive research and product development • To provide undergraduate students the opportunity to become directly involved in comprehensive research projects
MSU PLUG-IN TEAM • Automotive Engineering Technology Undergraduate Students Cliff Backler Christopher Bahn Eric Esselman Jacob Kriesel Jon Liu Tony Reichel Luke Markham Jacob Wilson Nate Starkson • Capstone Senior Design Project One Year Project • Faculty Advisors Dr. Bruce Jones – Automotive Engineering Technology Dr. Vince Winstead – Electrical & Computer Engineering and Technology
PARTNERS • Corporate Sponsor • Xcel Energy • Public Partners • Minnesota Travel Management • Minnesota Department of Natural Resources • Minnesota Department of Transportation
PLUG-IN HYBRID PRIUS • WHAT • Multi-phase project started as a senior design project in the Automotive and Manufacturing Engineering Technology Department (Fall 2006) • Modify a stock Toyota Prius Hybrid with the goals of demonstrating increased fuel economy coupled with flexible fuel (ethanol blended) capability without increasing tailpipe emissions
PLUG-IN HYBRID PRIUS • Specific Goals • Average fuel economy of 100 MPG • Operation on E-85 fuel • No negative impacts to drivability • No increases in stock vehicle emissions level (as measured based on drive cycle test measurements)
PLUG-IN HYBRID PRIUS • Enablers • 100 MPG • Increased battery pack capacity through use of higher energy density chemistries and/or via increased pack size • Plug-In* capability to enable battery pack charging when the vehicle is not in use *Although energy gained from the “grid” is not free, its equivalent fuel cost can be relatively low and hence it can greatly improve average fuel economy.
PLUG-IN HYBRID PRIUS • Enablers • Flexible fuel capability • Materials compatibility testing • Consideration of fuel pump and injector capacity constraints
PLUG-IN HYBRID PRIUS • Enablers • Drivability • Placement of battery cells to distribute the increased mass within the frame and interior constraints • Design of enclosures and mounting to reduce relative movement between the vehicle and the added mass components • Close adherence to weight and balance constraints.
PLUG-IN HYBRID PRIUS • Enablers • No impact to drive cycle emissions • Increased usage of battery capacity over the drive cycle (allows electric only operation*) • Base-lining and emissions lab familiarization for repeatability • Extensive tailpipe emissions test and measurement *This becomes an optimization problem since other vehicle systems are effected during engine off conditions such as catalyst cooling, etc.
PLUG-IN HYBRID PRIUS • Vehicle Modifications • After baseline testing for fuel economy, emissions and drivability, the vehicle will be modified with a number of enhancements • The next few slides show the anticipated progression of modifications…
FLEXIBLE FUELED VEHICLES • Ability to Use ANY Blend of 0% to 85% Ethanol • Larger Fuel Injectors • Some Different Fuel System Materials • Some Vehicles Use a Special Sensor • Others Let the Computer “Learn” the Type of Fuel In-Line Fuel Sensor
PLUG-IN HYBRID PRIUS • “Intelligent” Controller
PLUG-IN HYBRID PRIUS • Analyzing Controller Area Network (CAN) Traffic
PLUG-IN HYBRID PRIUS • Current case studies and decision matrices Battery MatrixWeight and Balance Study
PLUG-IN HYBRID PRIUS • Current case studies and decision matrices Battery cell distribution
Insert flex-fuel kit to run on ethanol. Material compatibility testing will be done to see if ethanol corrodes or erodes the components of the fuel system, such as the fuel rail and fuel pump. E-85 HYBRID2006 Toyota Prius PCM ENGINE FUEL TANK ELECTRIC MOTOR GENERATOR
E-85 HYBRID • Conversion components