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Novel testing procedures and analytical methodologies to assess the performance of hybrid electric vehicle batteries have been developed. Tests include both characterization and cycle life and/or calendar life, and have been designed for both Power Assist and Dual Mode applications. Analytical procedures include a battery scaling methodology, the calculation of pulse resistance, pulse power, available energy, and differential capacity, and the modeling of calendar- and cycle-life data. Representative performance data and examples of the application of the analytical methodologies including resistance growth, power fade, and cycle- and calendar-life modeling for hybrid electric vehicle batteries are presented.

Advanced battery safety is of concern for the successful commercialization of these technologies. The USABC (United States Advanced Battery Consortium) and PNGV (Partnership for a New Generation of Vehicles) are developing high power battery systems for use in electric and hybrid/electric vehicle applications. Part of the objectives of these programs is to establish and verify testing procedures regarding the safety and abuse resistance of particular batteries or battery technologies. This paper will discuss the status of abuse testing procedures that have been developed for battery systems. The goal of these tests is to determine the extent to which defined abuse conditions contribute to venting, rupture, release of hazardous substances, fire, smoke or uncontrolled energy releases. Areas of abuse testing that have been identified are (1) mechanical, (2) electrical, and (3) thermal.

Electric vehicle use has reached a new era, as vehicles are now available as commercial products from original equipment manufacturers. While previous vehicles were considered test products or prototypes, today's electric vehicles are being purchased or leased by fleet managers for utility, government, and private fleets. Unfortunately, these vehicles do not have documented histories in fleet applications, and fleet managers often need support when determining if electric vehicles fit mission requirements. In support of the electric vehicle deployment effort, the U.S. Department of Energy's Field Operations Program evaluates electric vehicles in real-world applications and environments with the goal of increasing the awareness and acceptance of electric vehicles.

A bi-fuel (Compressed Natural Gas [CNG] and gasoline) pickup truck has been developed using the Ford Alternative Fuel Qualified Vehicle Modifier (QVM) process. The base vehicle's 4.9L engine has been specially modified for improved durability on gaseous fuels. The base vehicle's configuration has been designed for conversion to bi-fuel CNG operation. A complete CNG fuel system has been designed and qualified, including fuel tanks, fuel system, and electrical interface. The completed vehicle has been safety and emission certified, demonstrating CARB Low Emission Vehicle (LEV) emissions in MY95. This paper details the design objectives, development process, CNG components, and integration of the two fuel systems.