MINNESOTA STATE, MANKATO’S PLUG-IN HYBRID VEHICLE PROJECT

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MINNESOTA STATE, MANKATOS PLUG-IN HYBRID VEHICLE
PROJECT
Minnesota Plug-In Hybrid (PHEV) Task Force
Meeting 11/17/2006

• Dr. Bruce Jones Dr. Vince Winstead
• Minnesota Center for Automotive Research (MnCAR)
• Minnesota State University, Mankato

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MINNESOTA CENTER FOR AUTOMOTIVE RESEARCH

• To provide industry and government with technical
  expertise in automotive research and product
  development
• To provide undergraduate students the opportunity
  to become directly involved in comprehensive
  research projects

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MSU PLUG-IN TEAM

• Automotive Engineering Technology Undergraduate
  Students
• Cliff Backler Christopher Bahn 
• Eric Esselman      Jacob Kriesel 
• Jon Liu         Tony Reichel        
• Luke Markham      Jacob Wilson      
• Nate Starkson  
• Capstone Senior Design Project
• One Year Project
• Faculty Advisors
• Dr. Bruce Jones Automotive Engineering
  Technology
• Dr. Vince Winstead Electrical Computer
  Engineering and Technology
•     
•              

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PARTNERS

• Corporate Sponsor
• Xcel Energy
• Public Partners
• Minnesota Travel Management
• Minnesota Department of Natural Resources
• Minnesota Department of Transportation
•     
•              

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MnCAR EMISSION LAB
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PLUG-IN HYBRID PRIUS

• WHAT
• Multi-phase project started as a senior design
  project in the Automotive and Manufacturing
  Engineering Technology Department (Fall 2006)
• Modify a stock Toyota Prius Hybrid with the goals
  of demonstrating increased fuel economy coupled
  with flexible fuel (ethanol blended) capability
  without increasing tailpipe emissions

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PLUG-IN HYBRID PRIUS

• Specific Goals
• Average fuel economy of 100 MPG
• Operation on E-85 fuel
• No negative impacts to drivability
• No increases in stock vehicle emissions level (as
  measured based on drive cycle test measurements)

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PLUG-IN HYBRID PRIUS

• Enablers
• 100 MPG
• Increased battery pack capacity through use of
  higher energy density chemistries and/or via
  increased pack size
• Plug-In capability to enable battery pack
  charging when the vehicle is not in use

Although energy gained from the grid is not
free, its equivalent fuel cost can be relatively
low and hence it can greatly improve average
fuel economy.
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PLUG-IN HYBRID PRIUS

• Enablers
• Flexible fuel capability
• Materials compatibility testing
• Consideration of fuel pump and injector capacity
  constraints

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PLUG-IN HYBRID PRIUS

• Enablers
• Drivability
• Placement of battery cells to distribute the
  increased mass within the frame and interior
  constraints
• Design of enclosures and mounting to reduce
  relative movement between the vehicle and the
  added mass components
• Close adherence to weight and balance
  constraints.

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PLUG-IN HYBRID PRIUS

• Enablers
• No impact to drive cycle emissions
• Increased usage of battery capacity over the
  drive cycle (allows electric only operation)
• Base-lining and emissions lab familiarization for
  repeatability
• Extensive tailpipe emissions test and measurement

This becomes an optimization problem since other
vehicle systems are effected during engine off
conditions such as catalyst cooling, etc.
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PLUG-IN HYBRID PRIUS

• Vehicle Modifications
• After baseline testing for fuel economy,
  emissions and drivability, the vehicle will be
  modified with a number of enhancements
• The next few slides show the anticipated
  progression of modifications

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FLEXIBLE FUELED VEHICLES

• Ability to Use ANY Blend of 0 to 85 Ethanol
• Larger Fuel Injectors
• Some Different Fuel System Materials
• Some Vehicles Use a Special Sensor
• Others Let the Computer Learn the Type of Fuel

In-Line Fuel Sensor
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PLUG-IN HYBRID PRIUS

• Intelligent Controller

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PLUG-IN HYBRID PRIUS

• Analyzing Controller Area Network (CAN) Traffic

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PLUG-IN HYBRID PRIUS

• Current case studies and decision matrices
• Battery Matrix Weight and
  Balance Study

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PLUG-IN HYBRID PRIUS

• Current case studies and decision matrices
• Battery cell distribution

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E-85 HYBRID2006 Toyota Prius
Insert flex-fuel kit to run on ethanol. Material
compatibility testing will be done to see if
ethanol corrodes or erodes the components of the
fuel system, such as the fuel rail and fuel pump.
PCM
ENGINE
ELECTRIC MOTOR
FUEL TANK
GENERATOR
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E-85 HYBRID

• Conversion components

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• QUESTIONS
• ?