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As demand for consumer electric vehicles (EVs) has drastically increased in recent years, manufacturers have been working to bring heavy-duty EVs to market to compete with Class 6-8 diesel-powered trucks. Many high-profile companies have committed to begin electrifying their fleet operations, but have yet to implement EVs at scale due to their limited range, long charging times, sparse charging infrastructure, and lack of data from in-use operation. Thus far, EVs have been disproportionately implemented by larger fleets with more resources. To aid fleet operators, it is imperative to develop tools to evaluate the electrification potential of heavy-duty fleets. However, commercially available tools, designed mostly for light-duty vehicles, are inadequate for making electrification recommendations tailored to a fleet of heavy-duty vehicles.

The combined anticipated trends of vehicle sharing (ride-hailing), automated control, and powertrain electrification are poised to disrupt the current paradigm of predominately owner-driven gasoline vehicles with low levels of utilization. Shared, automated, electric vehicle (SAEV) fleets offer the potential for lower cost and emissions and have garnered significant interest among the research community. While promising, unmanaged operation of these fleets may lead to unintended negative consequences. One potentially unintended consequence is a high quantity of SAEVs charging during peak demand hours on the electric grid, potentially increasing the required generation capacity. This research explores the flexibility associated with charging loads demanded by SAEV fleets in response to servicing personal mobility travel demands. Travel demand is synthesized in four major United States metropolitan areas: Detroit, MI; Austin, TX; Washington, DC; and Miami, FL.

The emergence of connected and automated vehicles and smart cities technologies create the opportunity for new mobility modes and routing decision tools, among many others. To achieve maximum mobility and minimum energy consumption, it is critical to understand the energy cost of decisions and optimize accordingly. The Route Energy prediction model (RouteE) enables accurate estimation of energy consumption for a variety of vehicle types over trips or sub-trips where detailed drive cycle data are unavailable. Applications include vehicle route selection, energy accounting and optimization in transportation simulation, and corridor energy analyses, among others. The software is a Python package that includes a variety of pre-trained models from the National Renewable Energy Laboratory (NREL). However, RouteE also enables users to train custom models using their own data sets, making it a robust and valuable tool for both fast calculations and rigorous, data-rich research efforts.

The key hurdles to achieving wide consumer acceptance of battery electric vehicles (BEVs) are weather-dependent drive range, higher cost, and limited battery life. These translate into a strong need to reduce a significant energy drain and resulting drive range loss due to auxiliary electrical loads the predominant of which is the cabin thermal management load. Studies have shown that thermal sub-system loads can reduce the drive range by as much as 45% under ambient temperatures below −10 °C. Often, cabin heating relies purely on positive temperature coefficient (PTC) resistive heating, contributing to a significant range loss. Reducing this range loss may improve consumer acceptance of BEVs. The authors present a unified thermal management system (UTEMPRA) that satisfies diverse thermal and design needs of the auxiliary loads in BEVs.

The Kia Soul battery electric vehicle (BEV) is available with either a positive temperature coefficient (PTC) heater or an R134a heat pump (HP) with PTC heater combination [1]. The HP uses both ambient air and waste heat from the motor, inverter, and on-board-charger (OBC) for its heat source. Hanon Systems, Hyundai America Technical Center, Inc. (HATCI) and the National Renewable Energy Laboratory jointly, with financial support from the U.S. Department of Energy, developed and proved-out technologies that extend the driving range of a Kia Soul BEV while maintaining thermal comfort in cold climates. Improved system configuration concepts that use thermal storage and waste heat more effectively were developed and evaluated. Range extensions of 5%-22% at ambient temperatures ranging from 5 °C to −18 °C were demonstrated. This paper reviews the three-year effort, including test data of the baseline and modified vehicles, resulting range extension, and recommendations for future actions.

This work details two approaches for evaluating transmission warming technology: experimental dynamometer testing and development of a simplified transmission efficiency model to quantify effects under varied real world ambient and driving conditions. Two vehicles were used for this investigation: a 2013 Ford Taurus and a highly instrumented 2011 Ford Fusion (Taurus and Fusion). The Taurus included a production transmission warming system and was tested over hot and cold ambient temperatures with the transmission warming system enabled and disabled. A robot driver was used to minimize driver variability and increase repeatability. Additionally the instrumented Fusion was tested cold and with the transmission pre-heated prior to completing the test cycles. These data were used to develop a simplified thermally responsive transmission model to estimate effects of transmission warming in real world conditions.

A new cell balancing technology was developed under a Department of Energy contract which merges the DC/DC converter function into cell balancing. Instead of conventional passive cell balancing technology which bypasses current through a resistor, or active cell balancing which moves current from one cell to another, with significant cost and additional inefficiencies, this concept takes variable amount of current from each cell or small group of cells and converts it to current for the low voltage system.

This research focuses on the technical issues that are critical to the adoption of high-energy-producing lithium Ion batteries. In addition to high energy density / high power density, this publication considers performance requirements that are necessary to assure lithium ion technology as the battery format of choice for electrified vehicles. Presentation of prime topics includes: • Long calendar life (greater than 10 years) • Sufficient cycle life • Reliable operation under hot and cold temperatures • Safe performance under extreme conditions • End-of-life recycling To achieve aggressive fuel economy standards, carmakers are developing technologies to reduce fuel consumption, including hybridization and electrification. Cost and affordability factors will be determined by these relevant technical issues which will provide for the successful implementation of lithium ion batteries for application in future generations of electrified vehicles.

Electric drive vehicles (EDVs) have complex thermal management requirements not present in conventional vehicles. In addition to cabin conditioning, the energy storage system (ESS) and power electronics and electric motor (PEEM) subsystems also require thermal management. Many current-generation EDVs utilize separate cooling systems, adding both weight and volume, and lack abundant waste heat from an engine for cabin heating. Some use battery energy to heat the cabin via electrical resistance heating, which can result in vehicle range reductions of 50% under cold ambient conditions. These thermal challenges present an opportunity for integrated vehicle thermal management technologies that reduce weight and volume and increase cabin heating efficiency. Bench testing was conducted to evaluate a combined fluid loop technology that unifies the cabin air-conditioning and heating, ESS thermal management, and PEEM cooling into a single liquid coolant-based system.

Battery second use-putting used plug-in electric vehicle (PEV) batteries into secondary service following their automotive tenure-has been proposed as a means to decrease the cost of PEVs while providing low cost energy storage to other fields (e.g., electric utility markets). To understand the value of used automotive batteries, however, we must first answer several key questions related to battery degradation, including: How long will PEV batteries last in automotive service? How healthy will PEV batteries be when they leave automotive service? How long will retired PEV batteries last in second-use service? How well can we best predict the second-use lifetime of a used automotive battery? Under the support of the U.S. Department of Energy's Vehicle Technologies Office, the National Renewable Energy Laboratory has developed a methodology and the requisite tools to answer these questions, including the Battery Lifetime Simulation Tool (BLAST).

Fast charging is attractive to battery electric vehicle (BEV) drivers for its ability to enable long-distance travel and to quickly recharge depleted batteries on short notice. However, such aggressive charging and the sustained vehicle operation that results could lead to excessive battery temperatures and degradation. Properly assessing the consequences of fast charging requires accounting for disparate cycling, heating, and aging of individual cells in large BEV packs when subjected to realistic travel patterns, usage of fast chargers, and climates over long durations (i.e., years). The U.S. Department of Energy's Vehicle Technologies Office has supported the National Renewable Energy Laboratory's development of BLAST-V-the Battery Lifetime Analysis and Simulation Tool for Vehicles-to create a tool capable of accounting for all of these factors. We present on the findings of applying this tool to realistic fast charge scenarios.

With support from the U.S. Department of Energy's Vehicle Technologies Office, the National Renewable Energy Laboratory developed BLAST-V-the Battery Lifetime Analysis and Simulation Tool for Vehicles. The addition of high-resolution spatial-temporal travel histories enables BLAST-V to investigate user-defined infrastructure rollouts of publically accessible charging infrastructure, as well as quantify impacts on vehicle and station owners in terms of improved vehicle utility and station throughput. This paper presents simulation outputs from BLAST-V that quantify the utility improvements of multiple distinct rollouts of publically available Level 2 electric vehicle supply equipment (EVSE) in the Seattle, Washington, metropolitan area. Publically available data on existing Level 2 EVSE are also used as an input to BLAST-V. The resulting vehicle utility is compared to a number of mock rollout scenarios.

The disparate characteristics between conventional (CVs) and battery electric vehicles (BEVs) in terms of driving range, refill/recharge time, and availability of refuel/recharge infrastructure inherently limit the relative utility of BEVs when benchmarked against traditional driver travel patterns. However, given a high penetration of high-power public charging combined with driver tolerance for rerouting travel to facilitate charging on long-distance trips, the difference in utility between CVs and BEVs could be marginalized. We quantify the relationships between BEV utility, the deployment of fast chargers, and driver tolerance for rerouting travel and extending travel durations by simulating BEVs operated over real-world travel patterns using the National Renewable Energy Laboratory's Battery Lifetime Analysis and Simulation Tool for Vehicles (BLAST-V). With support from the U.S.

Battery electric vehicles possess great potential for decreasing lifecycle costs in medium-duty applications, a market segment currently dominated by internal combustion technology. Characterized by frequent repetition of similar routes and daily return to a central depot, medium-duty vocations are well positioned to leverage the low operating costs of battery electric vehicles. Unfortunately, the range limitation of commercially available battery electric vehicles acts as a barrier to widespread adoption. This paper describes the National Renewable Energy Laboratory's collaboration with the U.S. Department of Energy and industry partners to analyze the use of small hydrogen fuel-cell stacks to extend the range of battery electric vehicles as a means of improving utility, and presumably, increasing market adoption.

Accurate evaluation of vehicles' transient total power requirement helps achieving further improvements in vehicle fuel efficiency. When operated, the air-conditioning (A/C) system is the largest auxiliary load on a vehicle, therefore accurate evaluation of the load it places on the vehicle's engine and/or energy storage system is especially important. Vehicle simulation models, such as "Autonomie," have been used by OEMs to evaluate vehicles' energy performance. However, the load from the A/C system on the engine or on the energy storage system has not always been modeled in sufficient detail. A transient A/C simulation tool incorporated into vehicle simulation models would also provide a tool for developing more efficient A/C systems through a thorough consideration of the transient A/C system performance. The dynamic system simulation software MATLAB/Simulink® is frequently used by vehicle controls engineers to develop new and more efficient vehicle energy system controls.

A simple cost analysis framework compares hydrogen and electricity as energy carriers delivering wind energy to light-duty vehicles (LDVs). We compare four wind energy pathways within a 2040-2050 timeframe and at large scale: a dedicated electricity transmission pathway and three distinct wind-hydrogen delivery pathways. Our results suggest that wind-hydrogen pathways will tend to be more costly than pure electricity transmission pathways on a per-mile driven cost basis ($/mile), but to a greater or lesser degree depending upon the pathway. The additional cost could be warranted to the degree that the hydrogen pathway adds value to consumers through full performance fuel cell electric vehicles (FCEV) compared to plug-in electric vehicles (PEVs), or through reduced variability in wind energy supply. If these benefits add value beyond the incremental costs suggested by our simple cost framework, some shift toward co-production or even dedicated hydrogen wind farms may be warranted.

The National Renewable Energy Laboratory (NREL) validated conventional diesel and diesel-hybrid, medium-duty parcel delivery vehicle models to evaluate petroleum reductions and cost implications of hybrid and plug-in hybrid diesel variants. The hybrid and plug-in hybrid variants are run on a field data-derived design matrix to analyze the effect of drive cycle, distance, engine downsizing, battery replacements, and battery energy on fuel consumption and lifetime cost. For an array of diesel fuel costs, the battery cost per kilowatt-hour at which the hybridized configuration becomes cost-effective is calculated. The results build on a previous analysis that found the fuel savings from medium-duty, plug-in hybrids more than offset vehicle incremental price for future battery and fuel cost projections; however, they seldom did so under present day cost assumptions in the absence of purchase incentives.

In 2011, the United States imported almost half of its petroleum. Lightweighting vehicles reduces that dependency directly by decreasing the engine, braking and rolling resistance losses, and indirectly by enabling a smaller, more efficiently operating engine to provide the same performance. The Future Automotive Systems Technology Simulator (FASTSim) tool was used to quantify these impacts. FASTSim is the U.S. Department of Energy's (DOE's) high-level vehicle powertrain model developed at the National Renewable Energy Laboratory. It steps through a time versus speed drive cycle to estimate the powertrain forces required to meet the cycle. It simulates the major vehicle powertrain components and their losses. It includes a cost model based on component sizing and fuel prices. FASTSim simulated different levels of lightweighting for four different powertrains.

Battery electric vehicles (BEVs) offer the potential to reduce both oil imports and greenhouse gas emissions, but high upfront costs, battery-limited vehicle range, and concern over high battery replacement costs may discourage potential buyers. A subscription model in which a service provider owns the battery and supplies access to battery swapping infrastructure could reduce upfront and battery replacement costs with a predictable monthly fee, while expanding BEV range. Assessing the costs and benefits of such a proposal are complicated by many factors, including customer drive patterns, the amount of required infrastructure, battery life, etc. The National Renewable Energy Laboratory has applied its Battery Ownership Model to compare the economics and utility of BEV battery swapping service plan options to more traditional direct ownership options.

One of the most critical elements in engineering a hydrogen fuel cell vehicle is the design of the on-board hydrogen storage system. Because the current compressed-gas hydrogen storage technology has several key challenges, including cost, volume and capacity, materials-based storage technologies are being evaluated as an alternative approach. These materials-based hydrogen storage technologies include metal hydrides, chemical hydrides, and adsorbent materials, all of which have drawbacks of their own. To optimize the engineering of storage systems based on these materials, it is critical to understand the impacts these systems will have on the overall vehicle system performance and what trade-offs between the hydrogen storage systems and the vehicle systems might exist that allow these alternative storage approaches to be viable.