iI
`
`AK
`
`CONS4209-Tl (Vol.7)
`
`1
`
`HYBRID VEHICLE POTENTIAL. ASSESSMENT
`
`Volume 7: Hybrid Vehicle Review
`
`By
`K. O. Leschly
`
`September 30, 1979
`
`Work Performed Under Contract No. EM-78.1.01-4209
`
`Jet Propulsion Laboratory
`California Institute of Technology
`Pasadena, California
`
`NT
`
`U. S. DEPARTMENT Q f ENERGY
`
`r
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`DISCLAIMER
`
`"This book was prepared as an account of work sponsored by an agency of the United
`States Govemment. Neither the United States Government nor any agency thereof, nor any
`of their employees, makes any warranty, express or Implied, or assumes any legal liability or
`responsibility for the accuracy, completeness, or usefulness of any information, apparatus,
`product, or process disclosed, or represent, that its use would not infringe privately owned
`rights. Reference herein to any specific; commercial product, process, or service by trade
`name, trademark, manufacturer, or otherwise, does not 1ecessarily constitute or imply its
`endorsement, recommendation, or favoring by the Unites. States Government or any agency
`thereof. The views and opinions of authors expressed herein do not necessarily state or
`reflect those of the united States Government or any agency thereof."
`
`This report has been reproduced directly from the best available copy.
`
`Available from the National Technical Information Service, U. S. Department of
`Commerce, Springfield, Y irginia 2-2161.
`
`Price: Paper Cc;py $6.00
`Microfiche $3.50
`
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`CONS-4209-Tl (Vol.7)
`Distribution Category UC-96
`
`ELECTRIC AND HYBRID VEHICLE SYSTEM
`RESEARCH AND DEVELOPMENT PROJECT
`
`HYBRID VEHICLE POTENTIAL ASSESSMENT
`VOLUME VII. HYBRID VEHICLE REVIEW
`
`September 30, 1979
`
`K. 0. Lerchly
`
`Approved by:
`
`F. T. Surber
`Manager, Studies and Assessments
`
`77CG 'a-^'(-/
`T. A. Barber
`Manager, Electric and Hybrid
`Vehicle System Research and
`Development Project
`
`Prepared for
`U.S. Department of Energy
`
`by
`Jet Propulsion Laboratory
`California Institute of Technology
`Pasadena, California
`
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`PREFACE
`
`In 1976 9 Congress passed the Electric and Hybrid Vehicle (EHV)
`Research, Developmment, and Demonstration Act of 1976, Public Law
`94-413, later amended by Public Law 95-238. The Department of Energy
`is conducting an EHV development program in compiiance with that Law.
`The EHV System Research and Development Project, one element of this
`Program, is being conducted by the Jet Propulsion Laboratory (JPL) of
`the California Institute of Technology through an agreement with the
`National Aeronautics and Space Administration. This report presents
`the results of the investigations conducted under the Hybrid Vehicle
`Potential Assessment Task which is a part of the EHV Systems R&D
`Project.
`
`Early results of this study were used as the technical basis for
`the Near Term Hybrid Vehicle Development Program now being carried out
`by the JPL Electric and Hybrid Vehicle System Research and Development
`Project.
`
`This report is in ten volumes. Volume I contains an overview of
`the study and the major findings. Volumes II through X are of
`technical supplementary reports that describe the details of the study
`and present the most important data generated by the study elements.
`
`STUDY TEAM MEMBERS
`
`Principal Investigator
`
`F. T. Surber
`
`Hybrid Vehicle Review
`
`K. 0. Leschly
`
`Mission Analysis
`
`F. T. Surber
`G. K. Deshpande
`
`Power Train Analysis S. P. DeGrey
`S. G. Liddle
`Z. Popinski
`
`Cost Analysis
`
`Impacts Analysis
`
`K. S. Hardy
`R. C. Heft
`
`K. 0. Leschly
`
`iii
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`Volumes Comprising the hybrid Vehicle Potential Assesement
`
`Report No.
`
`Subject
`
`Author(s)
`
`5030-345, Vol. I
`
`Summary
`
`5030-345, Vol. II
`
`Mission Analysis
`
`5030-345, Vol. III
`
`Parallel systems
`
`5030-345, Vol. IV
`
`Series Systems
`
`5030-345, Vo l . V
`
`Flywheel Systems
`
`5030-345, Vol. VI
`
`Cost Analysis
`
`F. T. Surber
`et al.
`
`F. T. Surber
`G. K. Leshpande
`
`S. P. DeGrey
`
`Z. Popinski
`
`S. G. Liddle
`
`K. S. Hardy
`
`5030-345, Vol. VII
`
`Hybrid Vehicle Review
`
`K. 0. Leschly
`
`5030-345, Vol. VIII
`
`Scenario Generation
`
`K. 0. Leschly
`
`5030-345, Vol. TX
`
`Power Train Summary,
`Component Descriptions,
`HYVEC Vehicle Simulator
`
`S. G. Liddle
`S. P. DeGrey
`
`5030-345, Vol. X
`
`Electric and Hybrid Vehicle
`Cost Handbook
`
`R. C. Heft
`S. C. Heller
`
`iv
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`CONTENTS
`
`1.
`
`2.
`
`3.
`
`4.
`
`5.
`
`APPROACH ---------------------------------------------------
`
`GENERAL FINDINCS AND ANALYSIS ------------------------------
`
`1
`
`2
`
`HYBRID VEHICLE DATA BASE ---------------------------•-------- 13
`
`REFERENCES ------------------------------------------------- 29
`
`REVIEW FORMS ----------------------------------------------- 31
`
`Fiauros
`
`Tables
`
`1.
`
`2.
`
`3.
`
`4.
`
`5.
`
`6.
`
`7.
`
`1.
`
`2.
`
`3.
`
`4.
`
`5.
`
`6.
`
`7.
`
`8.
`
`Aistorical Distribution of HV Configurations ---------
`
`Distribution of HV Configurations vs. Fuel -----------
`
`Distribution of HV Configurations vs. Storage --------
`
`Distribution of HV Configurations vs.
`Operating Modes --------------------- - -----------------
`
`Power Plants (Multiple Fuel Electric HVs Only) -------
`
`Conventional Powertrain Schemes ----------------------
`
`HV Powertrain Schemes --------------------------------
`
`Hybrid Vehicle Status -------------------------- ---- --
`
`Distribution of HV Configurations vs. Fuels and
`Operating Modes -------------------------------- ---- --
`
`Distribution of HV Configurations vs. HV Type
`with and without Separate Generator ----- -------------
`
`3
`
`4
`
`4
`
`G
`
`7
`
`8
`
`9
`
`2
`
`6
`
`7
`
`Key Characteristics of Hybrid Passenger Cars ------- --
`
`14
`
`Key Characteristics of Hybrid Trucks, Vans,
`Busses----------------------------------------- ------
`
`Summary Vehicle Description of Hybrid
`Passenger Cars --------------------------------- ---- --
`
`Summary Vehicle Description of Hybrid Trucks
`andVans --------------------------------------- --- ---
`
`Summary Vehicle Description of Hybrid Busses ------- ---
`
`16
`
`17
`
`23
`
`25
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`Performance of Ilybrid Passenger Cars ----------------- 26
`
`10.
`
`Performance of Ilybrid Trucks and Busses -- ---------••- 28
`
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`HYBRID VEHICLE REVIEW
`
`A review of hybrid vehicles M e) built during the past ten years or
`
`planned to be built in the near fut , tre has been conducted in support of the
`
`Hybrid Vehicle Potential Assessment. The primary purpose for this review was
`
`to generate an updated and more extensive data base on the state - of-the-art of
`
`hybrid vehicles, than reported in previous studies ( 1 9 2 9 3, 4 9 5 9 6).
`
`Furthermore, an attempt has been made to classify and analyze these vehicles
`
`to get an overall picture of their key characteristics.
`
`1. APPROACH
`
`The review included on-coed hybrid passenger cars, trucks, vans and
`
`busses. It has been structured as a four step process:
`
`1. Identify (INVENTORY) actually built and planned hybrid vehicles and their
`
`builders and owners. This activity included: a) literature search of
`
`bibliographies, reference listings, and recent study reports; h) scanning
`
`of relevant professional journals and conference proceedings; and c)
`
`follow up on hintrj and rumor1 + from people involved with electric and
`
`hybrid vehicle ^-elated work ( "ears to the ground").
`
`2. Comelete a 1-page SUMMARY VEHICLE DESCRIPTION (see pg. 30) for each
`
`vehicle, based on the literature and/or phone conversation with the
`
`particular builder. Foreign builders were approached through their
`
`embassies or business representatives here in the U.S.A.
`
`3. Mail a 6-page DETAILED VEHICLE SPECIFICATION QUESTIONNAIRE ( see pgs.
`
`31-36) to each builder in an attempt to get a more detailed description of
`their vehicle.
`
`4. TABULATE, CLASSIFY, and ANALYZE the data collected during steps 1 to 3.
`
`In support of the initial phase of the data collection activities, v isits
`
`were made to seven different sites in the U.S.A., covering 8 hybrid passenger
`
`cars, 1 hybrid van, and 1 hybrid bus.
`
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`F
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`2. GENERAL FINDINGS AND ANALYSIS
`
`All of she vehicles identified in the hybrid vehicle review are
`
`experimental and basically proof-of-concept vehicles. While a few of these
`
`vehicles are meant to be preproduction prototypesp none of them have actually
`
`led to any volume production larger than two-of-a-kind.
`
`A total of 81 hybrid vehicles were identified worldwide. Twelve of them
`
`are still at the design stage planned to be built in the near future, while
`
`the rest (69) have been built within tLe last ten years.
`
`Most of these vehicles have been o,jerated with cnly one particular hybrid
`
`powertrain configuration (i.e., a specific arrangement of a specific set of
`
`major powertrain components). Only three vehicles (all passenger care) have
`
`at one time or another been modified so dtamatically that they each can be
`
`said to represent more than one hybrid configuration:
`
`• GMC's Stir-Lec (2 configurations)
`
`• Kordesch's Austin (2 configurations)
`
`• Univ. of Florida's Urban Car (3 configurations)
`
`The 81 vehicles identified represent, in other words, a total of 85 hybrid
`
`vehicle configurations. It should be noted that existing hybrid vehicle
`
`designs which are not presently intended to be implemented in an actual
`
`vehicle have been excluded.
`
`A more detailed count of the reviewed hybrid vehicles in terms of their
`
`present status, national origin, and type of vehicle is given below in Table 1.
`
`TABLE 1: HYhRID VEHICLE STATUS
`
`Present
`Passenger Cars
`Trucks and Vans
`Busses
`Status
`USA
`Foreign
`Total
`USA
`Foreign
`USA
`Foreign
`---------------------=----------------------------------------------------------
`Running Condition
`6
`2
`2
`19
`6
`37
`2
`Out of Order
`1
`0
`0
`0
`1
`0
`0
`1
`4
`Disassembled
`2
`0
`0
`1
`0
`Status Unknown
`14
`8
`3
`1
`1
`0
`27
`-------------------------------------------------------------------------------
`Sub total
`36*
`14
`6
`3
`3
`7
`69
`Built to date
`-------------------------------------------------------------------------------
`Planned for the
`near future
`1
`9
`2
`0
`--•
`--------------------------------------------
`Total
`60
`15
`
`0
`0
`------------------------
`6
`
`12
`------
`81
`
`* Representing 40 configurations.
`
`-2-
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`Most of the 85 reviewed hybrid vehicle configurations are conversions of
`
`conventional production vehicles. Of the 64 configurations where chassis and
`
`body style are known, there are 45 ;or 70%) such conversions and 6 (or 102)
`
`with modified production chassis and/or custom made fiberglass bodies. Only
`
`13 (or 20%) are specially built from the ground up.
`
`The historical distribution of the hyb r id vehicle configurations is shown
`
`in Figure 1 9 in terms of the first year of operation. Most of the earlier
`
`hybrid vehicles were built in an attempt to make low pollution vehicles, while
`
`the later hybrids predominantly have been designed with a higher fuel economy
`
`in mind.
`
`?
`
`69 70 71 72 73 74 75 76 77 78 79
`
`23
`
`12
`
`11
`
`10
`
`9
`
`Z 8
`
`v 7
`
`6 5 4 3 2 1 0
`
`FIRST YEAR OF OPERATION
`FIGURE 1: HISTORICAL DISTRIBUTION OF HV CONFIGURATIONS
`
`Fuel. Almost 702 (59 configurations) of the reviewed configurations have
`
`been identified as "multiple fuel electric hybrids" (the present DOE
`
`definition of a hybrid vehicle) while only 182 (15 configuraticns) have been
`
`identified as single fuel hybrids (Figure 2).
`
`Storage. All of the 74 configurations with known type(s) of fuel and
`
`energy storage are "multiple storage hybrids", including dual battery systems
`
`for the 4 configurations with batteries only (Figure 3). It should he noted
`
`that the "multi-le storage" term was initially used to identify the hybrid
`
`vehicles in this review.
`
`-3-
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`Q MULTIPLE FUEL ELECTRIC HYBRIDS 1591
`
`GASOLINE
`
`OTHER FUEL
`
`O
`
`S
`
`ELECTRICITY
`
`THER I UEL
`-
`DIESEL :
`3
`PROPANE:
`METHANEt
`2
`HYDROGEN: I
`2
`SOLAR.
`
`ELECTRICITY
`'— 7-1
`ri
` FUEL
` 6
`OT EI t
`PROPANE s
`METFIANE; i
`
`PASSENGER CARS (56)
`
`TRUCKS, VANS & BUSSES 1161
`
`FIGURE 2: DISTRIBUTION OF HV CONFIGURATIONS VS. FUEL
`
`FUEL TANK \
`
`O
`43 4
`3BATTERIES
`
`6
`
`1
`
`OTHER
`
`STORAGEO
`.)
`
` PASSENGER CARS (56)
`
`TRUCKS, VANS & BUSSES 116)
`
`*OTHER STORAGE
`FLYWHEELr 8
`HYDRAULIC r 4
`
`*OTHER STORAGE
`FLYWHEEL. 2
`HYDRAULICr 1
`
`FIGURE 3: DISTRIBUTION OF HV CONFIGURATIONS VS. STORAGE
`
`-4-
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`Operating Modes. The operating modes of 59 of the reviewed configurations
`
`have been identified at the present. All of these configurations are designed
`
`to be operated in one or more of the following four operating modes
`
`exclusively:
`
`• Heat Engine On-Off. The heat eng,'Lne will automatically be turned on or
`
`off depending on the need for power and/or energy or at certain
`
`vehicles speeds.
`
`• Heat Engine Continuous. The heat engine will run continuously either
`
`at a constant rpm or a variable rpm depending on the need for power
`
`and/or energy.
`
`• All/Primary Heat Engine. The heat engine will deliver most or all of
`
`the needed power and energy to drive the vehicle, and in some cases
`
`even to recharge batteries (or other energy storage devices). In cases
`
`of extreme power demands, the batt ries (or other energy storage
`
`devices) :night be utilized as a supplementary power source.
`
`• All/Primary Electric. The batteries will deliver most or all of the
`
`needed power and energy to drive the vehicle. In cases of extreme
`
`power demands the heat engine (or other energy storage devices) might
`
`he utilized as a supplementary power source.
`
`The distribution of hybrid vehicle configurations on these four operating
`
`modes is shown in Figure 4. Regenerative braking is employed in a little more
`
`than half (or 34) of these 59 configurations. About 35% (21 configurations)
`
`of them have been designed with only one operating mode in mind. Most of
`
`these also happen to be single fuel hybrids which correspond closely to the
`
`general trend of equivalence between the number of fuels and operating modes
`
`(Table 2).
`
`Power Plants. The distribution of the 59 "multiple fuel electric :Iybrids"
`
`(identified above) in terms of their type of electric and non-electrical power
`
`plants is shown in Figure 5. It is seen that about 75% of them (or 44) are
`
`using a conventional Otto cycle engine combined with some kind of a DC motor.
`
`Most often the parallel hybrids (i.e:, hybrids with direct drive from the
`
`heat engine to the driveshaft) do not have a separate generator as opposed to
`
`the series hybrid which requires a separate generator. But four
`
`configurations, or about 20% of the parallel hybrids violate this general
`
`trend by having a separate generator (Table 3).
`
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`PASSENGER CARS (44)
`& TRUCKS. VANS & BUSSES (15)
`
`FIGURE 4: DISTRIBUTION OF HV CONFIGURATIONS VS. OPERATING MODES
`
`TABLE 2: DISTRIBUTION OF HV CONFIGURATIONS VS. FUELS AND OPERATING MODES
`
`Type oZ HV
`Single
`Dual
`Triple
`Unkown
`Configuration
`Fuel
`Fuel
`Fuel
`Fuel
`Total
`-------------------...----------------- ---------------------------------------
`Single Mode
`14
`7
`0
`0
`21
`
`0
`
`2
`
`30
`33
`5
`5
`0
`0
`Triple Mode
`0
`-------•------------------------------------------------------------------------
`15
`11
`0
`26
`Unknown Mode
`0
`-------------------------------------------------------------------------------
`Total
`15
`2
`57
`11
`85
`
`Dual Mode
`
`1
`
`-6-
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`20
`
`ELECTRICAL POWERPLANT (MOTOR)
`
`DC SERIES
`
`DC SEP EXCITED
`
`DC SHUNT
`
`DC COMPOUND
`
`AC MOTOR
`
`UNKNOWN
`NON-ELECTRICAL POWER PLANT
`OTTO ENGINE
`
`DIESEL. ENGINE
`
`7
`
`BRAYTON ENGINE
`
`4
`
`VIRLING ENGINE3
`
`FUEL CELL
`
`I
`
`FIGURE 5: POWER PLANTS (MULTIPLE FUEL ELECTRIC HVc ONLY)
`
`u
`
`TABLE 3: DISTRIBUTION OF HV CONFIGURATIONS VS. HV TYPE
`WITH AND WITHOUT SEPARATE GENERATOR
`
`Type of HV
`Separate
`No Separate
`Configuration
`Generator
`Generator
`Unknown
`Total
`--------------------------------------------------------------------------------
`Series
`30
`0
`0
`30
`
`26
`
`17
`
`18
`
`85
`
`2
`
`0
`
`18
`
`20
`
`Parallel
`
`4
`
`14
`
`Other
`0
`17
`------------------------------------------------
`Unknown
`0
`-------------------------------------------------
`Total
`34
`31
`
`0
`
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`

`Powertrain Schemes. A classification of the hybrid vehicle configurations
`was attempted in terms of their particular powertrain scheme ( Figure 7). The
`powertrain schemes for the conventional ICE and the conventional electri..
`
`vehicles are shown in Figure 6 for reference. A total of 20 hybrid vehicles
`
`powertrain schemes, distributed on five major configuration classes, were
`requ i red to cover all of the 61 hybrids with known powertrain scheme:
`
`CLASS S: SERIES HYBRIDS
`
`CLASS P: PARALLEL. HYBRIDS
`
`( 3 VARIATIONS/28 HVs)
`( 6 VARIATIONS / 16 HVs)
`(6 VARIA°LIONS/9 HVs)
`CLASS F: FLYWHEEL HYBRIDS
`CLASS D: DUAL BATTERY HYBRIDS 0 VARIATION/ 4 HV's)
`( 4 VARIAT*. ON/4 HVs)
`CLASS 0: OTHER HYBRIDS
`
`Even though this classification indicates that on the average no more than
`
`three hybrid configurations are alike, there is a strong tendency to
`
`clustering around a few typical powertrain schemes (like "Sa" and "Fa").
`
`DRIVE SHAFT
`
`HEAT ENGINE
`
`DIFFERENTIAL.
`
`TRANSMISSION KX^
`
`REAR AXLE
`
`-ON\,tNTIONAL
`
`ICE
`
`DYNAMOTOR
`
`ELECTRICAL POWER
`
`BATTERIES
`
`CONTROLLER
`
`OPTIONAL
`
`r*""^-----1
`TRANSMISSION
`L-------J
`
`CONVENTIONAL
`ELECTRIC
`
`FIGURE 6: CONVENTIONAL POWERTRAIN SCHEMES
`
`—8—
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`

`SE Rif 5H) FIR ID
`
`VAR A
`
`Sa
`
`SERIES HYBRID
`NAR BI
`
`Sb
`
`SERIES HYBRID_RI_D
`TVAR, CI
`
`Sc
`
`I
`
`HFAT ENGINE
`
`•
`
`GENFRATOR
`
`1
`` DYNAMOTOR
`
`t'^'^--^^^-^
`TRANSMISSION
`^_-_____.___
`
`BATTERIES
`
`.ONTROLUR
`
`I--------y
`"'v SOLAR PANELS /
`
`FIGURE 7: HV POWERTRAIN SCHEMES /Page 1
`
`-9-
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`CLUTCH
`
`HtAf ENGINE
`
`/
`
`/
`
`DYNAMOTOR
`
`r---^
`TRANSMISSION
`
`PARALLEL HYBRID
`(VAR A
`
`BATTERIES
`
`CONTROI Lip
`
`Pa
`
`HfA1 fNGINE
`
`fIYED
`C,fAR
`-L___J
`
`GENERATOR
`
`DYNAMOTOR
`
`TRANSMISSION
`---^
`
`PARALLEL HYBRIDV^_-
`
`Pt.
`
`BATTERIES
`
`CONTROLLER
`
`DYNAMOTOR
`
`HEAT ENGINE
`
`r----^
`TRANSMISSION
`
`PARALLEL HYBRID
`(VAR. C)
`
`BATTERIES
`
`CONTROLLER
`
`Pc
`
`PARALLEL HYBRID
`VAR-.57-
`
`Pd
`
`PARALLEL HYBRID
`VAR,E
`
`Pe
`
`TRANSMISSION
`
`HEAT ENGINE
`
`DYNAMOTO
`
`TRANSMISSION
`
`PARALLEL HYBRID
`TVA-R-. f
`
`BATTERIES
`
`CONTROLLER
`
`SOLAR PANELS/
`
`Pf
`
`FIGURE 7 (cont): HV POWERTRAIN SCHEMES /Page 2
`
`-10-
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`HEAT ENGINE
`
`FIXED
`R
`
`FLYWHEEL
`
`---^1L r------- i
`CVT
`TRANSMISSION J4
`
`HYBRID
`
`FLYWHIII
`"VAR A+
`
`FLYWHEEL
`
`CVT
`
`I
`
`HEAT ENGINE
`
`FIXED
`GEAR
`
`TRANSMISSION
`
`fa
`
`FLYWHEEL HYBRID
`(VAR. BI
`
`ED F
`
`_YWHEEL HYBRID
`(VAR G
`
`F V
`
`CONTROLLER
``
`
`BATTERIES
`
`DYNAMOTOR
`
`DYNAMOTOR
`
`PLANETARY
`GEAR
`
`FLYWHEEL
`
`FIXED
`GEAR
`
`J`
`
`FLYWHEEL HYBRID
`(VAR. D)
`
`Fd
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`
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`
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`
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`(VAR. E)
`
`Fe
`
`FIGURE 7 (cont): HV POWERTRAIN SCHEMES /Page 3
`
`-11-
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`18 of 44
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`HEAT ENGINE
`
`FLYWHEEL
`
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`FLYWHEEL HYBRID
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`
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`
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`
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`
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`
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`
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`
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`
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`
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`
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`
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`i
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`
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`FIGURE 7 (cont): HV POWERTRAIN SCHEMES /Page 4
`
`-12-
`
`19 of 44
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`

`3. HYBRID VEHICLE DATA BASE
`
`The data base presented on the following pages consists of three sets of
`
`tables:
`
`•
`
`KEY CHARACTERISTICS (Tables 4, 5).
`
`Lists the major component types, operating modes, and present
`
`status. Includes all 85 configurations.
`
`•
`
`SUMMARY VEHICLE DESCRIPTIONS (Tables 6, 7 9 8).
`
`Lists the general vehicle specification data, with emphasis on the
`
`sizes of the major power train component. Includes all 85
`
`configurations.
`
`•
`
`PERFORMANCE (Tables 9, 10).
`
`Lists test results and manufacturers estimates of the vehicle
`
`performance. Includes only 30 configurations.
`
`This data base is furthermore subdivided according to the following vehicle
`
`types: passenger cars (64 configurations), trucks and vans (15
`
`configurations), and busses (6 configurations).
`
`—13—
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`20 of 44
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`
`21 of 44
`
`FORD 1434
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`

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