gas (EVAA) 7
`
`Page 1 of 31
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`IO8....neSer0..
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`V/b
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`Sponsored by
`
`FORD 1107
`
`

`

`12TH NTERNATIONAL ELECTR C VEH CLE SYMPOS UM
`
`DECEMBER 5-7, 1994
`DISNEYLAND HOTEL AND CONVENTION CENTER
`ANAHEIM, CALIFORNIA, U.S.A.
`
`~.V.I
`
`Presented by the
`ELECTRIC VEHICLE ASSOCIATION OF THE AMERICAS (EVAA)
`
`EVAA Board of Directors
`
`Chairman
`Norman Bryan
`
`1st Vice Chair
`John R. Wallace
`
`2nd Vice Chair
`Ray Geddes
`
`Treasurer
`James J. Jackson
`
`Secretary
`Edwin Riddell
`
`Pacific Gas and Electric Company
`
`Ford Motor Company
`
`Unique Mobility, Inc.
`
`Alupower, Inc.
`
`Electric Power Research Institute
`
`William Adams
`Kenneth Barber
`Robert A. Bell
`Michael Crews
`Robert L. Davis
`Gale Klappa
`James Mathis
`Thomas D. Morron
`Frank L. Schweibold
`William H. Tiedemann
`Diane O. Wittenberg
`
`Electric Vehicle Association of Canada
`United States Department of Energy
`Consolidated Edison Company of New York, Inc.
`Duke Power Company
`Chrysler Corporation
`Georgia Power Company
`Collmer Semiconductor, Inc.
`Edison Electric Institute
`General Motors Corporation
`Johnson Controls, Inc.
`Southern California Edison Company
`
`Page 2 of 31
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`FORD 1107
`
`

`

`Chair: John R. Wallace
`
`Ford Motor Company
`
`North American Members:
`Norman Bryan
`Ray Geddes
`Robert T. Hayden
`James J. Jackson
`Thomas D. Morron
`Edwin Riddell
`Roland Risser
`Frank L.’ Schweibold
`David R. Smith
`William H. Tiedemann
`Pamela A. Turner
`Diane O. Wittenberg
`
`International Members:
`Giampiero Brusaglino
`C.C. Chan
`Fran~:ois Fantin
`Masazumi Ishikawa
`Hans Kahlen
`Jian Lai
`Gaston Maggetto
`Henri Payot
`David F. Porter
`Tsuneaki Takami
`
`Pacific Gas and Electric Company
`Unique Mability,: Inc.
`Electric Vehicle Association of the Americas
`Alupower, Inc.
`Edison Electric Institute
`Electric Power Research Institute
`Pacific Gas and Electric Company
`General Motors Corporation
`Chrysler Corporation
`Johnson Controls, Inc.
`EVSo 12 Symposium Manager
`Southern Cafifornia Edison Company
`
`Centro Ricerche Fiat
`University of Hong Kong
`AVERE France
`Japan Electric Vehicle Association
`University of Kaiserslautern
`Chinese Electric Vehicle Institution
`CITELEC
`AVERE France
`UNIPEDE
`Japan Electric Vehicle Association
`
`Page 3 of 31
`
`FORD 1107
`
`

`

`PROGRAM COMM TTE-
`
`Chair: Diane O. Wittenberg Southern California Edison Company
`
`North American Members:
`Bradford Bates
`Mary M. Brazell
`Thomas J. Doughty
`Ray Geddes
`Robert T. Hayden
`Cynthia Hernandez
`Kenneth Koyama
`George McCrae
`Athena Miller
`Thomas D. Morron
`Edwin Riddell
`Roland Risser
`David R. Smith
`Lee Stefanakos
`Pamela A. Turner
`Robert Wragg
`
`Ford Motor Company
`Brazell & Company
`Los Angeles Department of Water and Power
`Unique Mobility, Inc.
`Electric Vehicle Association of the Americas
`Electric Vehicle Association of the Americas
`California Energy Commission
`B.C. Hydro
`Electric Vehicle Association of the Americas
`Edison Electric Institute
`Electric Power Research Institute
`Pacific Gas and Electric Company
`Chrysler Corporation
`University of South Florida
`EVS- 12 Symposium Manager
`Delco Electronics/GM Hughes Electronics
`
`International Members:
`Noel Bureau
`C.C. Chan
`Cord-Henrich Dustmann
`Fran~:ois Fantin
`A. Fujisaki
`David F. Gosden
`Masazumi Ishikawa
`Pietro Menga
`Henri Payot
`Tsuneoki Takami
`Peter Van den Bossche
`
`PSA Peugeot Citroen
`University of Hong Kong
`AEG-ULM
`AVERE France
`Japan Electric Vehicle Association
`University of Sydney
`Japan Electric Vehicle Association
`ENEL
`AVERE France
`Japan Electric Vehicle Association
`CITELEC
`
`Page 4 of 31
`
`III
`
`FORD 1107
`
`

`

`Chair: Edwin Riddell
`
`Electric Power Research Institute
`
`Ray Geddes
`Robert T. Hayden
`Howard Hampton
`Cynthia Hernandez
`Athena Miller
`Joanne Rohn
`Melanie J. Savage
`Pamela A. Turner
`
`Unique Mobility, Inc.
`Electric Vehicle Association of the Americas
`Ford Motor Company
`Electric Vehicle Association of the Americas
`Electric Vehicle Association of the Americas
`General Motors Corporation
`Southern California Edison Company
`EVS- 12 Symposium Manager
`
`Page 5 of 31
`
`FORD 1107
`
`IV
`
`

`

`TECHNICAL BREAKOUT SESSIONS
`
`Session 3A: Drives
`
`Adaptive Control of an EV Drive System to Account
`for Time-Varying Battery Parameters
`Carlo Kopf, Unique Mobility, Inc.
`
`Development of an EV Drive Train for a California
`Vehicle
`Chris Kambouris, Ford Motor Company
`
`Power Trains for EVs, Design for Flexibility
`Frank Walker, Westinghouse Electric Corporation
`
`Session 3B: Battery Modeling
`
`Thermal Management for Hybrid Electric Vehicle
`Valve-Regulated Lead-Acid Batteries
`Frank Fleming, Hawker Energy Products, Ltd.
`
`Battery Management System for Nickel-Cadmium
`Batteries: Concept and Practical Experience
`Friedhelm Sch6pe, Aachen University of Technology
`
`The Need and Requirements of a Series Hybrid Electric
`Vehicle Battery
`Anders Romare, AB Volvo
`
`Session 3C: Infrastructure
`
`Electric Infrastructure for the EV Introduction Program in
`GBteburg
`Hans Ristborg, Vattenfall Utveckling AB
`
`Development and Evaluation of Quick Charging Systems
`at Tokyo Electric Power Company
`Hirokazu Suzuki, Tokyo Electric Power Company
`
`Page 6 of 31
`
`V
`
`FORD 1107
`
`

`

`Making the EV Connection: EV Charging Safely and the
`National Electrical Code
`Gloria Krein, Hart, McMurphy & Parks
`
`Session 4A: Vehicles
`
`Performances of Electric Vehicles
`Masahiko Tahara, Nissan Motor Company, Ltd.
`
`Toyota EV-50: An Effort to Realize Practical EVs
`Kunio Kanamaru, Toyota Motor Corporation
`
`*lsuzu Elf EV Third Generation
`Shouichi Taguchi, Isuzu Motors Ltd.
`
`Session 4B: Batteries
`
`Development of the VRLA Battery for Low Emission
`Hybrid Vehicles
`Yasuhide Nakayama, Yuasa Corporation
`
`Optimizing Lead/Acid Batteries for Electric Vehicle
`Applications: A Systems Engineering Approach
`Geoffrey May, Hawker Batteries Group
`
`Sealed Alkaline Batteries for Electric Cars
`Wolfgang Warthmann, Deutsche Automobilgesellscaft
`GmbH
`
`Session 4C: Utility System Impact
`
`Impact of Electric Vehicle Load on Residential Transformer
`Ratings
`Kenneth E. Brown, Salt River Project
`
`*Paper not available at time of printing.
`
`Vl
`
`Page 7 of 31
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`FORD 1107
`
`

`

`Study of Impacts of Electric Vehicle Charging to Power
`Supply Systems
`Eiii Hayashi, The Central Electric Power Council
`
`Modeling Electric Vehicle Utility System Impact Utilizing
`a Geographic Information System
`Richard E. Rice, Southern Cafifornia Edison Company
`
`Session 5A: Hybrid Drives
`
`Propulsion Control System for a 22-Foot Electric/Hybrid
`Shuttle Bus
`Kaushik Rajashekara, AC Delco Systems
`
`Development of a 225 kW Hybrid Drive System for a
`Low-Floor, Low-Emissions Transit Bus
`R.D. King, General Electric Company
`
`A Hybrid Drive Based on a Structure Variable
`Arrangement
`J. Mayrhofer, AVL-List GmbH
`
`Session 5B: Batteries
`
`Advanced Battery Systems for Electric Vehicles - New
`Impulses for the Electric Automobile
`F. Kruger, VARTA Batterie AG
`
`Ovonic Nickel-Metal Hydride Electric Vehicle Batteries:
`From the First 10,000 Miles to the First 10,000 Vehicles
`Dennis Corrigan, Ovonic Battery Company
`
`From Nickel-Cadmium to Nickel-Metal Hydride Battery:
`A Coherent Strategy for an Achieved Electric Vehicle
`Jean-Pierre Cornu , SAFT
`
`Electric Fuel and the Deutsche Bundespost Postdienst
`Jonathan Whartman, Electric Fuel Limited
`
`Page 8 of 31
`
`VII
`
`FORD 1107
`
`

`

`Session 5C: EV Policies
`
`*California’s Experience in Developing Incentives for
`Electric Vehicles
`David Modisette, Cafifornia Electric Transportation
`Coalition
`
`The Calfuels EV Infrastructure Study: The Status of
`Electric Vehicles in California
`Heather Raitt, California Energy Commission
`
`A Partnership in Paris for the Development of the
`Electric Vehicle
`Patrick Lefebvre, Technical Advisor to the Mayor of Paris
`
`*Electric Vehicles and Sustainable Transportation:
`A Vision of the Future
`Daniel Sperling, University of California at Davis
`
`Session 5D: National Electric Vehicle Infrastructure
`Working Council
`
`The Origin and Role of the National Electric Vehicle
`Infrastructure Working Committee
`Roland Risser, Pacific Gas and Electric Company
`
`Electric Power Research Institute Infrastructure Working
`Council - Connector and Connecting Stations Committee
`Rc.:commendations on EV Charging Infrastructure
`Craig Toepfer, Ford Motor Company
`
`Session 6A: Components
`
`A High Efficiency Electric Vehicle Drive System with
`Multi-Functional Battery Charger
`Masami Hirata, Toshiba Corporation
`
`*Paper not available at time of printing.
`
`VIII
`
`Page 9 of 31
`
`FORD 1107
`
`

`

`Phase Advanced Operation of Permanent Magnet Motor
`Drive System
`Jon F. Lutz, Unique Mobility, Inc.
`
`A Versatile AC Machine EV Drive Using Microprocessor
`Control
`David F. Gosden, University of Sydney
`
`Session 6B: Batteries
`
`U.S. Department of Energy Advanced Battery Systems
`Program: Meeting the Critical Challenge of EV
`Development
`R.A. Sutula, U.S. Department of Energy
`
`Development of a Solid Lithium Polymer Battery
`Technology
`P Baudry, Eledricit~ de France
`
`*The Ecostar/NaS Battery Integration Experience
`Wolfgang Dorrscheidt, ABB Hochenergiebatterie GmbH
`
`Session 6C: Demonstrations
`
`Consumer Impressions Before and After Driving an
`Electric Vehicle
`D.A. Wassmann, Ford Motor Company
`
`Hybrid Versus All-Electric: The Test of Performance
`Claude Boivin, Hydro-Quebec
`
`America PrEViewing the Impact
`Frank L. Schweibold, General Motors Corporation
`
`Progress of the Introduction Program for Electric Vehicles
`in G~teborg
`Stefan Liljemark: Cih/ of G6teborg Traffic and Transit
`Authorify
`
`*Paper not available at time of printing.
`
`IX
`
`Page 10 of 31
`
`FORD 1107
`
`

`

`Session 6D: National Electric Vehicle Infrastructure
`Working Council
`
`Utility System Electric Vehicle Load Impacts
`Steve Frost, Salt River Project
`
`Load Management and Power Qualily Issues
`John Kennedy, Georgia Power Company
`
`Infrastructure Working Council Health & Safely
`Committee
`John Olsen, Detroit Edison Company
`
`Identification of Safely Concerns for EVs
`Carol Hammel, National Renewable Energy Laboratory
`
`The IWC NEC Subcommittee
`David Brown, Baltimore Gas & Electric Company
`
`Infrastructure Working Council Health and Safely
`Committee; Building Code Subcommittee
`Robert Brown, National Conference of States on Building
`Codes and Standards
`
`Assessment of Methods for EV Charging Systems to
`Protect Against Electric Shock
`Gregory Nieminski, Underwriters Laboratories, Inc.
`
`Page 11 of 31
`
`FORD 1107
`
`x
`
`

`

`POSTER/DIALOGUE SESSIONS
`
`Electric Vehicles and Hybrid Electric Vehicles
`(Safety; Components; Simulation)
`
`A Cost Conscious Approach to the Design of an Electric
`Vehicle
`C.N. Spentzas, National Technical University of Athens
`
`Comparison of Hybrid and Conventional Bus Simulations
`using Toronto Transit Commission Bus Route Information
`Peter Drozdz, ORTECH
`
`Computer Simulation of Hybrid Vehicles with Fuel Cells
`and Batteries
`A. lacoba~i, ENEA
`
`Determination of Hybrid Vehicle Consumptions,
`Emissions, and Performances Using a Simulation
`Program
`Francois Badin, INRETS
`
`Development of the Electric Vehicle "Pivot"
`Shigenori Matsumura, Shikoku Research Institute, Inc.
`
`Electric Vehicles Integrated in Call-A-Car and Public
`Transportation Systems
`Richard Smokers, ECN
`
`Evaluation of Ovekall Dynamic Performance of a High-
`Performance EV, IZA, Based on On-Road Use Monitoring
`Data
`Yasuko Baba, University of Tokyo
`
`Fiat’s Conceptual Approach to Hybrid Car Design
`Oreste Vittone, Fiat Auto
`
`Prototype of an Innovative Electrical Scooter for
`Application in Zero-Emission Urban Mobility
`E Caricchi, University of Rome "La Sapienza"
`
`Xl
`
`Page 12 of 31
`
`FORD 1107
`
`

`

`Results of the Zurich Car Field Trial
`Philipp Dietrich, ETH Zurich
`
`Safety Considerations for Electric Vehicles
`Peter Van den Bossche, CITELEC
`
`Simulation Study of Two and Three Source Hybrid Drives
`Antoni Szumanowski, Warsaw University of Technology
`
`The Test Results of the Diesel-Electric Hybrid Bus on
`City Routes
`Tetsuo Koike, Hino Motors, Ltd.
`
`Electric Vehicle and Hybrid Electric Vehicle Batteries
`(Lead Acid & Nickel-Based; Sodium & Lithium-Based;
`System Components)
`
`A Dynamic State-of-Charge Model for Electric Vehicle
`Batteries
`Sung-Ku Song, Samsung Advanced Institute of Technology
`
`Advances in Electric Bus Batteries
`Klaus-Dieter Merz, CMP Batteries, Ltd.
`
`Development of Ni-Zn Battery for EVs
`Yukio Fujita, Yuasa Corporation
`
`Development of Sealed-Type Nickel/Metal-Hydride
`Battery for Electric Vehicles
`Munehisa Ikoma, Matsushita Battery Industrial Company
`
`Dryfit Electric Vehicle - Enhanced Dryfit Traction Block
`Dieter Hanauer, Accumulatorenfabrik Sonnenschein
`GmbH
`
`Lithium-Carbon (Lithium-Ion) Battery System for
`Electric Vehicles
`R. Staniewicz, SAFT
`
`Page 13 of 31
`
`FORD 1107
`
`XU
`
`

`

`New Sodium Batteries with Polymer Electrolytes
`Marca M. Doeff, Lawrence Berkeley Laboratory,
`University of Cafifornia
`
`On-Board Management System for EV Batteries - A Field
`Experiment on Different EVs in the EDF Fleet
`Patrick Gagnol, Electricit~ de France
`
`Status of the National Project on Lithium Secondary
`Batteries in Japan
`Kazuhiko Kurematsu, Lithium Battery Energy Storage
`Technology Research Association (LIBES)
`
`The Battery Built-in Frame - A New Frame Structure for
`an EV
`Hiroshi Shimizu, The National Institute for Environmental
`Studies
`
`Drive Systems and Motors
`(Control;Tests; Components; Climate Con~ol; Flywheels;
`Fuel Cells)
`
`A Comparison of Three Different Motor Types for Electric
`Vehicle Application
`J.R. Hadji-Minaglou, Institut fur Elektrische Maschinen
`
`A Novel DC/DC Step-Up Converter
`Ivor Smith, Loughborough University of Technology
`
`Design of New AC Power Train Using 2 Quadrant
`Chopper as an Input Converter
`Sung-Chul Oh, Korea Electrotechnology Research Institute
`
`*Efficiency and Performance of a 4.6 Ton Fuel Cell Van
`M.B. Virji, Loughborough University of Technology
`
`Endurance Tests for Electric Vehicle Drives
`Jurgen Weimer, University of Kaiserslautern
`
`*Paper not available at time of printing.
`
`Xlll
`
`Page 14 of 31
`
`FORD 1107
`
`

`

`Fully Integrated Electric Vehicle Control Unit
`Otmar Bitsche, Steyr-Daimler-Puch Fahrzeugtechnik
`
`*Motor and Drive Systems Project Criteria for Electric
`Vehicles
`R Ferraris, Politecnico di Torino
`
`Operating Characteristics of a 45kW Brushless DC
`Machine
`R.L. Hodkinson, Nelco Systems, Ltd.
`
`Performance Evaluation of EV Power Trains
`Thomas Chondros, University of Patras
`
`Performance Optimization for the Electrical Drive System
`of the Hybrid Ill Passenger Car
`Andrea Vezzini, ETHZ- Swiss Federal Technical Institute
`
`EV Infrastructure
`(Chargers; Utility & System Effects; Energy Efficiency;
`Air Quality & Emissions)
`
`Chassis Dynamometer for Evaluating EVs
`Ken Ichi Shimizu, Ministry of International Trade and
`Industry (MITI)
`
`Data Acquisition and Performance Analysis from a
`Network of EVs: Including PV Charging
`Howard C. Lamb, Clean Energy & Vehicles Research
`Center, University of South Florida
`
`Development of a Quick Charging Station for Electric
`Vehicles
`Akira Takano, Japan Storage Battery Company, Ltd.
`
`Electric Vehicle Impact Assessment Study
`Kevin Morrow, Salt River Project
`
`* Paper not available at time of printing.
`
`XlV
`
`Page 15 of 31
`
`FORD 1107
`
`

`

`Electromagnetic Impact of the Electric Vehicle
`A. Buonarota, ENEL SpA CRE
`
`Fleet Monitoring for Electric Utility Vans: Optimizing
`Operational Use and Maintenance
`Bernard Courty, Oldham France SA
`
`Lessons Learned in Acquiring New Regulations for
`Shipping Advanced Electric Vehicle Batteries
`Gary Henriksen, Argonne National Laboratory
`
`Progress in the Development of Recycling Processes for
`Electric Vehicle Batteries
`Rudolph Jungst, Sandia National Laboratories
`
`Survey on the Drive Systems, Battery Technology,
`Charging and Infrastructure Systems for German Electric
`Vehicles
`Dietrich Naunin, Technical University of Berlin
`
`The Results of an Infrastructure Build-Up Plan for
`Promoting Electric Vehicles
`Masaharu Nakamura, Osaka City Government
`
`Introduction, Demonstration and Test
`(Market Factors; Incentives, Mandates & Policy;
`Training)
`
`*Alternate Fueled Vehicle - Development and
`Demonstration: Chesapeake and Cedar Rapids
`Consortium Results
`Dallas Usry, Westinghouse Electric Corporation
`
`*Creating a Positive Image for ElectricVehicles in
`Switzerland
`Wilfried Blum, MobilE
`
`Current Hybrid Electric Vehicle Performance Based on
`Temporal Data from the World’s Largest HEV Fleet
`Keith Wipke, National Renewable Energy Laboratory
`
`*Paper not available at time of printing.
`
`xv
`
`Page 16 of 31
`
`FORD 1107
`
`

`

`Daily Traveling Distance of Internal Combustion Engine
`Vehicles and Capability of Electric Vehicles to Substitute
`the Vehicles
`Hiroshi Hasuike, The Institute of Appfied Energy
`
`Dynamometer and Road Testing of Advanced Electric
`Vehicles and Projections of Future Range Capability
`A.E Burke, University of California at Davis
`
`G-Van Data Acquisition and Analysis
`Dennis Landsberg, The Fleming Group
`
`Major Elements of an Electric Vehicle Technician
`Training Program
`Edward E Duffy, York Technical College
`
`Marketing Under Uncertainty: The Electric Vehicle Case
`with Reference to the French Experience
`Pascal Larbaoui, Centre de Recherche en Economie
`Industrielle
`
`Operation of a Research and Demonstration Fleet of
`Electric Vans in Canada
`William A. Adams, University of Ottawa (ESTCO)
`
`*Possibilities of Training for Economical Driving and
`Maintenance of Electric Vehicles
`C.A. Bleiis, Electricit~ de France
`
`Research and Development of the Mazda MX-5 EV
`Michio Yoshino, Mazda Motor Corporation
`
`Results of the Austrian Fleet Test with 150 Private EVs
`Wolfgang Streicher, Graz University of Technology
`
`The Fleet Testing Program for Lightweight Electric Vehicles
`Urs Muntwyler, Swiss Federal Office of Energy for the
`Promotion Program "Lightweight Electric Vehicles"
`
`The Various Measures Taken by the Government to
`Encourage the Use of EVs in the Principality of Monaco
`Raoul Viora, Ministere d’Etat de Monaco
`*Paper not available at time of printing.
`
`Xyl
`
`Page 17 of 31
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`FORD 1107
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`

`

`Session 3A:
`Drives
`
`Session 4A:
`Vehicles
`
`Session SA:
`Hybrid Drives
`
`Geoff Harding
`International Automotive
`Design (lAD)
`
`Craig Cambier
`Unique Mobility, Inc.
`
`Session 3B:
`Battery Modeling
`
`Ron Sims
`Ford Motor Company
`
`Mike Mangan
`Chloride Silent Power
`
`Session 3C:
`Infrastructure
`
`Franc;ois Fantin
`AVERE
`
`Thomas Doughb,
`Los Angeles Department
`of Water & Power
`
`C. C. Chan
`University of Hong Kong
`
`Terry Penny
`Midwest Research Institute
`
`David F. Gosden
`University of Sydney
`
`Allan Gale
`Ford Motor Company
`
`Session 4B:
`Batteries
`
`John Williams
`General Motors
`Corporation
`
`Ken Heitner
`U.S. Department of
`Energy
`
`Session 4C:
`Utility System Impact
`
`Roland Risser
`Pacific Gas and Electric
`Company
`
`David Owen
`PowerGen PLC
`
`Session 5B:
`Batteries
`
`Masazumi Ishikawa
`Japan Electric Vehicle
`Association (JEVA)
`
`Russell Moy
`Ford Motor Company
`
`Session 5C:
`EV Policies
`
`Kateri Callahan
`Electric Transportation
`Coafition
`
`Mary Brazell
`Brazell & Company
`
`Session 5D:
`National Electric Vehicle
`Infrastructure Working
`Council
`
`Roland Risser
`Pacific Gas and Electric
`Company
`
`XVII
`
`Page 18 of 31
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`FORD 1107
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`

`

`SS ON
`
`¯ VO
`
`ME
`
`2
`
`Paster/Dialogue Session:
`Electric Vehicles and
`Hybrid Electric Vehicles
`
`Alan Gilbert
`Unique Mobility, Inc.
`
`Paster/Dialogue Session:
`Drive Systems and Motors
`
`Chris Borroni-Bird
`Chrysler Corporation
`
`Poster/Dialogue Session:
`Electric Vehicle and
`Hybrid Electric Vehicle
`Batteries
`
`Ray Hobbs
`Arizona Pubfic Service
`Company
`
`Poster/Dialogue Session:
`EV Infrastructure
`
`Ronn E. Jamieson
`General Motors
`Corporation
`
`Poster/Dialogue Session:
`Introduction,
`Demonstration and Test
`
`Larry Brandenburg
`Ford Motor Company
`
`Session 6A:
`Components
`
`Frank Jamerson
`Jamerson & Associates
`
`Hans Kahlen
`University of
`Kaiserslautern
`
`Session 6B:
`Batteries
`
`William Adams
`Electric Vehicle
`Association of Canada
`
`Cord-Henrich Dustmann
`AEG-ULM
`
`Session 6C:
`Demonstrations
`
`Gary Purcell
`Electric Power Research
`Institute
`
`Michael Gage
`CALSTART
`
`Session 6D:
`National Electric Vehicle
`Infrastructure Working
`Council
`
`Roland Risser
`Pacific Gas and Electric
`Company
`
`Page 19 of 31
`
`FORD 1107
`
`XVlII
`
`

`

`FIAT CONCEPTUAL APPROACH TO HYBRID CARS DESIGN
`
`Ing. Oreste Vittone
`FIAT AUTO Engineering Department
`C.so Settembrini, 40
`TORINO 10135
`Ing. Filippo D’Aprile
`Ing. Giovanni Tornatore
`FIAT RESEARCH CENTRE
`Strada Torino, 50
`Orbassano, TORINO 10043
`
`Abstract
`
`In this paper the different motivations behind the development of hybrid cars are
`examined and various hybrid configurations are illustrated which can satisfy a
`wide range of different and contrasting user needs.
`Specific attention is then given to the definition of guidelines for the
`development
`of a hybrid car where parallel configuration of the propulsion system allows the
`fulfillment of two types of mission:
`
`¯ short trips in urban areas with zero emissions by only using the electric motor
`driveline;
`¯ long highway trips with performance close to that of conventional cars but
`lower emissions.
`
`The corresponding design criteria for a Fiat medium size hybrid car are described
`together with the propulsion system, consisting of an A.C. electric motor and an
`ICE, that has been implemented and bench tested. A prototype car has also been
`equipped with this hybrid system and the driveability demonstrated.
`The management of the two propulsion units: electric motor and ICE is
`performed via an ECU using suitable control logics to optimize, in terms of
`consumptions, emissions and battery energy management, the performance of
`the global system.
`
`Introduction
`
`In the last years the legislation scenario and the attention to the environmental
`issues have changed, also in relation with the inconvenience produced by the
`traffic density in the most congested urban centers; as a consequence the research
`and development effort of the automotive and component manufacturers has
`changed, in order to better cope with the problems which did not allow up to
`now an industrial development of the environmental friendly electrically
`
`Page 20 of 31
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`FORD 1107
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`458
`
`

`

`propelled vehicles.
`The range and performance limits which are tied to the characteristics of the
`batteries presently available or under development (power, energy, weight,
`volume) remain the principal obstacle against the electric traction diffusion, even
`within the assumption of the european scenario which forecasts the
`establishment of areas with circulation reserved to ZEV vehicles.
`A recent study of the MIP Consortium in Milan has put in evidence that only
`10% of the vehicles in circulation in the Milan area could be substituted by
`electric vehicles, provided that they can assure a real range of 85 Km. On the
`contrary, the hybrid vehicles, featuring a range in pure electric of some 40 Km,
`would allow a substitution of approximately 90% of the vehicle park.
`This study, whose results can be extended to other italian and european cities,
`puts in evidence the enormous potential of hybrid vehicle.
`The introduction of such a vehicle into the market, could have indeed an
`important impact on the enviromental quality improvement of the more
`congested urban areas and, in general, on the global pollution.
`
`Alternative hybrid vehicle configurations
`
`The hybrid vehicle features a powertrain which integrates a thermal engine with
`an electric motor.
`Toward the hybrid vehicle approach, various possible configurations have been
`examined. [1]
`The addi.tion of an independent electric power.train on the thermal vehicle
`originates the simplest mixed configuration, called "dua! mode".
`The two powertrains operate in alternative, to meet the requirements of the
`circulation in typical urban areas (electric traction) or those of the extraurban
`missions (thermal engine).
`This configuration allows the following advantages:
`
`¯ it does not require the integration of two powertrains; as a matter of fact, the
`simplest configuration is related to a conventional front drive ICE to which an
`electric powertrain is added on the rear axle.
`¯ it offers the possibility to make available a drive system on the two axles in the
`cases of critical mobility.
`
`On the other hand, some constraints exist:
`
`¯ critical layout due to the encumbrances on the two traction axles, with
`considerable modifications on structure and mechanics;
`¯ vehicle performance in the thermal mode penalized by the higher weight due
`to electric motor, related electronics and batteries;
`¯ system not optimized in terms of consumption and emissions.
`
`Another possible configuration is the series hybrid, which is constituted by a
`generating unit (thermal engine/electric generator) and by the electric
`powertrain.
`For this configuration, the following advantages are envisageable:
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`¯ utilization of the thermal engine within the most favourable working
`conditions in terms of efficiency. This offers the possibility, for a mission
`featuring variable speed and low power, of limiting the emissions of the
`traditional pollutants, to the minimum allowed by the technology;
`¯ equal vehicle performance in the electric and hybrid modes.
`
`On the other hand, the most important disadvantages of this configuration are:
`
`¯ the number of installed components (two electrical machines besides the
`therma! engine), which have an impact on the vehicle in terms of weight,
`volume and cost;
`¯ low efficiency over constant speed runs, as a consequence of the energy
`conversions (thermal-electrical-mechanical).
`
`A further possible configuration is the parallel hybrid.
`This solution, albeit a higher mechanical and system complexity, utilizes the
`combination of the two engines (thermal and electric), adding on the same shaft
`the respective torque and power to achieve the desired performance.
`In this case the advantages of the system can be summarized as follows:
`
`¯ low installed electric power, related to the urban mission, with consequent
`weight and volume reduction;
`¯ possibility of a direct conversion of the thermal energy into mechanical, with
`higher global efficiency of the system;
`¯ addition of the electric power to that of the thermal engine,’with power peaks
`covered by the electric motor.
`
`However, it is necessary to overcome the critical aspects deriving from the
`integration of the two systems, that are:
`
`¯ mechanical complexity;
`¯ complexity of the system for control and simultaneous management of the two
`propulsion systems.
`
`As far as the cost aspect is concerned, taking as a reference an electric vehicle of
`the same size, the hybrid vehicle would feature as follows:
`
`¯ the electric motor is of slightly smaller power;
`¯ the battery can be of lower capacity (roughly one half);
`¯ a thermal engine of relatively low power is added which is taken from the
`conventional mass production;
`¯ a mechanical transmission is substituted to that of the electric vehicle; a specific
`mechanical interface is added.
`
`Therefore, in this preliminary development phase, a not unreasonable goal
`would be a substantial equivalence of cost between the parallel hybrid and a pur
`electric vehicle of the same size.
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`Research and development activity in FIAT
`
`The optimum choice of the hybrid vehicle configuration is strictly connected
`with the mission. FIAT R&D activities in the field of electric traction are lined up
`to the development trend in Europe, where the reference mission can be
`summarized as follows:
`
`¯ city centers with mobility restricted to ZEV vehicles
`¯ extraurban and motorway runs with performances comparable to those of
`conventional vehicles.
`
`The uncertainties of the evolution of the market and of the introduction
`procedures of the regulations did not prevent activities on large fields of
`investigation, both to assess the different technology options and to identify the
`best synergy of thermal/electric/hybrid vehicle.
`The cost constraint requires a strong attention to the carry over among the
`various vehicles and in particular to the conventional normal production
`vehicle.
`Research activities have been started on a hybrid vehicle with parallel
`configuration, derived from a conventional medium size car; pursuing the best
`compromise among technical complexity, cost and performance, keeping the
`same characteristics of roominess, comfort, active and passive safety; in
`particular, design solutions have been followed which limit the required
`modifications on the basic vehicle and optimize the number of components
`drawn from the conventional vehicles already in production, keeping the final
`price of the product within acceptable values.
`In order to verify the functionality of the whole system and the potential of the
`technical choices, a demonstrator prototype of the hybrid vehicle has been
`designed, manufactured and tested both at the test bench and on the road.
`The global objectives of the vehicle, the specifications of the subsystems and the
`preliminary experimental results are discussed in the following paragraphs.
`
`Overall objectives and systems specifications
`
`The performances of the hybrid vehicle compared with those of the basic
`conventional vehicle are shown in Tab. 1, with reference to the operating modes
`electric and hybrid; the use of the pure "thermal" traction is considered only for
`the cases of some anomalous behaviour of the system.
`Throughout a preliminary investigation with mathematical simulation models,
`the deployment of the overall objectives has been performed into subsystem
`specifications.
`Tab. 2 exhibits the characteristics of the main group of the hybrid system. In this
`first phase of the project, the maintenance free Pb/Gel battery has been
`considered for the energy storage system.
`This choice does not hinder the further use of new batteries for the optimization
`of the System in terms of weight and encumbrances.
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`Vehicle Packaging
`
`The hybrid vehicle under study is derived from the conventional model of
`normal production FIAT TEMPRA, which features a weight of some 1100 Kg and
`the following external dimensions:
`
`¯ Length= 4354 ram; width= 1695 mm; Height= 1445 nun
`
`The conversion requires a careful analysis of the main design constraints, which
`bring to a deep review of the layout of all subsystems, with a considerable weight
`increase related to the energy strorage system and to the double drive system (A
`weight ~450Kg).
`The established layout is shown in Fig. 1.
`In order to obtain dynamic characteristics equivalent to those of a conventional
`vehicle, it has been necessary to redefine the main parameters of the suspensions
`(stiffness, damping) according to the new operating conditions.
`In order to obtain the same working conditions and driving comfort within the
`different modes, electric and hybrid, power steering and power braking are
`supplied by electrical pumps.
`The weight increase of approximately 40% over the basic vehicle has requested
`considerable modifications on the structure in order to make the hybrid vehicle
`consistent with the safety standards and with the strength and the stiffness of
`conventional vehicles.
`Preliminary analyses performed by means of computer simulations have
`produced indications on the guidelines to follow in the definition of the
`structural modifications.
`In order to make the interventions compatible with the industrial constraints, it
`has been decided to modify the structure mainly in the lower part, as shown in
`the scheme of Fig. 2. With reference to consumption and emissions, the
`developed solution allows to counterbalance the negative effects due to the
`weight increase, since it allows to:
`
`¯ install a thermal engine of reduced power insofar the maximum performances
`are given by the sum of the power of the thermal engine and of the electric
`motor, with benefits in terms of Overall efficiency at the same total output
`power;
`¯ recover energy during braking phases, thus reducing the negative impact due
`to weight increase;
`¯ use the electric motor and the thermal engine in the highest efficiency
`conditions, through the optimization of the control strategy of the system;
`¯ reduce .the emissions both in transient and starting conditions, through an
`appropriate control strategy.
`
`Hybrid powertrain
`
`In fig. 3 the main components of the hybrid powertrain are shown. Preliminary
`bench tests have been performed on all main components, in order to ver