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    Presentation (Powerpoint Format) Presentation (Powerpoint Format) Presentation Transcript

    • DESIGN AND TESTING OF A LOW-COST LEAD-CARBON REPLACEMENT BATTERY PACK FOR A HONDA CIVIC D. Karner, T. Grey, R. Newnham Work Conducted for the Advanced Lead Acid Battery Consortium And The U.S. Department of Energy
    • Project Overview
      • Furukawa Ultra Battery has shown promise in mild HEV applications
      • East Penn Manufacturing has licensed Ultra Battery technology for US production
      • US Department of Energy and ALABC are interested in evaluating the East Penn Ultra Battery in a mild HEV application
      • Electric Transportation Applications has been engaged to evaluate the East Penn Ultra Battery in a Honda Civic HEV
    • Project Objectives
      • Convert a Honda Civic HEV to operate using an Ultra Battery manufactured by East Penn
      • Retain an 800 pound vehicle payload
      • Provide packaging favorable to battery life
      • Maintain vehicle fuel economy performance
      • Maintain vehicle emissions performance
      • To obtain an "Experimental Vehicle" permit
      • Maintain vehicle FMVSS certification
      • To evaluate vehicle performance/durability
    • Progress
      • Development and testing of Simulated Honda Civic HEV profile (HCHEVP)
      • Characterization of Ultra Batteries from Furakawa (FUB)
        • Capacity at various rates
        • Discharge resistance at various SOCs
        • Performance of FUB and standard lead-acid (STLA) under HEV screening test
        • Full HPPC analysis of FUB and STLA
    • Progress
      • Preliminary optimization of HCHEVP
      • Operation of FUB under HCHEVP
      • Vehicle Preparation
        • Design of battery compartment
        • Evaluation of vehicle safety features
        • Design of Battery Management Syst em
          • Analog/Digital/Analog converter
          • Emulation software
    • Honda Civic
    • East Penn Ultra Battery Pack Preliminary packaging with extension, but without thermal management
    • Development and Testing of HCHEVP
      • Battery data logged during field and dyno (UDDS, HWFET) operation
      • Information obtained on affects of air conditioning, hill climbing, etc.
      • Profile based on one pass through UDDS and HWFET schedules
      • Data from five individual passes through both profiles used to obtain an average
      • UDDS schedule = 1380 s, 7.5 miles, 19.5 mph
      • HWFET schedule = 760 s, 10.2 miles, 48.5 mph
      Development of simulated profile
    • Development and Testing of HCHEVP Battery current and vehicle speed on dyno. HCHEVP – one pass through UDDS followed by one pass through HWFET
    • Development and Testing of HCHEVP Battery voltage (STLA) over seven passes and one pass through the HCHEVP
    • Development and Testing of HCHEVP Battery current (STLA) over seven passes and one pass through the HCHEVP
    • Development and Testing of HCHEVP
      • 3 months of cycling provides >64,000 miles of simulated HEV driving
      • Energy/power levels of profile equivalent to that experienced in the field and on dyno
      • One pass through the HCHEVS – battery delivers and accepts 2.89 Ah. Over the design life of the vehicle (160,000 miles), the battery would deliver 26,000 Ah, the equivalent of 4,000, 100% cycles
      • Comparative calculations performed for a Toyota Prius battery pack indicate the delivery of almost 6,000, 100% cycles over the same distance.
      Application of simulated profile
    • FUB Characterization - Capacity
    • FUB Characterization – Discharge Resistance
    • FUB Characterization – HEV Screening
      • Discharge at 1C for 30 min (to ~ 50% SOC nominal)
      • Rest for 10 s
      • Charge at 2C for 60 s (to ~ 53% SOC nominal) terminate test if voltage hits 17.5 V;
      • Rest for 10s
      • Discharge at 2C for 60 s (to ~ 50% SOC nominal).
      • If voltage during (v) drops to 11.5 V (~ 40% SOC), then recharge an additional 5% SOC over the next 100 cycles.
    • STLA Characterization - HEV Screening
    • FUB Characterization - HEV Screening
    • STLA Characterization - HPPC Testing
    • FUB Characterization - HPPC Testing
    • Conclusions
      • Simulated HCHEVP complete and validated
      • Furakawa has been characterized
      • Preliminary vehicle design complete – continuing work on thermal management
      • Next steps
        • Characterize EPUB modules
        • Cycle full EPUB pack under HCHEVP for 3 months (64 000 miles equivalent)