Electric Vehicles - Oregon Electric Vehicle Association

Electric Vehicle Update
Gary Graunke
Oregon Electric Vehicle Association
July, 2013
Agenda
•
•
•
•
Electric vehicle benefits
Costs vs gasoline vehicles
Available manufactured EV’s
Charging infrastructure update
– Battery swap technology
• Driving, charging, maintenance
• Electricity vs other alternative fuels
• Conclusion: a question of time and money
Benefits of Electric Vehicles
• National security: electric power from
diverse, local sources
– 15% of US defense budget
just for Straights of Hormuz
• Economy: cost-effective EVs fueled locally
– Oil money leaves our economy
• United States: $1 Billion per day
• Oregon: $6-7 Billion per year
$$$
– $25000 Leaf saves $13000 in lifetime fuel
• Tires and wiper blade maintenance
• Fun to drive, home charging convenience
More EV Benefits
• Sustainability: electricity prices are stable
– Estimated life of our sun is 5.5 billion years
• Better grid utilization, stability
– Vehicles charge off-peak now
– Future potential to provide storage
for intermittent renewables
• Environment: EVs are cleaner
– Pollution reduction saves health care costs
– Reduce greenhouses gases affecting climate
Solar year house and EV’s
PV generated 5479 KWH
$406.48 electricity cost TOU
$121.20 base charge (grid
rental—a big battery)
non-TOU cost: $77.26 more
Time
Direct Gen
Used
OnPeak
435
771
796
MidPeak
1239
2196
1405
OffPeak
302
536
5067
PGE gained $25.76: peak KWH
traded for off-peak KWH
PV investment: $7000 returned
$709.68 electricity: 10% less
3.3% deprecition = 6.6% tax
free
risk: full faith and credit of sun
Nissan Leaf S Savings vs Versa
Cummulative savings for various annual miles driven
60000
50000
40000
6000
30000
9000
12000
20000
15000
10000
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
-10000
Assumes 60 month loan, 8.5% gas inflation, 2% electric, replace
battery after 8 years, maintenance included
Spreadsheet available—provide your own data, assumptions
Lease price of $200/month is also available—less than many folks pay for gas
USDOE says $1.18 / gal equivalent vs $3.49 nationally:
http://energy.gov/articles/egallon-how-much-cheaper-it-drive-electricity
US-available 2013 Battery Electric Vehicles
Description
Make / Model
Price
Range
(USD)
The Focus Electric is based on Ford's next
Ford
Focus Electric
generation Focus body. The vehicle is powered
76 mi
by 23 kWh of Li-ion batteries with active liquid
$39,20
0
cooling. J1772 charging only.
The Mitsubishi i is one of the most efficient
Mitsubishi
'i'
passenger vehicles in North America, rated at
112 MPGe. The 'i' is powered by a 47kW AC
62 mi
$29,12
5
synchronous motor and a 16-kWh Li-ion battery
pack... ChaDeMo DCQC available.
The Nissan LEAF is a 5-seater, 4-door hatchback
Nissan
LEAF
based on Versa/Tida platform. The LEAF has an
80kW electric motor... ChaDeMo DCQC
75 mi
$28,80
0
available.
An OEM conversion of the Smart Fortwo. Smart
Smart
EV
began life as Swatch car in 1998, and was first
converted into EV form in 2006. The Smart ED
will have 16.5kWh of Li-ion batteries... J1772
charging only.
63 mi TBA
Image
The Model S is a new ground-up 4-door,
7-seat sedan built by California EV
Tesla Motors
Model S
startup Tesla Motors. It's range will be
based on battery options of 230 mi and
300 mi. J1772, NEMA 240V/120V, and
300
mi
$57,400
Tesla Supercharger charging. 90 second
battery swap demonstrated.
Two seater City car with 180km range
THINK
City
(based on MES DEA Zebra battery, US
model will use EnerDel LiFEPO4 batteries).
111
mi
Was
$35,495
Body is ABS recycled plastic, steel...
The second generation Toyota RAV4 EV is
Toyota
2nd Gen.
RAV4 EV
the result of the Toyota and Tesla Motors
collaboration. Based on the popular RAV4
compact SUV and powered by a Tesla
100
mi
$49,800
82
mi
$19,185
electric powertrain...
The 2014 Spark EV features a lithium-ion
Chevy Spark
EV
battery , includes regenerative braking, offers
liquid thermal conditioning. SAE DC quick
charing is an option. Sold only in California and
Oregon.
Speed is (mostly) air speed (increase ground speed for headwinds, decrease for tailwinds
Decrease in efficiency due to air speed applies to all vehicles regardless of fuel
Rule of thumb for elevation gain: 1000 ft gain = 5 miles of range
Level 2 (SAE
J1772)
adapter
240V 7.2 KW
22 miles/hour
Charging
Infrastructure
Update
Fully Operational
I5: Portland to Ashland
Coast: Astoria to Newport
Columbia River: Astoria to
the Dalles
Central OR: Sisters,
Redmond
TBD (as of 7/2013)
Madras, Warm Springs, Govt
Camp, Coos Bay, Mill City,
Marion Forks, Elkton, Aurora
Future: Tesla demonstrated
model S battery swap in 90 sec
Plugshare
Map of
NW
June
2013
Tesla Superchargers July 2013
Tesla 2 Year Plan
EV Maintenance
•
•
•
•
•
Tires, wiper blades same as gas car
As car ages: suspension, seat covers
No drive train maintenance
Cooling system much lower temperature
Battery maintenance automated
– Annual checkup for battery management system or (if
none) cell balancing (cost: $20)
• Vehicle is very durable
– Buy new battery instead of new vehicle/engine
– Thermal management optimizes life (Tesla, GM
Spark EV)
PV + EV is Sun-to-Wheels Champ
• PV/EV sun-to-wheels efficiency ~16%
– PV cells 20% efficient sun-to-electricity
– EV >80% efficient electricity-to-wheels
• Bio-fuels sun-to-wheels efficiency <1%
– Alcohol sun-to-fuel is 1-2% in practice
• Heat engine <20% fuel-to-wheels
– May require other resources (H2O, land)
– Bio-fuels still useful for PHEV long trips
• Fossil fuel sun-to-wheels efficiency 0%
– Sun to fuel 10-10%, fuel to wheels <20%
– But utility generation + EV is more efficient
than mobile heat engine with any fuel
• Example: >2X better for natural gas
3 KW of PV on an Oregon garage (12 KWH) is good for 36 to 72 miles/day
Carbon Footprint of Alternative Fuels
Fuel
It’s Your Oregon
Gasoline
Ultra Low Sulfur Diesel
Compressed Natural Gas (CNG)
Ethanol (Corn)
Electricity
Biodiesel (Midwest Soybeans)
Cellulosic Ethanol (NW Farmed
Trees)
Biodiesel (Yellow Grease)
* Without indirect effects
Oregon
Carbon
Intensity*
(gCO2e/MJ)
92.34
91.53
70.22
64.82
37.80
19.99
15.54
10.28
Investing, Divesting
• Live better, live sustainably—start now!
– Current fossil fuel reserves will create 2795 gigatons of CO2 if burned
– But only 565 giga-tons will create thermal runaway
with probability 0.2 (worse than Russian roulette)
• 2° C temp rise (industrial revolution to now: 0.8°C)
• About 14 years at present rate of increase in consumption
• The car you buy today determines your impact
for the life of the vehicle
• Coupling electric vehicles with sustainable
generation saves money, better vehicle
performance with comfort and convenience
Converting a Vehicle
(addendum to main talk)
Potential EV Safety Issues
• Professional vehicles
– Discharge, remove battery after damaging crash to
avoid slow heat buildup and fire
• Home conversions
– High voltage electrocutes
• Service disconnects reduce to <60V segments
– High current welds
– Short circuit may cause plasma fire
• Use contactors, DC-rated fuses, heater relays
– Loose connections cause heat—fires
– Use safe chemistries—LiFePO, LiMn, not LiCo
EV Myths
Long Tailpipe Myth: Pollution is worse for electric utility
than gas car
Fact: To do better than the grid your car would have
to get 75 mpg in Pacific NW
Fact: Cars get worse with age; EV’s get better as we
clean up the grid / use more renewables
Myth: EV’s are tiny cars unsuitable for most people’s needs
Fact: Any vehicle may be converted (e.g., Humvee)
Fact: VIA motors is building class 6, 7 trucks as
Plug-in Hybrids, Alt-E is converting Ford
F150/250/350s
More myths???
EV Driving Experiences
• Limited range may require more planning
– Leaf battery sufficient for 2 hrs local driving
– Trips: charging station locations, charging power
• Charging stations may be unavailable
• GPS is your friend
– no energy to get lost / extra time to charge
• Bad weather (rain, headwinds) may require
significantly more (40%) energy
• Going slower stretches your range
Air Speed
35
45
55
65
Leaf Range
125
100
75
60
Gas Vehicle Conversions
• Select efficient vehicle, right size motor,
motor controller, battery charger
• Design adaptor plate, coupler shaft
– Check strength of motor mounts, drive train
•
•
•
•
Accelerator speed control
Power brake vacuum pumps
Cooling for motor, controller, batteries
Battery management or monitoring
Proper Tools for Safety
• Certified lineman gloves
to 1000V
• Fiberglass shaft
screwdrivers / nutdrivers
• Rubber handle wrenches
• Electrical tape on metal
sockets and other
wrenches
• Certified and isolated test
equipment (meters and
scopes)
Selecting an Electric Vehicle
•
•
•
•
•
Lightweight
Lightweight
Lightweight
Aerodynamic
Can hold weight of batteries
– Rule of thumb: 30% of final weight is batteries
• Room for batteries
Where Does the Energy Go?
• Acceleration (hills)
force =
mass*acceleration
• Heating up tires (rolling
resistance) force =
mass*velocity
• Pushing air out of the
way (esp. v > 40 mi/hr)
force = frontal area *
coefficient of drag *
velocity2
!!!
Wheel wells catch
cross-wind
Square back
creates vacuum
that sucks vehicle
back (needs tail)
Ideal vehicle is light, raindrop-shaped
Minimize
frontal area
Looks smooth on
Top, but rough
underside
creates turbulence
Theoretical Energy Calculations
• Rolling resistance (Fr) is proportional to weight and velocity
• Wind resistance (Ftd) is proportional to frontal area, coefficient of drag,
and velocity squared
• Fh is acceleration (also hill climbing: 1 mph/sec is about 5% incline)
• Insight with LiIon batteries: 2200 lbs, 28 KWH, area 20.5 sq ft, Cd 0.25
V
10
20
30
40
50
60
30
30
30
30
30
30
incline Fr
0
0
0
0
0
0
0
3
6
9
12
15
Ftd
Fh
12.78
13.94
15.10
16.26
17.42
18.59
1.62
5.79
12.57
21.98
34.01
48.66
0.00
0.00
0.00
0.00
0.00
0.00
15.10
15.09
15.07
15.04
14.99
14.93
12.57
12.57
12.57
12.57
12.57
12.57
0.00
65.97
131.76
197.20
262.12
326.35
Ftotal
HP
KW
Range
mi/kwh
14.40
0.41
0.31
661.11
32.61
19.73
1.13
0.84
482.57
23.80
27.67
2.37
1.77
343.97
16.97
38.24
4.37
3.26
248.90
12.28
51.44
7.35
5.48
185.07
9.13
67.25
11.52
8.59
141.55
6.98
27.67
93.64
159.41
224.82
289.69
353.86
2.37
8.02
13.66
19.26
24.82
30.32
1.77
5.98
10.19
14.36
18.51
22.61
343.97
101.66
59.71
42.34
32.86
26.90
16.97
5.01
2.95
2.09
1.62
1.33
Electric Motor Torque and Power
Siemens 5105WS12 at 312 Volts
Torque and mechanical power vs. rotation speed
Max torque
Rated torque
Max power
Rated power
100.0
80.0
90.0
70.0
Torque (ft/lbs)
60.0
70.0
60.0
50.0
50.0
40.0
40.0
30.0
30.0
20.0
Mechanical power
(KW)
80.0
20.0
10.0
10.0
0.0
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
0.0
10000
Shaft rotation speed, RPM
Insight torque 79 ft lbs at 1500 RPM
Insight power 54.4 KW at 5700 RPM
Transmission
• EV’s have adequate torque at low RPM
• AC motors can go as high as 14,000 RPM
• Result: some EV’s don’t need gears, clutch
– Direct drive is common--saves weight
– Slower motor RPM is slightly more efficient
Motor RPM
3.461
1.750
1.096
0.857
0.710
mph
1st
2nd
3rd
4th
5th
40
6923
3501
2192
1714
1420
50
60
65
70
80
90
100
110
120
130
8654 10385 11250 12116 13846 15577 17308 19039 20769 22500
4376 5251 5688 6126 7001 7876 8751 9627 10502 11377
2740 3289 3563 3837 4385 4933 5481 6029 6577 7125
2143 2571 2786 3000 3429 3857 4286 4714 5143 5571
1775 2130 2308 2485 2840 3196 3551 3906 4261 4616
Adaptor Plate Design
Shaft Coupler Design
Adaptor Plate and Coupler
Shaft Coupler
Mount, Hanger, Motor, Adaptor
Plate
Mounting Motor Controller
Accelerator Pot Box
Power Brake Vacuum Pump
Cooling Motor and Inverter
Note: reversed inverter hose connections were fixed later
Thank you!
Questions?
Oregon Electric Vehicle Association
www.oeva.org