Lowering Emissions and Costs Associated Lowering Emissions and Costs Associated with Urban Deliveries Utilising Advanced with Urban Deliveries Utilising Advanced

VRLA TechnologyVRLA Technology

Allan Cooper, EALABCNick Vaughan, Cranfield University

Andy Eastlake, Millbrook Proving GroundMike Kellaway, Provector Ltd.

Marcus Leong, University of Oxford

13th Asian Battery Conference

Macau 2 September 2009

ADDADDZEVZEV

AFFORDABLE ADD-ON AFFORDABLE ADD-ON ZERO EMISSIONS ZERO EMISSIONS VEHICLEVEHICLE

Aim of the ADDAim of the ADDZEVZEV project project• To build a demonstration vehicle with low cost, additional To build a demonstration vehicle with low cost, additional

electrical drive, capable of covering 20km on electric drive electrical drive, capable of covering 20km on electric drive only.only.

• Target: a light urban delivery vehicle.Target: a light urban delivery vehicle.

ObjectivesObjectives• System must be sized to achieve 20km zero emission rangeSystem must be sized to achieve 20km zero emission range• Parts must be chosen to reduce costs (especially energy Parts must be chosen to reduce costs (especially energy

store)store)• Must be designed for minimal vehicle integration (post-Must be designed for minimal vehicle integration (post-

production and retro-fit options)production and retro-fit options)• Must be capable of plug-in rechargeMust be capable of plug-in recharge• Cost target in production £2,000 - £3,000Cost target in production £2,000 - £3,000

ADDADDZEVZEV : System Overview

Functional requirements for system sizing:Functional requirements for system sizing:

Range:Range: In electric drive only the vehicle shall be In electric drive only the vehicle shall be capable of capable of covering 20km, over the ECE phase of covering 20km, over the ECE phase of the NEDC.the NEDC.

Load:Load: In electric drive only the vehicle shall be capable of In electric drive only the vehicle shall be capable of operating with the load range expected of a operating with the load range expected of a

standard standard vehicle.vehicle. Speed:Speed:In electric drive only the vehicle shall be capable of In electric drive only the vehicle shall be capable of

sustaining a maximum speed of 50km/h over sustaining a maximum speed of 50km/h over flat flat ground. ground.

Incline:Incline: In electric drive only the vehicle shall be In electric drive only the vehicle shall be capable of capable of progressing up an incline of 10% at progressing up an incline of 10% at 40km/h.40km/h.

In electric drive only the vehicle shall be In electric drive only the vehicle shall be capable of capable of progressing up an incline of 14% at any progressing up an incline of 14% at any low speed.low speed.

Headwind:Headwind: In electric drive only the vehicle shall be In electric drive only the vehicle shall be capable of capable of fulfilling all above requirements, when fulfilling all above requirements, when encountering a encountering a headwind of 10km/h.headwind of 10km/h.

Efficiency:Efficiency: The vehicle shall demonstrate increased The vehicle shall demonstrate increased efficienciesefficiencies over existing technologiesover existing technologies.

ADDADDZEVZEV : System Overview

ADDADDZEVZEV : Funding BodiesFunding Bodies

The Energy Saving TrustThe Energy Saving Trust

An independent organisation funded by both UK An independent organisation funded by both UK government (DEFRA, DfT, DTI) and the private government (DEFRA, DfT, DTI) and the private sector.sector.

The Advanced Lead-Acid Battery The Advanced Lead-Acid Battery ConsortiumConsortium

Industry based consortium aimed at driving R&D Industry based consortium aimed at driving R&D on VRLA battery performance and their on VRLA battery performance and their demonstration in hybrid electric vehicles.demonstration in hybrid electric vehicles.

ADDADDZEVZEV : Project Partners & ResponsibilitiesProject Partners & Responsibilities

Cranfield UniversityCranfield University

• Project CoordinationProject Coordination• Vehicle modelling and simulation for feasibilityVehicle modelling and simulation for feasibility• Systems engineering approach to interface Systems engineering approach to interface definitiondefinition• Supervisory control system designSupervisory control system design• Dynamometer testing of full systemDynamometer testing of full system

EALABCEALABC

• Battery AcquisitionBattery Acquisition• Assistance with CoordinationAssistance with Coordination

ADDADDZEVZEV : Project Partners & ResponsibilitiesProject Partners & Responsibilities

Millbrook Proving GroundMillbrook Proving Ground• Test vehicle provisionTest vehicle provision• Mechanical design and integrationMechanical design and integration• Data Data acquisition from providersacquisition from providers• Dynamometer & track testing facilityDynamometer & track testing facility

University of OxfordUniversity of Oxford• YASA electrical machine designYASA electrical machine design• Machine bench testingMachine bench testing

ProvectorProvector• Battery pack design & constructionBattery pack design & construction• Battery management control system Battery management control system • Electric machine drive electronicsElectric machine drive electronics

ADDADDZEVZEV : Systems Engineering

• Vehicle based on Vauxhall (GM) Combo vanVehicle based on Vauxhall (GM) Combo van• Diesel engine with front wheel drive Diesel engine with front wheel drive • Modification of rear axle to accommodate two Modification of rear axle to accommodate two

electric motors and drive to rear wheelselectric motors and drive to rear wheels• Conversion designed to use as many standard GM Conversion designed to use as many standard GM

parts as possible for low costparts as possible for low cost• Battery pack and power electronics mounted at Battery pack and power electronics mounted at

front of load space in the vanfront of load space in the van• Hand over system from ICE drive to electric Hand over system from ICE drive to electric

designed for maximum safetydesigned for maximum safety• Cooling system incorporated for motors and Cooling system incorporated for motors and

power electronics.power electronics.• System designed to accept regen energy.System designed to accept regen energy.

ADDADDZEVZEV : Systems Engineering: Physical View

ABS

Other controllers

ADC

EMC

Other loads

Battery Pack

M/GB

M/GB

Diesel

Chargeportinlet

Rad

Power electronics FM

+ -Perm 12V

Charger

P

Display

DC/DC

ON

ADDADDZEVZEV : Systems Engineering

• Modified rear EV drive Modified rear EV drive assemblyassembly

• Electric motors Electric motors mounted in protective mounted in protective cradlecradle

ADDADDZEVZEV : Battery Pack

• Requirement to provide 3 kWh of energy during ZEV Requirement to provide 3 kWh of energy during ZEV operation while optimizing cycle lifeoperation while optimizing cycle life

• Also needs to provide 50kW peak power in drive and Also needs to provide 50kW peak power in drive and accept 30kW+ in regen to maximise energy recoveryaccept 30kW+ in regen to maximise energy recovery

• Rechargeable from 13A supply with on-board chargerRechargeable from 13A supply with on-board charger• Utilised 6V 25Ah (Utilised 6V 25Ah (CC2020 rate) rate) Exide Orbital modulesExide Orbital modules• To allow for lower capacity at higher discharge rates To allow for lower capacity at higher discharge rates

a 240V pack was designed with air cooling (approx a 240V pack was designed with air cooling (approx 5kWh)5kWh)

• Battery management was provided to control Battery management was provided to control charge/discharge of the battery and equalisation of charge/discharge of the battery and equalisation of the modules.the modules.

• Data logging was also fitted to monitor battery Data logging was also fitted to monitor battery parameters when in use.parameters when in use.

ADDADDZEVZEV : Battery Pack

• Battery pack under Battery pack under constructionconstruction

• Battery pack and Battery pack and power electronics in power electronics in the vehiclethe vehicle

• Two packs produced Two packs produced to maximise testing in to maximise testing in the time availablethe time available

ADDADDZEVZEV : Project Problems

• Major delays in the completion of the BMS and Major delays in the completion of the BMS and power electronics delayed integration into the power electronics delayed integration into the vehiclevehicle

• There were further problems arising from the There were further problems arising from the added complexity of the 6-phase motors – further added complexity of the 6-phase motors – further compounded by the encoders slipping in usecompounded by the encoders slipping in use

• Additional problems with the cooling system Additional problems with the cooling system caused a motor burn-out in the integration phase caused a motor burn-out in the integration phase and shake-down phase at Cranfieldand shake-down phase at Cranfield

• As a result there was very little time available for As a result there was very little time available for testing of the vehicle - other than the testing testing of the vehicle - other than the testing required to confirm that the vehicle could required to confirm that the vehicle could complete the 20km required on the ECE section complete the 20km required on the ECE section of the New European Drive Cycle. of the New European Drive Cycle.

ADDADDZEVZEV : Testing - Cranfield

Vehicle on the Cranfield dynamometerVehicle on the Cranfield dynamometer

ADDADDZEVZEV : Testing - Cranfield

• SoC and vehicle speed v time. Analysis shows vehicle SoC and vehicle speed v time. Analysis shows vehicle covered 19kmcovered 19km

• While below the target of 20km – battery charge was from While below the target of 20km – battery charge was from 78% down to 38% - so looked promising78% down to 38% - so looked promising

0 500 1000 1500 2000 2500 3000 3500 40000

10

20

30

40

50

60

70

80

Time (s)

SO

C &

Vehic

le S

peed (

%,

km

/h)

Cranfield Dyno Test Results

VehicleSpeed

Battery SOC

ADDADDZEVZEV : Testing - Millbrook

• In a test to the NEDC atIn a test to the NEDC at Millbrook the vehicle Millbrook the vehicle achieved a range of 20.6 km with the battery SoC achieved a range of 20.6 km with the battery SoC going from 87% to 35% - thus should be capable going from 87% to 35% - thus should be capable of 22-24km on a full charge.of 22-24km on a full charge.

• The energy consumption was 0.13 kWh/kgThe energy consumption was 0.13 kWh/kg

• On the Urban Delivery Driving Cycle the range On the Urban Delivery Driving Cycle the range was 13.6 km and the power consumed was 0.29 was 13.6 km and the power consumed was 0.29 kWh/kg kWh/kg

ADDADDZEVZEV : Testing - Millbrook

COCO2 2 FiguresFigures

• Vehicle not fully hybridised – need to idle engine Vehicle not fully hybridised – need to idle engine to provide for power steering and braking. to provide for power steering and braking.

• This emits 49.4 g/km over NEDC cycleThis emits 49.4 g/km over NEDC cycle

• Using EU energy mix value for COUsing EU energy mix value for CO2 2 of 430 g/kWh of 430 g/kWh for the electric part of the cycle – this calculates for the electric part of the cycle – this calculates as 56 g/km over the NEDCas 56 g/km over the NEDC

• Thus the total COThus the total CO2 2 emitted over the cycle is 105.4 emitted over the cycle is 105.4 g/km. This compares with a figure of 137.1 for the g/km. This compares with a figure of 137.1 for the original vehicle.original vehicle.

ADDADDZEVZEV : Testing - Millbrook

Millbrook ‘real world’ cycle derived from field data (53km)Millbrook ‘real world’ cycle derived from field data (53km)

0 1 2 3 4 5 6

x 104

0

20

40

60

80

100

120

Time (s)

Spe

ed (

km/h

)

Millbrook2

ADDADDZEVZEV : Testing - Millbrook

Baseline CO2 ADDZEV CO2

Modelling of results to different vehicle sizesModelling of results to different vehicle sizes

CycleCycle ComboCombo ZafiraZafira MovanMovanoo

ComboCombo ZafiraZafira MovanMovanoo

NEDCNEDC 137137 165165 240240 105105 122122 180180

UDDCUDDC 238238 284284 419419 106106 130130 170170

MillbrooMillbrookk

251251 324324 440440 204204 232232 351351

ADDADDZEVZEV : Positives

• While VRLA batteries are not While VRLA batteries are not really a candidate in passenger really a candidate in passenger cars, they could be possible for cars, they could be possible for light commercial vehicles light commercial vehicles where available volume rather where available volume rather than weight is important e.g. than weight is important e.g. mail.mail.

• The 20 km electric range was The 20 km electric range was achieved with effective achieved with effective reductions in COreductions in CO2 2 emissions in emissions in urban delivery duty.urban delivery duty.

• The system would be suitable The system would be suitable for retro-fit.for retro-fit.

ADDADDZEVZEV : Negatives

• Re-vamping of project at start put additional work Re-vamping of project at start put additional work on Provectoron Provector

• There was added complexity of the power There was added complexity of the power electronics due to the use of the two 6-phase electronics due to the use of the two 6-phase electric motorselectric motors

• Unreliability of the motorsUnreliability of the motors• Resulting delays in the full integration of the Resulting delays in the full integration of the

vehicle limited testing time due to EST deadlines vehicle limited testing time due to EST deadlines and financial restraints.and financial restraints.

• The rush to meet the targets of the call meant the The rush to meet the targets of the call meant the BMS was not properly implemented. Thus there BMS was not properly implemented. Thus there were clear signs of pack damage at the end.were clear signs of pack damage at the end.

• We thus have only limited data on battery We thus have only limited data on battery operation under this type of deep cycle/hybrid operation under this type of deep cycle/hybrid operation.operation.

ADDADDZEVZEV : What next ?

• The ALABC declined to contribute to further The ALABC declined to contribute to further testing on the present vehicle because of the testing on the present vehicle because of the motor issuesmotor issues

• The Partners may seek additional funding to The Partners may seek additional funding to progress the work but:progress the work but:• Need to run with single motor driving rear wheels Need to run with single motor driving rear wheels

through a differential to simplify the electronicsthrough a differential to simplify the electronics• Should probably utilise single fixed pack in conjunction Should probably utilise single fixed pack in conjunction

with a fast charging option to reduce weight and volumewith a fast charging option to reduce weight and volume• Look at additional means of reducing battery weight and Look at additional means of reducing battery weight and

volume with new battery developmentsvolume with new battery developments

• Should consider some bench testing of batteries Should consider some bench testing of batteries to this type of cycle to determine effect on life.to this type of cycle to determine effect on life.