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Medium- and Heavy-DutyVehicle Duty Cycles forElectric PowertrainsKenneth KellyNREL Team: Kevin Bennion, Eric Miller, Bob ProhaskaNational Renewable Energy LaboratoryApplied Power Electronics ConferenceLong Beach, CAMarch 20-24, 2016NREL/PR-5400-66228NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
NREL Transportation RD&D Activities & ApplicationsVehicle Thermal ManagementIntegrated Thermal ManagementClimate Control/Idle ReductionAdvanced HVACVehicle Deployment/Clean CitiesGuidance & Information for Fleet DecisionMakers & Policy MakersTechnical AssistanceOnline Data, Tools, AnalysisVehicle Systems Modelingand SimulationConnected and AutomatedVehiclesVehicle Systems AnalysisRegulatory SupportEPAct ComplianceData & Policy AnalysisTechnical IntegrationFleet AssistanceInfrastructureVehicle-to-Grid IntegrationIntegration with RenewablesCharging Equipment & ControlsFueling Stations & EquipmentRoadway ElectrificationAutomationAdvanced Combustion/FuelsAdvanced Petroleum and BiofuelsCombustion/Emissions MeasurementsVehicle & Engine TestingVehicle and Fleet TestingMD/HD Dynamometer TestingMDV & HDV Testing/AnalysisDrive Cycle Analysis/Field EvaluationsTechnology Performance ComparisonsData Collection, Storage, & AnalysisAnalysis & Optimization ToolsIllustration by NRELAdvanced Power Electronicsand Electric MotorsThermal ManagementThermal Stress and ReliabilityAdvanced Energy StorageDevelopment, Testing, AnalysisThermal Characterization/ManagementLife/Abuse Testing/ModelingComputer-Aided EngineeringElectrode Material Development2
NREL Medium- and Heavy-Duty Fleet EvaluationsThis project provides medium-duty (MD) and heavyduty (HD) test results, aggregated data, and detailedanalysis. Third party unbiased data: Provides data that would notnormally be shared by industry in an aggregated anddetailed manner Over 5.6 million miles of advanced technology MD and HDtruck data have been collected, documented, and analyzedon over 240 different vehicles since 2002 Data, analysis, and reports are shared within DOE, nationallaboratory partners, and industry for R&D planning andstrategy developmentNREL 34433NREL 19908 Results:o Guide R&D for new technology developmento Help define intelligent use of newly developed technologyo Help fleets/users understand all aspects of advanced technologyNREL 183373
Medium- and Heavy- Vehicle Field Testing ApproachEvaluate the performance of alternative fuels and advancedtechnologies in MD and HD fleet vehicles in partnership withcommercial and government fleets and industry groups vehicles.Collect, analyze, and publicly report data:– Drive cycle and system duty cycle analysis– Operating cost/mile– In-use fuel economy– Chassis dynamometer emissions and fuel economy– Scheduled and unscheduled maintenance– Warranty issues– Reliability (% availability, miles between road calls)– Implementation issues/barriers– Subsystem performance data & metrics (energy storagesystem, engine, after-treatment, hybrid/electric vehicle [EV]drive focus)Data stored in Fleet DNA for security and limited publicaccessibilityFrequent interactions and briefings with stakeholders – fleets,technology providers, researchers, and government agenciesFleetsUPS, FedEx, Coke,Frito-Lay, FoothillTransit, PG&E, MiamiDade, Verizon, Walmart,Waste ManagementVehicle &EquipMfrsProterra, Navistar,Smith EV, Eaton,Allison, BAE, EDI, Altec,International, PACCAR,Oshkosh, dPublishedReports4
NREL Field Data & Analysis ToolsData from fieldevaluations helpspopulate Fleet DNAdatabaseCollect Laband Field DataDOE Fleet Tools (DRIVE, FASTSim,AFleet, etc.) used to analyze andinvestigate impacts – data usedto validate and improve toolsCapture, Storeand AnalyzeExplore &OptimizePublished information anddata used by fleets, industry,DOE and other researchprograms, and other agenciesCommunicate& InformIdentifyBarriers andNew R&DOpportunities,ValidateEffortsPartnership with Fleets and Technology Providers Relevant Results & OptimizedSolutions for Real World Applications5
Medium- and Heavy-Duty EV Data CollectionFoothill Transit EV12 Proterra EV transit busesEaton 500-kW fast chargerNREL 28804NREL 35803- Dedicated EV bus routein West Covina, CA- 1-Hz data from over92,000 miles of transitbus EV drivingNREL 35588EV Delivery Trucks459 Smith Newton EVsDistributed around U.S.- Frito-Lay, Staples, FedEx,Coca Cola, AT&T, PG&E- 1-Hz data from over 5million miles ofcommercial EV driving- Detailed Frito-Lay fieldstudyEV Delivery Vans101 class 2-3 electric vansDistributed around U.S.Port of LA – EV DrayageClass 8 tractor trailersTransPower and US HybridNREL 18624- Servicing Port of LAand surroundingdistribution centers- 1-Hz data from over24,000 miles ofcommercial EVdriving (on-going)Deployments include:- FedEx, Cascadia Dealer,PG&E- 1-Hz data from over353,000 miles ofcommercial EV driving6
EV Vehicle and Component Data – 1 HzVehicle Data ParametersComponent Data ParametersVehicle IDVehicle weight or massPayloadDoor statusTimestampOperation stateShifter positionTransmission gear state (if applicable)Accelerator positionBrake pedal on state or appliedpressureVehicle speedDistance drivenGPS latitudeGPS longitudeGPS elevationAmbient temperatureAir conditioner stateAir conditioner compressor powerHeater stateAir compressor status / pressureBattery currentBattery voltageBattery pack SOCBattery pack min cell voltageBattery pack max cell voltageBattery pack balance mode stateAC charging currentAC charging voltageBattery pack bulk temperatureBattery pack min cell temperatureBattery pack max cell temperatureMotor temperaturePower electronics/charger temperatureDC/DC voltageDC/DC currentMotor speedMotor torqueMotor power (electrical)7
EV Transit Bus Example:Foothill Transit / Proterra EV Transit BusVehicle SpecificationsLength (feet)35Curb Weight (lb)27,680GVWR (lb)37,320Capacity (passengers)35 Seated / 18 StandingNREL 500027Electric Drive SystemNREL 36043Battery (Mfr / Model)Altairnano - TerraVolt 368Battery Type368 V lithium titanateBattery (Energy/Capacity)88 kWh / 60 AhNumber of Packs(8) 6-floor, 2-roofMotor (Mfr / Model)UQM / PP220Motor Power (kW)120 Nominal / 220 PeakFast Charging Power (kW)5008
Foothill EV Bus Route & Duty Cycle OverviewDedicated EV Bus RoutePhoto: L. Eudy/NRELBus Daily Drive Cycle Statistics9
Typical Daily OperationSOC: state of charge10
Kinetic Intensity (KI) Kinetic Intensity is measure of drive cyclekinetics to define how much “stop and go” isin the cycleDerived from ratio of aerodynamic speed andcharacteristic accelerationo Characteristic acceleration: Measures the inertialwork to accelerate and/or raise the vehicle perunit mass per unit distance over the cycle.o Aerodynamic speed: Measures the ratio of theoverall average cubic speed to the average speedoDuty Cycle Characterization and Evaluation Towards Heavy Hybrid Vehicle 9.pdf11
EV Bus In-Use Motor Power CharacteristicsMotor Continuous Rating 120 kWPower duration (min)Duty Cycle StatisticsPhoto: L. Eudy/NRELDriving days774Kinetic intensity (1/mi)1.71Stops per mile3.70Avg acceleration (ft/s2)1.44Avg speed (mph)17.6612
Delivery Van (Class 3)Motor Continuous Rating 55 kWPower duration (min)Duty Cycle StatisticsDriving days17,447Kinetic intensity (1/mi)3.85Stops per mile5.85Avg acceleration (ft/s2)0.52Avg speed (mph)15.6NREL 1862413
Delivery Truck (Class 6)Motor Continuous Rating 80 kWPower duration (min)Duty Cycle StatisticsDriving days173,007Kinetic intensity (1/mi)1.78Stops per mile2.03Avg acceleration (ft/s2)1.01Avg speed (mph)21.6NREL 3446014
Drayage Truck (Class 8)Motor Continuous Rating 240 kWPower duration (min)Duty Cycle StatisticsDriving days173Kinetic intensity (1/mi)0.96Stops per mile1.18Avg acceleration (ft/s2)0.84Avg speed (mph)27.4NREL 3558415
Aggregate Delivery van has the highest peak tractionpower per vehicle mass Transit bus has the highest peak regenerationpower per vehicle mass Delivery van was driven most aggressively,while the bus had the least variation in dutycycle.16
Summary Understanding the vocational duty cycle is critical for appropriate sizing of EVcomponents for MD and HD plug-in EV applications. NREL has extensive in-usedata NREL field data show the ratio between peak power and continuous powerrequirements varies by vocation (motor specs shown in blue)o Transit Bus 160 kW / 60 kW (2.7) 220 kW / 120 kW (1.8)o Delivery Van 70 kW / 55 kW (4.0) 70 kW /55 kW (1.3)o Delivery Truck 90 kW / 40 kW (2.3) 150 kW / 80 kW (1.9)o Class 8 Drayage Tractor 300 kW / 90 kW (3.3) 300 kW / 240 kW (1.25) The transit bus and drayage truck data showed symmetric distributions oftraction and regeneration power usage profiles. Power electronics must be designed to handle power and heat requirements forboth traction and regenerative power. Additional evaluation of NREL commercial EV data will be conducted andpublished in 2016.17
Additional InformationAvailable through Fleet DNAwww.nrel.gov/fleetdnaObjectives: Capture and quantify drive cycle and technology variations forthe multitude of medium- and heavy-duty vocationsProvide a common data storage warehouse for medium- andheavy-duty vehicle data across DOE activities and labs –www.nrel.gov/fleetdnaIntegrate existing DOE tools, models, and analyses to providedata-driven decision-making capabilitiesFor Government: Provide in-use data for standard drive cycledevelopment, R&D, tech targets, and rule makingFor OEMs: Real-world usage datasets provide concreteexamples of customer use profilesFor Fleets: Vocational datasets help illustrate how to maximizereturn on technology investmentsFor Funding Agencies: Reveals ways to optimize impact offinancial incentive offersFor Researchers: Provides a data source for modeling andsimulation18
Thank You!Questions/Discussionkenneth.kelly@nrel.gov19
NREL Medium- and Heavy-Duty Fleet Evaluations . This project provides medium -duty (MD) and heavy - duty (HD) test results, aggregated data, and detailed analysis. Third party unbiased data: Provides data that would not normally be shared by industry in an aggregated and detailed mann
