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`

`
`NEAR-TERM JWBRID VEHICLE PROGRAM
`
`FINAL REPORT -- PHASE I
`
`
`
`contract No. 955190
`
`Sulmltted to
`
`Jet PI-opulelon Laboratory
`celllornla Institute ol Technology
`4300 Oak Grove Drlvo
`Pasadena. California 91103
`
`Submitted by
`
`General Electric company
`Cotporate Research and Development
`Schenectady. New York 12301
`
`Octohet 8, ‘I979
`
`ssusnngusctnuc
`
`Page 2 of 572
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`
`csnaufimctnu:
`
`FOREWORD
`
`The Electric and Hybrid vehicle (EHU) Program was estab-
`lished in DOE in response to the Electric and Hybrid Vehicle
`Research, Development, and Demonstration Act of 19?6. Respon-
`sibility for the EMU Program resides with the Office of Electric
`and Hybrid vehicle Systems of DOE.
`The Near-Term Hybrid Vehicle
`(NTHV) Program is an element of the EHV Program.
`DOE has assigned
`procurement and management responsibility tor the Near—Term Hybrid
`vehicle Program to Jet Propulsion Laboratory (JPL).
`
`The overall objective of the DOE EHV Program is to promote
`the development of electric and hybrid vehicle technologies and
`to demonstrate the validity of these systems as transportation
`options which are less dependent on petroleum resources.
`
`As part of the NTHV Program, General Electric and its sub-
`contractors have completed studies leading to the Preliminary
`Design of a hybrid passenger vehicle which is projected to have
`the maximum potential for reducing petroleum consumption in the
`near term (commencing in l985). This work has been done under
`JPL Contract Number 955190. Modification 3, Phase I of the Near-
`Term Hybrid vehicle Program.
`
`The ma-
`This report is Deliverable Item 1, Final Report.
`terial included in this report summarizes all of the effort in
`Phase I.
`In accordance with Data Requirement Description 7 of
`the Contract,
`the following documents are submitted as appendices:
`
`APPENDIX A is the yission Anal sis and Performance 5 ecifi-
`cation studies He ort.
`‘This is Deliverable Item I and reports
`on the work of TasE 1.
`It presents the study methodology:
`the
`vehicle characterizations;
`the mission description, characteriza-
`tion, and impact on potential sales:
`the rationale for the selec-
`tion of the ICE reference vehicle: and conclusions and recommenda-
`tions of the hission analysis and performance specifications
`studies.
`
`APPENDIX B is a three volume set that constitutes Deliverable
`Item 2 and reports on the work of Task 2.
`The three volumes are:
`
`9 Volume I
`
`-- Design Trade-Off Studies Report
`
`0 volume II
`
`lement to Desi n Trade-Off Studies
`-- su
`
`Report, Volume T
`
`._..._=..._-.__.._._—-—
`.-.._..-M-;—....._.l.._-.—.__..-
`0 Volume III —- Computer Program Listings.
`
`the evaluation and com»
`Volume I presents the study methodology;
`parison of candidate power trains:
`the control strategy and the
`selected design concept. Volume 11 presents reports submitted by
`subcontractors on heat engines. battery power sources, and vehicle
`
`Page 3 of 572
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`&3fii?j:m
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`FORD 1122
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`

`
`pg-sauna‘ - - - v o .. -1:
`
`technology along with detailed background on motors and controls.
`volume III consists of listings of computer programs used in
`analyzing the various design options.
`
`nppsusxx C is the Preliminary Desi n Data_Packa o. This is
`Delivé?EBI§”1tem 3 and repfirts on €fiE"wor
`o-”T5EE'?."_It pre-
`sents the design methodology,
`the design decision rnnionale,
`the
`vehicle preliminary design summary, and the advanced technology
`developments.
`Included in the Preliminary Design Data Package
`are five appendices which present the detailed vehicle design:
`vehicle ride and handling and front structural crashworthiness
`the
`analysis:
`the microcomputer control of the propulsion system:
`design study of the battery switching circuit,
`the field chopper,
`and the batter charger; and the recent HYVEC program refinements
`and computer results.
`
`the
`
`APPENDIX D is the Sensitivity Anal sis Report. This is
`Deliverable Item 8 and reports on Tas
`4.
`It presents the study
`methodology,
`the selection of input parameters and output vari-
`ables,
`the sensitivity study results, and the conclusions of the
`sensitivity analysis.
`
`The three classifications - Appendix, Deliverable Item, and
`Task Number — will be used interchangeably in these documents.
`The work accomplished on this contract. which is fully described
`in this report and its appendices, was performed by the Electric
`vehicle Program in the Power Electronics Laboratory of General
`Electric corporate Research and Development in Schenectady, New
`York. Subcontractors and their areas of support were:
`
`
`ggbccntractor
`
`Area of Support
`
`9 ESE, Inc.
`
`Batteries
`
`* General Electric Space
`Systems Division
`
`Heat Engines
`
`G Professor Gene Smith,
`University of
`Michigan
`
`Mission Analysis and
`Sensitivity Analysis
`
`0 Triad Services
`
`Vehicle Design and
`Analys is
`
`other contributors to the General Electric Vehicle Program
`whose consultations were applicable to this study were:
`
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`iIII'll.iH!'l. law l'.'I.K.-I:-I'J'l'|'IIU
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`I
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`Ganeral Electric DE
`Motor and Generator
`Department
`
`HYhFifi Uvhimlva
`
`bhifiirs
`
`General Electric
`
`Transmigaiuna and Other
`
`Ordnanun System
`Produqta Department
`
`Volkswagen AG
`
`Mechanical Components
`
`Heat Engines and Hybrid
`Vehicle Pmwmr Trains
`
`Page 5 of 572
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`
`GEIIEHHI-ifltlieinur.
`
`FBONTISPIECE
`
`UIIIJEII
`
` PlDPUl.5|0'N BNNEQY
`
`HE A1 ENGINE
`
`EIICHIIC IIOIDH
`
`Near-Term Hybrid Vehicle, Three-Dimensional Cutaway
`
`PEEOEDING PAGE BLAH!‘ NOT FILMED
`
`vii
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`
`Ukllflflla
`
`Elnlil-Ifllly
`
`TAELE OF CONTENTS
`
`
`Seotigg
`
`1
`
`INTRODUCTION AND SUMMARY
`
`1.1
`1-2
`
`1.4
`
`2
`
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`Introduction .
`o
`i
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`3
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`1.2.1 overall DOE EHV Program Objectives.
`1.2.2 DOE Near-Term Hybrid Vehicle Program
`Objectives.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`1.2.3 specific Phase I Objectives .
`.
`.
`.
`1.3 Description of Major Tasks .
`.
`.
`.
`.
`.
`.
`.
`1.3.1 Task 1, Mission Analysis and
`Performance Specification Studies .
`1.3.2 Task 2, Design Trade-off Studies.
`.
`1.3.3 Task 3, Preliminary Design.
`.
`.
`.
`.
`1.3.4 Task 4, Sensitivity Analysis.
`.
`.
`.
`1.3.5 Task 5, Proposal for Phase II .
`.
`.
`1.3.6 Task 6, Phase I Documentation .
`.
`.
`1.3.? Task 1, Program Management and
`.
`.
`Integration .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`Summary of Phase I Program Results .
`.
`.
`1.4.1 Preliminary Design Summary.
`.
`1.4.2 Major Alternative Design Options.
`1.4.3 Interface Component and System
`Control Developments.
`.
`.
`.
`.
`I
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`
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`.
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`
`2.1
`Introduction .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.2 Task I - Mission Analysis and Performance
`Specification Studies Summary.
`.
`.
`.
`.
`.
`2.2.1 objectives.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.2.2 Methodology .
`.
`.
`.
`.
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`.
`.
`.
`.
`.
`2.2.3 Conclusions .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.3 Task 2 - Design Trade-Off Studies.
`.
`.
`.
`2-3-1
`Itj-‘yes:
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`2.3.3 Major Findings.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.4 Task 3 - Preliminary Design.
`.
`.
`.
`.
`.
`.
`2.4.1 Objectives.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.4.2 Methodology .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.4.3 Major Findings/Accomplishments.
`.
`2.5 Task 4 - Sensitivity Analysis.
`.
`.
`.
`.
`.
`2.5.1 Objectives.
`.
`.
`.
`.
`—
`.
`-
`.
`.
`.
`.
`2.5.2 Methodology .
`.
`.
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`2.5.3 Conclusions .
`.
`.
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`
`3
`
`HUMMARY OF THE HYBRID VHHICLE DESIGN.
`
`.
`
`.
`
`.
`.
`.
`.
`3.1 General Layout and Styling .
`3.2
`Power Train Speciticatjons and Hoigh
`Breakdown.
`.
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`1.".3
`1 3
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`
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`
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`
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`2-3
`2-3
`2-10
`2-12
`
`2-17
`2-20
`2-20
`2-20
`2-22
`2-24
`2-24
`2-24
`2-25
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`
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`l.lI:l'II.:l'Ifll.w3Il.I'.l.all|Ih
`
`geption
`3
`
`TABLE OF CONTENTS (Cofifd)
`
`(Cont'd)
`3.2.1
`Power Train Specifications.
`3.2.2
`Vehicle Weight and Weight Break
`Vehicle Performance.
`.
`.
`.
`
`Measures of Energy Consumption .
`Initial coat and Ownership Cost.
`
`Introduction .
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`-bib-h-II-bib-h-h-lb
`
`Parallel Vs. Series Arrangement.
`Secondary Energy Storage .
`Power Split Fraction .
`.
`.
`4
`5 Battery Type .
`.
`.
`.
`.
`.
`.
`6 Engine Type.
`.
`.
`.
`.
`.
`.
`Electric Drive options .
`Transmission Type and Gear Ratios
`Torque Combination options
`
`O
`
`O
`
`0
`
`Ouittiouo
`
`DESCRIPTION OF COMPUTER SIMULATIONS
`
`5.1
`
`Introduction ,
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
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`T L 1 2 3
`
`7 8 9
`
`AL ERNATE DESIGN OPTIONS CONSIDERED AND THEIR
`RE ATIONSHIP TO THE DESIGN ADOPTED.
`.
`.
`.
`.
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`0
`6
`
`Page
`
`3=4
`3-14
`3-17
`3-20
`3-23
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`5.2 Daily Travel Statist cs.
`ions IHYVELD}
`5.3 Hybrid Vehicle Design Calculat
`5.4 Hybrid Vehicle Simulation Calculation
`O
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`
`ECONOMIC ANALYSES .
`
`6.1
`6.2
`
`Introduction .
`
`.
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`
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`
`.
`.
`.
`Methods of Analysis.
`6.2.1
`Determination of Component Costs.
`6.2.2
`Calculation of the Initial Cost
`.
`6.2.3
`
`Calculation of the Ownership Cost
`
`MAINTENANCE AND RELIABILITY CONSIDERTIONS.
`
`.
`.
`
`.
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`.
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`.
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`Introduction .
`7.1
`7.2 fiaintenance Considerations .
`
`1.3 Reliability Considerations .
`
`DESIGN FOR CRASH SAFETY .
`
`3.1
`
`Introduction .
`
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`B.2 Methodology for Crashworthinoss Evaluation
`8.3 Crashworthinoss Analysis Conclusions .
`.
`.
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`Characterization and Salon of Conventional
`5
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`‘taste OF columns (Conroy
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`§.§,et~_i.22.
`
`9
`
`(Cont'd}
`
`.
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`9.3 Heat Engines and Transmissions .
`.
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`9.4 Electric Drive syotemn .
`.
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`9.6 Hybrid and Electric vehicle Evaluations.
`
`_
`Figure
`
`LIST OF n.Lusimmons
`
`1.d.1—l Near—Term Hybrid vehicle, Three-Dimensional
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`1.d.1—2 Artist's Rendering of the Hybrid vehicle.
`
`l.4.1—3 Battery State-of—Charge and Fuel Economy
`for Urban and Highway Driving .
`.
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`1.4.1—4 Total Energy and Petroleum Fuel Usage in
`Urban Driving for the Near-Term Hybrid Vehicle.
`
`1.4.1-5 Ownership Cost as a Function of Gasoline Price.
`
`1.4.1-6 Annual Net Dollar Savings as a Function of
`I
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`
`Phase I Activities Flowchart.
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`2.2.2-1 Power—to—Height Ratio Requirements
`
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`2.2.2-2 Projected 1985 Composite Fuel Economy .
`
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`
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`
`3.2.lw3 Torque Transfer Unit.
`
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`
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`
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`
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`
`Battery State—of~Charge and Fuel Economy
`for Urban and Highway Driving .
`.
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`Ownership Cont an a Function of Gasoline Price.
`
`3.5ufl
`
`Annual not Dollar Savings as a Function of
`C”-Za.§QLILn!3 Pricflo -s
`..a
`1!
`I
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`
`Torque Cominetion Options.
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`
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`U'II'II.'I'IHI-WI l.I=L!lIIIIlI
`
`us? OF ILLUSTRATIONS (cunfd)
`
`___..
`Pugg
`
`Calculation of Daily Travel Stntintien Usinq
`the Monte Carlo Trip Length Gnnoratnr Program .
`
`Daily Random Travel = PeroenL of Days w an a
`Function of Annual Miles.
`.
`.
`.
`.
`.
`.
`.
`.
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`
`.
`
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`
`Daily Random Travel = Percent of Vehicle Milnn -
`as a Function CII Annuai Milfiffi
`0
`0
`0
`a
`a
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`
`Schematic of the Hybrid Vehicle Design {HYVELD}
`Calculation Procedure .
`n
`o
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`o
`n
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`
`Schematic of the Hybrid vehicle Simulation
`Ca1Cu].atiDL‘.
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`
`Schematic of the Hybrid vehicle Forward
`Structure and Components for Crash Simulation .
`
`Hybrid Vehicle Body Structure, Exploded View.
`
`.
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`a
`
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`
`Maximum Deceleration as a Function of Maximum
`Intrusion (Refer to Table 8.2-1 for Run
`Identification)
`.
`.
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`
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`
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`
`Comparison of the Transverse Hybrid Driveline
`and Stock Malibu Crash Test Performance .
`.
`.
`
`.
`
`.
`
`LIST OF TABLES
`
`Power Train Design Options Considered in Depth.
`
`.
`
`Fuel Use by Size Class in 1985.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`Daily and Annual Travel Distances Inside SMSAs
`for Various Driving Missions.
`.
`.
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`
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`
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`
`Daily and Annual Travel Distances Outside SMSAS
`I
`O
`for various Missions.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`
`Hybrid Power Train Configurations and Components
`Considered in the Design Trade~0ff Study
`.
`.
`.
`
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`
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`
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`
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`
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`
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`
`5.2s3
`
`5.3-l
`
`5.4-1
`
`8.2-l
`
`8.2-2
`
`80
`
`3.3-2
`
`Table
`
`1.4.2*l
`
`232i
`
`2.2.2~2
`
`3.Z.3=3
`
`2.3.2-1
`
`2.3.2*2
`
`vehicle and Economic Factor Input Parameters
`for the Design Trade—0ff Calculations .
`.
`.
`
`2.5.2=l
`
`Summary of Parameter Sensitivities Studied
`Ufiing
`o
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`0
`0
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`-3-
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`u
`o
`o
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`o
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`
`3.2.2-1
`
`Weight Breakdown - Malibu Based Hybrid.
`
`3.3-1
`
`3.3=2
`
`3.4wl
`
`Vehicle Performance Characteristics .
`
`Vehicle Performance Characteristics .
`
`Energy Consumption Measures
`(Near=Term Hybrid Vehicle).
`
`3e
`
`Cost Breakdown.
`
`.
`
`.
`
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`
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`
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`
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`
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`nrmrnnmfimctmc
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`.!-’.9..‘.!.‘_‘.*.
`
`4-3
`
`4»4
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`4-12
`
`5-2
`
`7-2
`
`7-4
`
`9-5
`
`Ll8.T ~U-.'.'»’ TABLE3 (Con|'d)
`
`Power Train Arrangement Considerations.
`
`0
`
`0
`
`Secondary Storage (Flywheel) Qousidurationa
`
`Storage Unit Characmeriaticn in the Defiiqn
`0
`Trade—0f£ Studies .
`.
`¢
`
`fl
`
`O
`
`0 a
`
`v
`
`C
`
`0 0 c
`
`Battery Type Conaideratiuna .
`
`Engina Type Considerations.
`
`0
`
`Electric Drive System Considerations.
`
`Tranamiasion Selection Consiéerationa .
`
`summary of the Use of Computer Simulatinnfl
`0
`D
`C
`in the Phase I Study.
`.
`
`0
`
`Maintenance for DOE/GE Near—Term Electric
`O
`0
`II
`Vehicle .
`.
`.
`.
`.
`.
`.
`.
`
`vehicle Maintenance and Reliability Factors
`
`O
`
`Summary at Crash Simulatiun Results .
`
`.'.'L‘*_§.-1:."
`
`4.2-1
`
`40
`
`4.5-2
`
`1.6=1
`
`do?-1
`
`4.fl~l
`
`5.1-1
`
`7.2-1
`
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`Beouon 1
`
`IHTHODIICTIOH All! SUHHAIIY
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`I-ldulilxliflfl W I-It-51:1--II--u
`
`$&eHofi'I
`
`EHTHODUCTEON AND SIUMHAIW
`
`‘L1 INTHODUCMDN
`
`This report in Deliverable item 7, Fiflfllmflflnpfii, and in the
`summary report of a series which dooumcnt
`the resfiitn of Phase T
`oi Lhe Ncar=Tcrm Hybrid vehicle Program. This phase oi the pro-
`gram was a study lending to the preliminary design of n 5=pu3r;n=
`yer hybrid vehicle ut;i1.‘1z:i.ng ‘two :_-znt.-rgy sotiroos (:;alc.-c..r;i.oit;y anti
`gasoline/diesel fuel)
`to minimize petroleum usage on a fleet
`basis.
`
`The program is sponsored by the Us Department of Energy
`(DOE) and the California Institute of Technology, Jet Propulsion
`Laboratory (JPL}. Responsibility for this program at DOE resides
`with the Office of Electric and Hybrid vehicle Systems. work on
`the Phase I portion of the program was done by General Electric
`Corporate Research and Development and its subcontractors under
`JPL contract 955190.
`
`This report presents a complete summary of the work done on
`Phase I,
`in the following manner:
`
`0 Overall summary of the Phase I activity
`
`I Summary of the individual tasks
`
`0 Summary of the hybrid vehicle design
`
`9 Summary of the alternative design options
`
`0 Summary of the computer simulations
`
`i Summary of the economic analysis
`
`0 Summary of the maintenance and reliability
`considerations
`
`° Summary of the design for crash safety
`
`9 Bib]. iography
`
`These summaries arc based on and are supported by the series
`of task reports that were submitted as deliverable items during the
`contract.
`The task. reports are being resubmitted as appendices to
`this Final Report.
`The interrelationship of appendices, deliver"
`able items, and tasks is tabulated below:
`
`I]
`
`|--I
`
`|_n
`
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`Gauss-.A1.@ ELEIITIIIB
`
`D(.el’3‘."““ ‘tle
`
`...m1;.5';*—Ir-
`
`.'£;i.J.=._1£f_
`
`1
`
`2
`
`3
`
`B
`
`1
`
`2
`
`3
`
`4
`
`Mission Analyaie and PerE9:mw
`avce Specification Studies Report
`
`I — Design Trade-Off
`Vol.
`Studies Report
`
`Vol. II — Supplement to Design
`Trade=0ff Studies Report
`
`Vol. III — Computer Program
`Listings
`
`Preliminary Design Data Package
`
`Sensitivity Analysis Report
`
`A
`
`B
`
`C
`
`D
`
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`1-2
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`snasnuflmctnic
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`1 .2 OBJECTIVES
`
`The objectives that were set forth for this effort are iden-
`tirieu in the following subsections.
`
`
`1.2.1 OVERALL DOE EHV PROGRAM OBJECTIVEQ
`
`The overall objective of the DOE EHV Program is to promote
`development of electric and hybrid vehicle technologies and to
`demonstrate the validity of these systems as transportation
`options which are less dependent on petroleum resources.
`
`The Near—Term Hybrid Vehicle Program is an element of the
`EHV Program.
`DOE has assigned prccurement and management re-
`sponsibility for the Near—Tera Hybrid vehicle Program to JPL.
`
`
`1.2.2 DOE NEAR~TERM HYBRID VEHIELE PROGRAM OBJECTIVES
`
`The DOE Near—Term Hybrid Vehicle {NTHv) Program Objectives
`are summarized as follows:
`
`Advance the state of the art in hybrid vehicles
`
`I
`
`Show that hybrid vehicles can be
`
`Practical
`
`Energy efficient
`Safe
`Producible
`Affordable
`Functional
`
`0
`
`I
`
`Develop validated vehicle designs that can be
`useful candidates for the demonstration program
`
`Provide analytical and test methodologies and
`tools for general application to hybrid vehicle
`technology.
`
`The NTHV Program is planned as a multiyear project of two
`phases:
`
`0
`
`9
`
`Phase I
`
`=~ Design Trade=0ff Studies and Preliminary
`Design
`
`Phase II
`
`—= Final Design and Fabrication of Test Vehicles
`
`.__.._.
`.._.._..._....__..._i-.___.__.—.._..._..._...__..__...
`.1 _.._,_ _._....
`1.2.3 spsciric PHASE I onJsCTIvms
`
`The specific objectives of Phase I of the Near=Term Hybrid
`Vehicle Program are to:
`
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`
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`rmmm
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`- IIIGTIIG
`
`Identify missions for hybrid vehicles that
`promise to yield high petroleum impact,
`
`Characterize the single vehicle concept which
`satisfies the mission or set of missions that
`provide the greatest potential reduction in
`petroleum consumption,
`
`Develop performance specifications for the
`characterized vehicle concept,
`
`through trade-off studies, a hybrid
`Develop,
`vehicle preliminary design that satisfies the
`performance specifications,
`
`Identify technologies that are critical to
`successful vehicle development,
`
`Develop a proposal for the Phase II activities
`that include vehicle design, critical technology
`development, and vehicle fabrication.
`
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`1.3 DESCRIPTION OF MAJOR TASRS
`
`The Phase I program was divided into discrete tasks in
`accordance with the contract.
`The work consisted of the follow-
`ing major tasks:
`
`Task 1 — Mission Analysis and Performance Specification
`Studies
`
`Task 2 - Design Trade-off Studies
`
`Task 3 - Preliminary Design
`
`Task 4 - Sensitivity Analysis
`
`Task 5 — Proposal for Phase II
`
`Task 6 — Phase I Documentation
`
`Task 7 - Program Management and Integration
`
`The work done on this program is described in subsequent
`sections of this report. Section 2, Summary of the Phase I
`Tasks, describes how the tasks interrelate and gives details of
`the four major tasks (Tasks 1 through 4}. These sections include
`the specific tasks objectives, and a discussion of the methodology,
`and the major findings, conclusions, or recommendations.
`In addi-
`tion,
`the complete reports associated with Tasks 1, 2, 3, and 4
`are submitted as appendices to this report.
`A brief summary
`description of the major tasks and identification of the task
`reports follows.
`
`1.3.1 TASK 1, MISSION ANALYSIS AND PERFORMANCE SPECIFICATION
`STUDIES
`
`(1)
`The major elements of Task 1 included the following:
`definition of the missions or set of missions which maximize the
`
`potential for reduction of petroleum consumption by a single
`hybrid vehi‘1e,
`(2)
`identification of vehicle characteristics
`associated with these missions, and (3) preparation of specifica-
`tions defining the performanco requirements which the vehicle
`should achieve to safely and efficiently perform the mission or
`set of missions identified in the mission analysis.
`The work
`done on this task is reported in its entirety in Appendix A,
`
`
`Mission Anal sis and_Eerformmn5L£flE§gI}cation_Studies Report.
`
`—_;\-...-4._.=— ...-..___. ....,.-.-_»... ....... _..__..__._....._... .._.
`1.3.2 IASK 2, DESIGN TRADE"0FF STUDIES
`
`included tradeeoff studies of alternate system cone
`Task 2
`figurations and components in order to arrive at a hybrid vehicle
`design concept which best achieves the vehicle specifications
`
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`developed in Task 1 and offers the greatest promise of reducing
`petroleum consumption.
`The work done in this task is reported in
`its entirety in Appendix B. Design Trade—off Studies Report,
`Volumes I, II, and III.
`
`1.3.3 TASK 3; PRELIMINARY DESIGN
`
`Task 3 carried out a preliminary design of the most promising
`hybrid vehicle concept identified in the Task 2 studies.
`It in-
`cluded definition of all major parameters and components, such
`as internal and external dimensions: all power train components:
`materials for body and chassis; weight breakdown by major sub-
`assemblies; projected production and life cycle costs; performance
`(including all categories specified in Task 1); and identification
`of technology development required to achieve this preliminary
`design.
`The work done on this task is reported in its entirety
`in Appendix C. Preliminary Design Data vackage.
`
`1.3.4 TASK 4, SENSITIVITY ANALYSIS
`
`Task 4 carried out a sensitivity analysis which determined
`the impact of variations in selected parameters on the utility,
`the economic attractiveness. and the marketability of the hybrid
`vehicle.
`The parameters varied included travel characteristics,
`energy costs. hybrid vehicle lifetime, maintenance cost, and fuel
`economy of the Reference ICE Vehicle.
`The work done in Task 4 is
`reported in its entirety in Appendix D, Sensitivity Analysis Report.
`
`1.3.5 TASK 5, PROPOSAL FOR PHASE II
`
`Task 5 consisted of p-oparing a proposal for Phase II of the
`program which included a final vehicle design based upon results
`of Task 3 preliminary design. Subject to JPL approval of this
`final design,
`two hybrid vehicles with spares and support equip=
`ment will be fabricated in Phase II.
`The Phase II effort also
`includes testing the vehicles, delivering them to JPL, and provid-
`ing field support during acceptance testing.
`The Phase 11 pro-
`posal was prepared in response to RFP JC—2—2974—3U5 issued by JPL
`on July 6. 1979.
`The proposal, Phase II of the Near-Term Hybrid
`Vehicle Pro ram, Proposal REP JCZE-§§7Z—35§, was submitted to JPL
`on August 23.
`l9?9.
`It consisted of three volumes Vhich were:
`volume I = Technical Proposal; volume II ~ Management Proposal;
`and Volume III — Cost Proposal.
`
`.......=._._-..-..
`1.3.5 TASK 6, mess I n9cun§NTAT1gg
`
`Task 6 consisted of preparation of monthly status reports:
`the separate reports for Tasks 1, 2, 3, and 4, respectively:
`the proposal for Phase II: and this final report for all of Phase
`
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`aauznnflnscrnuc
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`I. These reports have been identified where appropriate in the
`preceding paragraphs.
`
`
`1.3.7 TASK 7, pnqg_n_An MANRGEMEN1‘ AND INTEGRATION
`
`Task ? consists of the program management and integration
`effort required to maintain technical and cost control and assure
`achievement of the Phase I objectives. This is mentioned for
`completeness, since it played a vital role in the successful
`execution of the program.
`It is not covered in this final report
`or in the technical reports which were submitted previously.
`
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`LIlIlfil|l.EI.EI:'lIlE
`
`1.! SUMMARY OF PHASE I PROGRAM RESULTS
`
`The completed Phase I Program has resulted in the Prelimin=
`ary Design of a hybrid vehicle which fully meets or exceeds the
`requirements set forth in JPL Contract 955190. This work is
`fully documented as discussed in Section 1.3. Highlights of the
`preliminary design are presented in the following sections along
`with the alternative options which were considered.
`
`1.4.1 PRELIMINARY DESIGN sum-may
`
`There are many aspects of the preliminary design that are
`considered important.
`The following sections discuss those deemed
`to be most relevant.
`
`1.4.1.1 General Layout and Styling
`
`The general characteristics of the vehicle layout and
`chassis are:
`
`0 Curb weight
`
`— 1786 kg (3930 lb)
`
`0 Body style
`
`- Four—door hatchback
`
`— Drag Coefficient — 0.40
`— Frontal area - 2.0 m2
`(21.5 ft’)
`
`0 Chassis/Power Train Arrangement
`
`— Front wheel drive
`
`- Complete power train,
`of firewall
`
`including the batteries.
`
`in front
`
`- Fuel
`
`tank under rear seat
`
`' Baseline ICE Vehicle
`
`- 1979 Chevrolet Malibu
`
`A threevdimensional cutaway of the hybrid vehicle indicating
`the placement of the power train is shown in Figure l.4.1«l. Note
`that the complete_hybrid power train is located in front of the
`firewall with no intrusion into the passenger compartment.
`The
`drive train consists of an 30 hp {peak} 1.6 litor fuelwinjoctcd
`gasoline engine, a 45 hp (peak) separately excited do motor, an
`automatically shifted transmission, clutches, and accessory drive
`components.
`An artist's rendering oi the vehicle styling is shown
`
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`mmIALQmcrIuc
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`PROP Ul.SION B-ATTERY
`
`FUEL YANU.
`
`E I.EC IRIC IIOTOI
`
`10401-10
`
`ET
`
`.1r.Du!H
`EEIhT'B1C.1hEV10
`Dimensional Cutaway
`
`—
`
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`
`l3£llElIr.I.QElE|:TlllB
`
`A four-door hatchback body type was selected
`in Figure 1.4.1-2.
`because it maximizes the a11—purpose character of the five-
`passenger vehicle and hence its marketability.
`
`1.4.1.2 Energy Use
`
`The primary goal of the hybrid vehicle program is to conserve
`petroleum.
`The vehicle which was designed in Phase I offers great
`promise in meeting this goal. Figure 1.4.1-3 shows that the fuel
`economy of the near-term hybrid vehicle is in excess of 68 mpg for
`trips of 30 miles or less.
`Figure l.4.l—4 illustrates the petro-
`leum fuel enery savings when compared to the Reference ICE Vehicle
`(1985 model).
`The total energy used (fuel and electricity,
`in-
`cluding generating efficiency) by the near-term hybrid vehicle is
`about
`5% less than the Reference ICE Vehicle.
`
`1.4.1.3 Cost Considerations
`
`A second important goal of the hybrid vehicle design was to
`be competitive with the Reference ICE Vehicle in first cost and
`equal or lower in total ownership cost.
`The hybrid vehicle
`sticker price is estimated at $7600 in 1978 dollars, versus
`$5700 in 1978 dollars for the Reference ICE Vehicle.
`The owner-
`
`ship cost advantage of the hybrid vehicle can be seen in Figures
`1.4.1-5 and 1.4.l—6 which show the ownership cost and net annual
`dollar savings as a function of gasoline price.
`The hybrid
`vehicle has the advantage of lower ownership cost as gasoline
`prices exceed $1/gal.
`
`1.4.1.4 Major Features of the Design
`
`The major features of the design are summarized in this sub-
`section.
`In Section 3 of this Final Report.
`the vehicle Per-
`formance characteristics and the Energy Consumption Measures are
`given in the format provided by JPL. These features are discussed
`in the following sections.
`
`l.4.l.4.l Vehicle Design - The Vehicle Design features which
`are considered to be of greatest importance in reducing technical
`risk while meeting JPL performance requirements are:
`
`(l) A microprocessor-based controller evolved from vehicle
`and electricai system controIs*deve[oped 5- GE/CRD for the Near-
`Term Electric Vehicle Program and the highlyerefined electronic
`engine controls developed by VW,
`
`(2) A Qrigggmgtgr based on the motor developed by GE DC Motor
`and Generator Department for the NeareTerm Electric Program,
`
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`fiillllloillttfilt
`
`
`
`Left Rear Quarter View
`
`
`
`Left Front Quarter View
`
`Figure 1.4.1-2. Artist's Rendering of the Hybrid Vehicle
`
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`naneantflmcmlc
`
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`run.economy1.-um;ANDam.-renvs~.'n1r.-0:“-ca-mas;men $
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`MPG IEFJH HIGHWAY C'I‘l'.'t.E|
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`‘W
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`20
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`.___L.L......_..LJ.__..1_..J_..,..
`30
`40
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`60
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`..._
`1:: MILES
`
`50
`
`TO
`
`90
`
`110
`
`km
`
`UH SAN DSSTANCE TRJWELED
`
`Figure 1.4.1—3. Battery State-of-Charge and Fuel Economy
`for Urban and Highway Driving
`
`UPDNFED VEHICLE DESIGN
`
`4.0
`
`REFERENCE WE \FEH|C1.E {1935 MODEL]
`-_u
`‘FDTAL ENERGY USED (FUEL En i-ILECTRl|.‘.’I'l\'j
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`2.0 Fl-.TRI'.'l1.E‘..IM $'Ui_'L
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`3.0
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`Inn
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`50
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`50
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`IJHBAN DlS1.r9nNCF Tl"-IIEWELED
`
`Figure 1.4.1~4. Total Energy and Petroleum Fuel Usage
`in Urban Driving for the Nea.I_r:='1'erm
`Hybrid Vehicle
`
`Page 24 of 572
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`1"”
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`FORD 1122
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`Page 24 of 572
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`FORD 1122
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`

`
`ererrsrmflmcrrrrc
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`:24
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`22
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`20
`
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`
`
`
`OwnershipCars!inenrs.'r:-25.1-err
`
`13
`
`Electricity Price: 4.2 centeikwh
`
`.5
`
`1 .0
`
`1 .5
`
`2.0
`
`2.5
`
`Gasoline Price {small
`
`Figure 1.4.1-5. Ownership Cost as a Function of Gasoline Price
`
`
`
`
`
`AnnuaiNetSavings{Doilarsl
`
`
`
`Electricity Price: 4.2 centsikwh
`
`HI)
`
`9
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`.,.I /1. _Lm_
`1.0
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`2.0
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`
`Gasoline Price fiigell
`
`Figure 1.4.1-6.
`
`iinnual Net Dollar Savings as Ll Funr:1:_1'.(m
`of Gu:sr31_.inc: Price
`
`Page 25 of 572
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`Page 25 of 572
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`FORD 1122
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`

`
`a2n£nAL® metals
`
`(3) A bggtgryflggbgyntom based on the battery developed by
`Globe-Union for the Noar~Tcrm Electric Vehicle Program and rncont
`developments on nlectrolytn circulation for the Argonne National
`Laboratory Near~Term flattery Program,
`
`(4) An Engine based on a vw production engine, VW advanced
`studies and experiments on emissions, and VW proprietary work on
`quick start for on/off engine operation,
`
`
`(5) A gghicle subsystem design by Triad Services based on the
`extensive use of major components from late model production cars
`with a minimum of new design,
`
`{6} A hybrid Ercpulsion subsystem (including the battery)
`which is packaged entirely under the hood with no intrusion into
`the passenger compartment or the luggage compartment.
`
`(7) Performance analysis models and computer programs which
`have been developed and validated by GE/CRD for second—by—second
`analysis of system performance during the Phase I Hybrid Vehicle
`Program.
`
`l.4.l.4.2 Power Train Design
`
`The Hybrid vehicle designed in this study has the following
`power train characteristics:
`
`{1} The propulsion subsystem is a parallel configuration
`in which the heat engine and the electric motor can deliver
`mechanical
`torque to the drive shaft, either together or indie
`vidually.
`
`(45 hp peak} will be used primarily
`{2} The electric motor
`for urban driving with moderate accelerations, speeds below 30
`mph,
`ranges of less than 35 miles, and regenerative braking at
`all speeds.
`
`(3) The heat engine (30 hp peak) will be used primarily for
`highway driving at speeds above 30 mph and to augment the elec=
`tric motor for fast accelerations at lower speeds.
`
`(4) The electric motor will augment th