The Science of Electric Vehicles

Alan Soule and Chris Jones North Bay Electric Auto Association www.nbeaa.org Presentation to Science Buzz Caf French Garden Restaurant, Sebastopol July 22, 2010 6:30 PM
This presentation is posted at www.nbeaa.org/presentations/ev_science.pdf.

Alan Soule NBEAA PR Director Tesla Roadster owner

Chris Jones NBEAA President Mustang EV Converter

Agenda
Reasons to Drive an EV EV Components Buying an EV Driving an EV The Tesla Roadster EV Show and Tell

Reasons to Drive an EV
Energy Independence
60% of 2006 US oil consumption was imported per the US Government Energy Information Administration Basic Petroleum Statistics, www.eia.doe.gov/neic/quickfacts/quickoil.html.

Greenhouse Gas Reduction

Transportation accounted for 42% of greenhouse gas emissions in Sonoma County in 2000, according to the Climate Protection Campaigns January 2005 report Greenhouse Gas Emission Inventory for all sectors of Sonoma County, California, www.climateprotectioncampaign.org/news/documents/AP_INVEN.PDF.

Air and Water Pollution Reduction

Asthma cost $12.7B in 1998 and can be caused by vehicle exhaust, per the Center for Disease Control Asthma Speakers Kit, www.cdc.gov/asthma/speakit/default.htm.

See www.nbeaa.org/bev_faq.htm for more frequently asked EV questions.

Energy Independence
100% NonRenewable Energy Consumed: 71% 24% 0%
Efficiency: Combustion Grid Energy Generation Charger Battery AC Drive System TOTAL Petrol ICE 15% n/a n/a n/a n/a n/a 15% EVs charged by ICE grid 35% 90% n/a 90% 90% 85% 21% EVs offset by PVs made by ICE grid 35% 90% 300% 90% 90% 85% 63% EVs offset by PVs made by PV grid n/a 90% 300% 90% 90% 85% Infinite for 5.5B years

Efficiency of fuel input to motor shaft output only. Energy to make EV can be higher, but it makes up a small amount of the total energy consumed from cradle to grave of an ICE. Emissions vary based on type of fuel used to power the grid.

Greenhouse Gas Reduction

Cost
The great news: EVs cost far less to operate. Tesla Roadster: 71% less gas (Lotus Elise): $3 per gallon / 22 MPG = $.14 per mile electric: $.12 per kWh / 3.5 miles per kWh = $.04 per mile Mustang Conversion: 60% less gas: $3 per gallon / 20 MPG = $.15 per mile electric: $.12 per kWh / 2.0 miles per kWh = $.06 per mile Note: charging at peak rate is more, but less with an E9 Time of Use PG&E meter, solar, or free work or public charging.

Cost
The bad news: EVs can cost more to own overall if you purchase or convert one with advanced technology, and gas prices remain low.
The following examples for our vehicles assume car is scrapped in 10 years, the batteries deliver enough power and capacity for the life of the car, there is no significant difference in maintenance cost, and gas prices do not increase.
Tesla Car purchase Fuel to travel 150K miles 41 miles per day 18% DOD Total Gas (Lotus Elise) $60,000 $21,000 electric $109,000 $6,000

$81,950

$115,000 $33,050 more $9.05 more per day: 3 medium Peets lattes

Mustang Car purchase Fuel to travel 73K miles 20 miles per day 50% DOD Total

Gas $10,000 $10,950

electric $10,000 donor car $30,000 EV conversion $4,380

$20,950

$44,380 $23,430 more $6.42 more per day: 2 medium Peets lattes

Cost
The good news: EVs will cost less to own if EV prices come down, or if EV incentives or gas prices go up.
The following example for the Nissan Leaf assumes car is delivered as announced, is scrapped in 10 years, the batteries deliver enough power and capacity for the life of the car, there is no significant difference in maintenance cost, and gas prices do not increase.

Leaf Car purchase Fuel to travel 150K miles 41 miles per day 18% DOD Total

Gas (Versa hatchback) $15,000 $16,071 at 28 MPG

electric $25,000 after federal rebate $6,000

$31,107

$31,000 $107 more $.03 more per day: same cost at $3 per gallon

EV Components
Motor Batteries and Electronics

2-Pole Series Wound DC Motor Demonstration

Field Windings

Armature Windings

Commutator

Brush

Current flows through the brushes, commutator, armature windings and field windings to create electromagnetic forces that oppose each other, which causes the armature to turn.

Electric Motor Types

type DC Series brushes Yes Stator (stationary part) Field windings Rotor (rotating part) Armature windings, commutated through brushes and split rings, in series with field Armature windings, commutated through brushes, separately excited from field Armature windings, commutated through brushes Field permanent magnet Field windings, DC energized through brushes and slip rings Opposing magnetic field induced via eddy currents caused by slip between stator and rotor in copper or aluminum squirrel cage frame

DC Shunt

Yes

Field windings

DC Brushed Permanent Magnet DC Brushless Permanent Magnet AC Synchronous

Yes No Yes

Field permanent magnet Armature windings, PWMd via rotor position sensor Armature windings, PWMd via rotor position sensor Armature windings, PWMd via rotor position sensor

AC Induction

No

The field produces a magnetic field to be acted upon by armature; it can be an electromagnet or permanent magnet. The armature carries current normal to field to generate torque.

Electric Motor Types

Nail / Tube / Salt Water Battery Demonstration

Nail / Tube / Salt Water Battery Demonstration

A chemical reaction between the zinc nail, salt water and copper tube causes current to flow through the LED, which causes it to light up.

Battery Types

Batteries in Development

Stanford University Silicon Nanowire electrodes have 3X capacity improvement expected for Lithium batteries

Not technically a battery, but MIT Nanotube ultracapacitors have very high power, 1M+ cycle energy storage approaching Lithium battery capacity

Motor and Battery Charge Control via Pulse Width Modulation

100% duty cycle
on off on

75%

off on

50%

off

25%

on off

0%
time

on off

Reducing the duty cycle reduces the power delivered to the load.

Switch Mode Power Supply Buck Regulator: a common building block for motor and charge control

Filter From power capacitors source: batteries, grid or motor in regen mode

Freewheel diodes From PWM control circuit

To load: motor or batteries

Power switching transistors: MOSFETs or IGBTs

When power is applied to input, capacitors are charged up. When transistors are switched on, current flows from the batteries and capacitors to the motor. When the transistors are off, the capacitors are recharged by the batteries while current flows from the motor to the freewheel diodes while the motors magnetic field collapses to keep from increasing the voltage across the transistor to the point of failure.

Buying an EV in the U.S.

Refer to Plug In America Plug-in vehicle tracker Currently available EVs in California: Tesla Roadster ($109,000) EVs Scheduled for production: Audi e-tron BMW ActiveE CODA Daimler Smart EV Ford Focus Hyundai i10 Electric Mitsubishi iMiEV Nissan Leaf Peugeot iOn Rolls Royce Tesla Model S Toyota Rav4 (Tesla drivetrain)

2011 2011 2010 2012 2011 2012 2010 2011 2011 2010 2012 2012

? ? $45,000 ? ? ? $47,000 $22,000 ? ~$500,000 $50,000 ?

Driving an EV
The process of driving an EV is no different than drive an ICE car High torque for quick acceleration No shifting (no transmission) Regenerative braking monitoring your speed with the gas pedal No loss of Range going up hill, as long as you come down Charging outdoors in the rain is not a problem Accurate metering of charge to monitor how much Range is left HOV exemption for EVs until the end of 2015 Range is the biggest concern Charge at home at night and start out every day with full Range Wind resistance is the biggest factor affecting Range Currently, a trip that requires charging, requires planning because of limited public chargers

Tesla Roadster
TESLA BATTERY
ELECTRICAL CAPACITY: CELL CAPACITY: QUANTITY OF CELLS: CELLS PER BRICK: BRICKS PER MODULE: MODULES PER BATTERY: BATTERY WEIGHT: ELECTRON CAPACITY: WEIGHT OF FUEL: CRASH TEST: ACID LEAK TEST 52.8 KWHR 7.73 WHR (2.2 AMPHR) 6,831 69 9 11 970 LB.S (CHARGED OR NOT) 34.1328 X 10 to the 23rd 0.003089 grams (GRAIN OF SALT) 50 MPH REAR IMPACT HANG CAR VERTICALLY FOR 12 HR.S

TESLA MOTOR

375 volt AC induction air-cooled electric motor with variable frequency drive Max Net Power: 248 HP (185 kW) @ 5000-8000 rpm (40-65 MPH) Max rpm 14,000 Efficiency 92% average, 85% at peak power Torque 276 ft/lb (375 Nm) @ 0-4500 rpm (0-40 MPH)

TESLA TRANSMISSION
Single speed fixed gear with electrically-actuated parking lock mechanism and mechanical lubrication pump Overall Final Drive 8.28:1 Reverse direction of motor, limited to 15 mph

Tesla Battery Fabrication and Disposal

Lithium is the lightest naturally occurring element Largest Producers are located in Chile (65% of worlds total), Argentina, Australia and China with a large deposit being developed in Bolivia Largest manufacturer of Lithium products is China Tesla battery is manufactured in Japan. The manufacturer complies with the Directive on the Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment After use in the car, batteries can be used to level off grid power The battery modules will be recycled by Toxco in British Columbia The results of the current recycling process are: 60% of the materials are recycled 10% of the materials are reused 25% of the materials are disposed of
http://www.teslamotors.com/blog/mythbusters-part-3-recycling-our-non-toxic-battery-packs