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`Page‘lof572
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`

`NEAR-TERM iW’BRID VEHICLE PROGRAM
`
`FINAL REPORT -- PHASE I
`
`
`
`Contract No. 955190
`
`Sunni-titted to
`
`Jet Propulsion Laboratory
`Calliornia institute oi Technology
`4300 Oak Grove Drive
`Pasadena. California 91103
`
`Submitted by
`
`General Electric Company
`Corporate Research and Development
`Schenectady. New York 12301
`
`October a. 1979
`
`“arrangements
`
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`untaufi lemme
`
`FOREWORD
`
`The Electric and Hybrid Vehicle (EHV) Program was estab—
`lished in DOE in response to the Electric and Hybrid Vehicle
`Research, Development, and Demonstration Act of 1976. Respon-
`sibility for the EHV 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 DOB 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 1985). 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 7, Final Report.
`terial included in this report summarizes all of the effort in
`Phase I.
`In accordance with Data Requirement Description 1 of
`the Contract,
`the following documents are submitted as appendices:
`
`APPENDIX A is the yission Anal sis and Performance 5 ecifi-
`cation Studies Re ort.
`'Efiis 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:
`
`0 Volume I
`
`-- Design Trade—Off Studies Report
`
`0 Volume II
`
`lement to Desi n Trade-Off Studies
`w- Su
`
`Report, Volume T
`
`9 Volume III
`
` MIN-h..-
`MM”
`-- Computer Program Listings.
`
`the evaluation and comm
`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
`
`figditjru
`
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`

`y-cuuun- 1 -I-‘oI-l‘
`
`technology along with detailed background on motors and controls.
`Volume III consists of listings of computer programs used in
`analyzing the various design Options.
`
`.rw—l‘l'
`APPENDIX C is the Preliminary Desi n Data Packs o. This is
`Deliv3?aBIe Item 3 and reports on EHEHwor
`o ”TEEE'3.
`It pre-
`sents the design methodology.
`the design decision rulionale.
`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
`DeliveraEle Item 8 and reports on TasE i.
`It presents the study
`methodology.
`the selection of input parameters and output vari-
`ables,
`the sensitivity study results, and the cenclusions or 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
`
`3 EBB, Inc.
`
`Batteries
`
`3 General Electric Space
`Systems Division
`
`Heat Engines
`
`I Professor Gene Smith,
`University of
`Michigan
`
`Mission Analysis and
`Sensitivity Analysis
`
`0 Triad Services
`
`Vehicle Design and
`Analysis
`
`Other contributors to the General Electric Vehicle Program
`whose consultations were applicable to this study were:
`
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`
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`{Mcm fibgjl Hunflmi
`
`Hybrid Uflhifilflfl
`
`0 Ganeral filflctrifl DE
`Motor and Genurator
`Department
`
`Hutnrs
`
`6 Genorél Electric
`
`Transmiggiuna and other
`
`Ordnance Syfltfim
`Producta Department
`
`Hafihanical Cnmpuuentfi
`
`I Volkswagen AG
`
`Heat Engines and Hybrid
`Vehicle Fewer Trains
`
`Page 5 of 572
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`FBONTISPIECE
`
`
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`EIICHIIC H010!
`
`Near-Term Hybrid Vehicle, Three-Dimensional Cutaway
`
`BRECEDING PAGE BLANK NOT FILMED
`
`vii
`
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`Utlflfiflln ' Elli-II";
`
`TABLE OF COHTENIB
`
`
`Sectigg
`
`1
`
`INTRODUCTION AND SUMMARY
`
`.
`
`.
`
`.
`
`.
`
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`Introduction .
`1.1
`o
`-
`o
`o
`s
`n
`I
`o
`a
`u-
`1. 2 Objectivea .
`1.
`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 .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`Summaary 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.
`.
`.
`.
`.
`SUMMARY OF PHASE I ACTIVITY .
`.
`.
`.
`.
`.
`.
`
`1.4
`
`2
`
`.
`.
`.
`.
`
`.
`.
`
`.
`.
`
`.
`.
`
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`
`1-1
`
`1—2
`1‘3
`1w3
`
`1-5
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`3—5
`
`1—5
`1—5
`1-6
`1—6
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`1-8
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`1—15
`
`1—18
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`
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`
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`2~10
`2~12
`2‘12
`2-12
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`2—20
`2—20
`2n20
`2‘22
`2‘24
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`2- 24
`2~25
`
`3—1
`
`3&1
`
`3-4
`
`.
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`
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`
`.
`
`2.1
`Introduct.ion .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.2 Task I - Mission Analysis and Performance
`Specification Studies Summary.
`.
`.
`.
`.
`.
`2.2.1 Objectives.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.2.2 Methodology .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.2.3 Conclv.sions .
`.
`.
`.
`.
`.
`.
`.
`.
`2.3 Task 2 — Design Trade*0ff Studies.
`.
`.
`.
`2 3-]-
`0b:
`tj‘NBS.
`-
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`t
`o
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`2.3.3 Major Findings.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.4 Task 3 — Preliminary Design.
`.
`.
`.
`.
`.
`.
`2.4.1 Objectives.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.4.2 Methodology .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.4.3 Major Findings/Accomplishments.
`.
`2.5 Task 4 n Sensit.ivity Analysis.
`.
`.
`.
`.
`.
`2.5.1 Objectives.
`.
`.
`.
`.
`—
`.
`-
`.
`.
`.
`.
`2.5.2 Methodology .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`2.5.3 Conclusions .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`
`3
`
`tiUMmeY OF THE HYBRID Vl-‘illli‘H'i DEEIGN.
`
`.
`
`.
`
`.
`.
`.
`3.1 General Layout and Stvlinq .
`3.2
`Power Train Speciticritjons and Height
`Breakdown.
`.
`.
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`o
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`.
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`viii
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`UENEHILWFELILIIIIH
`
`fiegtion
`3
`
`(Cont' d)
`
`TABLE OF CONTENTS (Coni'd)
`
`.
`.
`3.2.1 Power' Train Specifications.
`3.2.2 Vehicle Wei.ght and Weight Breakdown .
`3.3 Vehicle Performance.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`3.4 Measures of Energy Consumption .
`.
`.
`.
`.
`.
`.
`3.5
`Initial Cost and Ownership Cost.
`.
`.
`.
`.
`.
`.
`
`4
`
`ALTERNATE DESIGN OPTIONS CONSIDERED AND THEIR
`RELATIONSHIP TO THE DESIGN ADOPTED.
`.
`.
`.
`.
`.
`
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`Introduction .
`4.1
`.
`4.2 Parallel Va. Series Arrangement.
`.
`4.3 Secondary Energy Storage .
`.
`.
`.
`o
`4.4
`Power Split. Fraction 0
`o
`o
`o
`o
`o
`.
`4.5 Battery Type .
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`4.6 Engine Type.
`.
`.
`.
`.
`.
`.
`.
`.
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`.
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`4.7 Electric Drive Options .
`.
`.
`.
`4.8 Transmission Type and Gear Ratios .
`4.9 Torque Combination Options .
`.
`.
`
`5
`
`DESCRIPTION OF COMPUTER SIMULATIONS .
`
`.
`
`.
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`IntrOdUCtj-on O
`5 I 1
`.
`.
`.
`5.2 Daily Travel Statistics.
`5.3 Hybrid Vehicle Design Calculations (HYVELD).
`5.4 Hybrid Vehicle Simulation Calculation
`{HYVEC) '
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`6
`
`ECONOMIC ANALYSES .
`
`601
`
`Introduction 9
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`6. 2 MethOds 0f Analysis.
`6.2.1 Determination of Component Costa.
`6.2.2 Calculation of the Initial Coat
`.
`
`6.2.3 Calculation of the Ownership Coat
`
`7
`
`MAINTENANCE AND RELIABILITY CONSIDERATIONS.
`
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`7.1
`7.2 Haintenance Considerations .
`
`7.3 Reliability Considerations .
`
`DESIGN FOR CRASH SAFETY .
`
`3.1
`
`Introduction .
`
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`8.2 Methodology for Craahworthineaa Ewaluation .
`8.3 Craahworthinoaa Analysis conclusions .
`.
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`BIBIJIUGRAPIIY a
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`9.1 Mission Analysis and Us 0 Patterne.
`9.2 Characterization and 81-1101; of Conventional
`
`ICE Passenger Cars .
`
`.
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`ix
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`Page 8 of 572
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`

`TESLE 0F COHTERTS (le'd)
`
`”mu—- -._—.—_-
`Section
`
`9
`
`(Cont'd)
`
`.
`.
`.
`.
`9.3 Heat Bnginee and Transmissions .
`I
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`9. 4 EIEctric Drive Effitemfl
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`9. 5 Batteries and F1.ywhee1 .
`.
`.
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`9. 6 Hybrid and Electric Vehicle Evaluations.
`
`LIST OF iLLUSTFIATIONS
`
`Near-Term Hybrid vehicle. Three-Dimensional
`cutaway I
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`Battery State-of—Cbarge and Fuel Economy
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`Total Energy and Petroleum Fuel Usage in
`Urban Driving for the Near—Term Hybrid Vehicle.
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`Ownership Cost as a Function of Gasoline Price.
`
`Annual Net Dollar Savings as a Function of
`GafiOline priCEI
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`Hear-Term Hybrid Vehicle, Three-Dimensional
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`I
`I
`I
`I
`I
`
`Artist"s Rendering of the Near-Term Hybrid
`vehiCIe I
`I
`I
`I
`I
`I
`I
`I
`I
`I
`I
`O
`G
`I
`I
`I
`I‘
`
`.
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`.
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`.
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`I
`
`I
`
`.
`
`2—4
`
`2-6
`
`3‘2
`
`3“ 3
`
`3-7
`
`3.2.1fl2
`
`3.2.1e3
`
`3.2.ir4
`
`3.2.le5
`
`3.4=1
`
`304:2
`
`3e5ol
`
`3.563
`
`4.9=i
`
`Hybrid Power Train.
`
`.
`
`.
`
`.
`
`.
`
`Schematic of Drive Package.
`
`Torque Tran3fer Uflit-
`
`I
`
`I
`
`I
`
`.
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`I
`
`.
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`I
`
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`
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`I
`
`.
`
`I
`
`Propulsion Source Sequencing Strategy .
`
`Hybrid Vehicle Microcomputer Control.
`
`.
`
`Battery State—of—Charge and Fuel Economy
`for Urban and Highway Driving .
`.
`.
`.
`.
`
`Total Energy and Petroleum Fuel Usage in
`Urban DriVing I
`I
`I
`I
`I
`I
`I
`I
`I
`I
`I
`I
`e
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`I
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`I
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`I
`
`.
`
`.
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`I
`
`Dunership Coat as a Function of Gasoline Price.
`
`Annual Net Dollar Savings e3 a Function of
`Gasgiine PriGQ.
`u
`o
`w
`e
`I
`I
`a
`I
`I
`e
`I
`a
`I
`
`Torque Combination Options.
`
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`3‘12
`
`3-13
`
`3—15
`
`EvZL
`
`3521
`
`3e25
`
`3W25
`
`~.5
`
`x
`
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`“IfllflHI-wl' Luna-Inu-
`
`LIST OF ILLUSTRATIONS (Cunl'd)
`
`liege:
`
`5.2w1
`
`5.2“?
`
`5.2‘3
`
`5.3-1
`
`5.4-1
`
`8.2-1
`
`8.2-2
`
`8. 3-1
`
`3.3-2
`
`Table
`
`1.4.2*l
`
`2_2_2-1
`
`2.2.2w2
`
`3.3.3=3
`
`2.3.2-1
`
`Calculation of Daily Travel Statintien Usinq
`the Monte Carlo Trip Lnnqth Gunnratnr Program .
`
`Daily Random Travel 5 Percent of Days w an a
`Function of Annual Miles.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`
`.
`
`.
`
`Daily Random Travel = Percent of Vehicle Miles -
`as a Function or Annual Miles .
`.
`.
`.
`.
`.
`.
`.
`.
`
`Schematic of the Hybrid Vehicle Design {HYVELD}
`Calculation Procedure .
`.
`.
`.
`.
`u
`.
`.
`.
`.
`.
`.
`.
`
`Schematic of the Hybrid Vehicle Simulation
`Calculation (HYVEC)
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`
`.
`
`.
`
`.
`
`Schematic of the Hybrid Vehicle Forward
`Structure and Components for Crash Simulation .
`
`Hybrid Vehicle Body Structure, Exploded View.
`
`Maximum Deceleration as a Function of Maximum
`Intrusion (Refer to Table 8.2-1 for Run
`Identification)
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`
`.
`
`.
`
`.
`
`Comparison of the Transverse Hybrid Driveline
`and Stock Malibu Crash Test Performance .
`.
`.
`
`BESS
`
`5-4
`
`5*5
`
`Sufi
`
`SwB
`
`5—10
`
`s2
`
`8-3
`
`8—?
`
`8-8
`
`Page
`
`1&16
`
`2-6
`
`2-8
`
`2~9
`
`.
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`
`.
`
`LIST OF TAELES
`
`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.
`.
`.
`.
`.
`.
`.
`.
`.
`
`.
`
`.
`
`Daily and Annual Travel Distances Outside SMSAS
`for Various Missions.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`.
`
`Hybrid Power Train Configurations and Components
`Considered in the Design Trade«0ff Study
`.
`.
`.
`
`Vehicle and Economic Factor Input Parameters
`for the Design Trade—Off Calculations .
`.
`.
`
`Summary of Parameter Sensitivities Studied
`Ufiing I‘IYVELDe
`o
`o
`o
`o
`o
`a
`a
`I
`o
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`
`2~15
`
`2-16
`
`2:26
`
`3—16
`
`3—18
`
`3-19
`
`3:22
`
`J~24
`
`.
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`c
`
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`
`2.3-2w'2
`
`2.5.2sl
`
`3.3-1
`
`3.3=2
`
`3.4ml
`
`3.2.2-1
`
`Weight Breakdown - Malibu Based Hybrid.
`
`Vehicle Performance Characteristics .
`
`vehicle Performance Characteristics .
`
`Energy Consumption Measures
`(NearmTerm Hybrid Vehicle).
`
`3e 5:1
`
`C.C)5t, Breakdgwn.
`
`o
`
`o
`
`I
`
`a
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`
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`e
`
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`tsusnuflmcmc
`
`3932.
`
`4-3
`
`4&4
`
`'1'”?
`
`45mg
`
`any
`
`fiwll
`
`4-12
`
`5'2
`
`-2
`
`?*4
`
`8-5
`
`.
`
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`
`a
`
`o
`
`a
`
`0
`
`0
`
`0
`
`.
`
`'
`
`*
`
`LIST {17-3 names (Gourd)
`
`Dave: Train Arrangamnnt Connidnratiunfl.
`
`.
`
`0
`
`fieconflaxy Storage (Flywheel) Conaidurationa
`
`Storage Unit Characteristics in the Deaiqn
`‘i
`0
`O
`Trade-Off Studies .
`
`(I
`
`0
`
`O o
`
`C
`
`0 o c
`
`Battery Type Conaideratiuna .
`
`Engina Type Conaiderationfi.
`
`o
`
`Electric Drive System Considerations.
`
`Transmissian Salection Ccnsiéerations .
`
`
`
`0Summary of the Use of Computer Simulatinnav
`C
`in the Phase I Study.
`
`0
`
`Maintenance for DOE/GE Neaererm Electric
`O
`I
`i
`C
`I
`u
`O
`Vehicle .
`
`vehicle Maintenance and Reliability Factors
`
`I
`
`Summary 01'. Crash Simulatiun Results .
`
`TEE-12.“!
`
`4.2*1
`
`4. 3H)»
`
`4.5»1
`
`4.5-2
`
`4.6=1
`
`GOT-1
`
`4.flnl
`
`5.1-1
`
`7.2»1
`
`‘4.
`
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`8m 1
`
`INTRODUCTIOH nun W!"
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`M‘IIIJIOHH w cum-n... ..... ..
`
`Sasflflfl'I
`
`UHTHGDUCTMN AND SHMMAKW
`
`”1.1 INTRODUCMDN
`
`
`This report in Dnlivorablc item 7, Fiasl,flsu0££* and is the
`summary report of a series which document
`the rcdfilts of Phase I
`oi the NcarmTcrm Hybrid Vehicle Program. This pnasc oi the pro-
`gram was a study loading to the preliminary design of a 5=pascon=
`gar hybrid vehicle utilizing two energy sources (electricity and
`gasoline/diesel fuel)
`to minimize petroleum usage on a fleet
`basis.
`
`The procram is spensored by the US Department of Energy
`(DOE) and the California Institute of Technology, Jet Propulsion
`Laboratory (JPL). Respousibility for this program at DOE resides
`with the Cities 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:
`
`8 Overall summary of the Phase I activity
`
`I Summary of the individual tasks
`
`‘ Summary of the hybrid vehicle design
`
`0 Summary of the alternative design options
`
`0 Summary of the computer simulations
`
`' Summary of the economic analysis
`
`C Summary of the maintenance and reliability
`considerations
`
`0 Summary of the design for crash safety
`
`0 Rib], iography
`
`Those summaries are 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]
`
`|-—l
`
`|—‘
`
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`

`GEHEEAI.® mum:
`
`éflflflflgii
`
`Deliv*” Ele
`
`.hfilfigm
`
`EEEE
`
`ELEM?
`
`A
`
`B
`
`C
`
`D
`
`1
`
`2
`
`3
`
`B
`
`1
`
`2
`
`3
`
`4
`
`Mission Analyaie and Perfiormw
`ance Specification Studies Report
`
`I — Design Trade-Off
`Vol.
`Studies Report
`
`Vol. II — Supplement to Design
`Tradew0ff Studies Report
`
`Vol. III — Computer Pregram
`Listings
`
`Preliminary Design Data Package
`
`Sensitivity Analysis Report
`
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`oeusnuflmcmc
`
`1 .2 OBJECTIVES
`
`The objectives that were set forth for this effort are iden-
`titluu in the following subsections.
`
`1.2.1 OVERALL DOE EHV PROGRAM OBJECTIVESIa-
`
`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 procurement and management
`re—
`sponsibility for the NearvTera Hybrid Vehicle Program to JPL.
`
`
`1.2.2 DOE EEARWTERM HYBRID VEHIELE PROGRAM OBJECTIVFS
`
`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
`
`'
`
`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
`
`a
`
`Phase I
`
`=~ Design Trade=0ff Studies and Preliminary
`Design
`
`Phase II
`
`== Final Design and Fabrication of Test Vehicles
`
`..“_.._...__...__._..._....____..._.—.._._.._..=u _.._‘.._.==__.__ _
`1.2.3 sesame PHASE I OBJECTPIVEE
`
`The specific objectives of Phase I of the Near=Term Hybrid
`Vehicle Program are to:
`
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`

`GIIEIALOIIIG‘IIIG
`
`0
`
`Identify missions for hybrid vehicles that
`promise to yield high petroleum impact,
`
`0 Characterize the single vehicle concept which
`satisfies the mission or set of missions that
`provide the greatest potential reduction in
`petroleum consumption.
`
`0 Deve10p performance specifications for the
`characterized vehicle concept,
`
`through trade-off studies, a hybrid
`0 Develop,
`vehicle preliminary design that satisfies the
`performance specifications,
`
`0
`
`Identify technologies that are critical to
`sucCessful vehicle development,
`
`0 Develop a proposal for the Phase II activities
`that include vehicle design, critical technology
`development, and vehicle fabrication.
`
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`

`neuinuflmcmc
`
`1.3 DESCRIPTION OF MAJOR TASR'S
`
`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 l, 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-le,
`(2)
`identification of Vehicle characteristics
`associated with these missions, and (3) preparation of specifics“
`tions defining the performance 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.
` “sup-«WW ._....._... . ___....‘___.=_._-...,__
`
`
`MVMHo-h‘fl- ... ”N..~.._..____..__._...._m .._.
`1.3.2 258K 2, DESIGN TRADSrOFF STUDIES
`
`Task 2 included tradoeoff studies of alternate system cons
`figurations and components in order to arrive at a hybrid vehicle
`design concept which best achieves the vehicle specifications
`
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`

`asunufi mum
`
`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 Repeat;
`
`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 Package.
`
`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-eparing 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 RPP JC—2—2974—305 issued by JPL
`on July 6. 1979.
`The proposal, Phase II of the Near-Term Hybrid
`Vehicle Pro ram, Proposal RFP JC:§-§§VI—35§, was submitted to JPL
`on August 22,
`I9?9.
`It consisted of three volumes which were:
`Volume I = Technical Proposal; Volume II ~ Management Proposal;
`and Volume III — Cost Proposal.
`
`.wfimg...“
`1.3.6 TASK 6, sense I nosusgnen'rlgy
`
`Task 6 consisted of preparation of monthly status reports:
`the separate reports for Tasks I, 2, 3, and 4. respectively:
`the proposal for Phase II: and this final report for all of Phase
`
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`

`GENERAL. nmm
`
`I. These reports have been identified where appropriate in the
`preceding paragraphs.
`
`
`1.3.7 TASK 7, PRO‘EEAM MANAGEMENT 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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`RIIEEM.ELEETIIB
`
`1.4 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 iorth 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-1AM
`
`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:
`
`' Curb weight
`
`— 1786 kg (3930 lb)
`
`0 Body style
`
`- Four-door hatchback
`
`— Drag Coefficient — 0.40
`- Frontal area - 2.0 m2
`(21.5 ftz)
`
`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 threewdimensional cutaway of the hybrid vehicle indicating
`the placement of the power train is shown in Figure 1.4.lvl. 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 liter fuelwinjectcd
`gasoline engine, a 45 hp (peak) separately excited do motor, on
`automatically shifted transmission, clutches, and accessory drive
`components.
`An artist's rendering of the vehicle styling is Shown
`
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`atuennfimcmc
`
`PROP UtSION BATTERY
`
`HEATER
`
`FUEL ‘ANI’.
`
`HE AT
`
`ENGINE
`
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`Term Hybrid Vehicle. Three-
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`A fourmdoor hatchback body type was selected
`in Figure 1.4.1-2.
`because it maximizes the allwpurpose 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 6G mpg for
`trips of 30 miles or less.
`Figure 1.4.1—4 illustrates the petro—
`leum fuel enery savings when compared to the Reference ICE Vehicle
`(1985 model}.
`The total energy used (fuel and electricity.
`inn
`cluding generating efficiency) by the near-term hybrid vehicle is
`about
`5% less than the Reference ICE Vehicle.
`
`1.4.1.3 Coat 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
`l.4.1»5 and 1.4.1—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/ga1.
`
`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.
`
`1.4.1.¢.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) h microprocessor—based controller evolv-ed Ercm vehicle
`and electrica.E system controlsdeveloped 8! GE/CRD for the Near-
`Term Electric Vehicle Program and the highlyerefined electronic
`engine controls developed by VW,
`
`-.«...—-.._Mama»:-
`.A drive motor based on the motor developed by GB DC Meter
`(2)
`and Generator Department for the NearaTeim El.ectric Program,
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`Left Rear Quarter View
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`
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`Left Front Quarter View
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`Figure 1.4.1-2. Artist's Rendering of the Hybrid Vehicle
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`NEAR-TERM Hmml} nutmeg;
`
`
`
`
`‘0
`
`m
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`
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`
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`rue.ecouommm)momurmursum-mamas];we $
`
`m...— MPG (L'PA unam CYCLE}
`
`
`
`
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`anncnv STATE‘OF-CHkFGE /
`{EPA URBAN cvcm
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`MPG IEFfi HIGHWAY CTIIUEI
`
`0
`
`we
`
`20
`
`50
`
`10
`
`90
`
`110
`
`km
`
`.———Ll————-——L—L-——_.I—._L“nl_——u—L—l_._
`so
`no
`so
`so
`In hMLES
`
`UH SAN DSSTANCE TRAVELED
`
`Figure 1.4.1—3. Battery State—of-Charge and Fuel Economy
`for Urban and Highway Driving
`
`UPDAI’ED VEHICLE D‘ESlGN
`
`
`
`
`
`MJ-‘km-AVERAGEENERGYUSE
`
`4.0
`
`3.0
`
`2.0
`
`1.0
`
`REFERENCE *CE VEHICtE {1985 MODEL}
`——”a——-‘—Q—--fin-——dh—_fln—mu
`
`fDTAL ENERGY USED [FUEL fl- ELECTRiCiTY]
`
`PE‘RULEUM yUEl
`
`
`Inn
`"0
`9f}
`30
`50
`"3
`
`W_L.._.._‘ 1.4....
`..._.1.L .
`...1._l WLEHAL—WLLmM
`1U
`20
`30
`4G
`50
`ED
`3'0 M‘LE‘S
`
`,.
`
`unanNLmsxamcrrnauELen
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`Figure 1.4.1~4. Total Energy and Petroleum Fuel [sage
`in Urban Driving for the Near=Term
`Hybrid Vehicle
`
`1~12
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`m
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`OwnershipCars!Em'mile}
`
`9.4
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`22
`
`18
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`Electricity Price: 4.2 cantsrkwh
`
`.5
`
`1n
`
`'
`
`'
`
`15
`
`10
`
`25
`
`Gasoline Prices {alga}!
`
`Figure 1.4.l~5. Ownership Cost as a Function of Gasoline Price
`
`1B
`
`
`5 300
`iU!
`
`m #
`
`5
`‘53
`
`Electric itv Price: 4.2 centsikWh
`
`100
`
`E g 5
`
`0 MM
`' LO
`1.5
`2.0
`2.5
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`Figure 1.491-6. Annual Net Dollar Savings a5 a Function
`of Gasatfline Price
`
`Gasoline Price {3193”
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`(3) A pagtggyflflgbgyntom based on the battery developed by
`Globe-Union for tho Noaerorm Electrio Vehicle Program and racont
`developments on electrolyte circulation for the Argonne National
`Laboratory Near~Term flattery Program,
`
`(4) An Engine based on e vs prndnotiOn engine, VW advanood
`studios and osperimonts on emissions, and VW proprietary work on
`quick start for on/off engine operation,
`
`mu
`(5] A vehicle subsystem design by Triad Services based on the
`extensive use of major cemponents from late model production cars
`with a minimum of new design,
`
`{6) A hybrid propulsion subsystem (including the battery)
`which is pac aged 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.
`
`1.4.1.4.2 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 an