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GM Study Shows E-REVs Could Cut PHEV Real-World Fuel Consumption by More Than 50%

Savagian1
Average fuel usage over the complete RTS dataset. Click to enlarge.

An Extended-Range Electric Vehicle such as the Volt can reduce real-world fuel consumption compared to a comparable 40-mile all-electric range (urban cycle) Plug-in Hybrid Electric Vehicle by more than 50%, according to a set of simulations run by GM using the operational data from 621 drivers captured in the Southern California Association of Governments (SCAG) Regional Travel Survey (RTS).

Furthermore, while only 5% of the simulated PHEV drivers would achieve EV-only operation, fully 64% of the E-REV drivers would achieve 100% EV operation. The E-REV platform showed only one-third the total number of initial cold engine starts, compared to the cold starts required by the PHEV systems, according to Peter Savagian, Engineering Director of GM’s Hybrid Powertrain Systems Organization. Savagian presented the initial results of the study at the 2008 SAE Hybrid Vehicle Technology Symposium in San Diego (13-14 February).

GM has written a draft paper—The Electrification of the Automobile: From Conventional Hybrid, to Plug-in Hybrids, to Extended-Range Electric Vehicles—describing the study and results in more detail.

GM is defining an extended-range electric vehicle as:

A vehicle that functions as a full-performance battery electric vehicle when energy is available from an onboard RESS [Rechargeable Energy Storage System] and having an auxiliary energy supply that is only engaged when the RESS energy is not available.

By contrast, the two predominant PHEV operating strategies under discussion today (both for parallel-hybrid configurations) are either a blended strategy which is very similar to a conventional hybrid, but with a larger, rechargeable battery; or an initial EV strategy that allows electric-only operation over the complete power and speed range of a defined cycle, often the urban schedule. Both of these approaches require more usage of the engine than the series-hybrid E-REV, which runs all-electric, regardless of the cycle demands, until the battery pack—a larger pack than used in the PHEV configurations—is depleted to the defined threshold. (See diagram below.)

Savagian3
Battery charge and engine use in the two PHEV operating strategies and the E-REV operating strategy. Click to enlarge.

In the study, using the basic specifications of a Malibu-like sedan, GM simulated the performance of:

  • Conventional powertrain;

  • Hybrid Electric Vehicle (HEV) with a 40 kW electrical power constraint;

  • Conversion PHEV: a PHEV powertrain with a 35 mph (56.32 kph) speed constraint, a 40 kW electrical power constraint, 3.5 kWh of usable electrical energy (as opposed to total battery pack energy), and a blended operating strategy;

  • Urban-Capable PHEV: a PHEV powertrain with a 60 mph (96.56 kph) speed constraint, a 53 kW electrical power constraint, and 3.5 kWh of useable electrical energy; and

  • E-REV: a powertrain with 8 kWh of useable electrical energy (Volt pack is spec’d at 16 kWh total) and EV capability not limited by electric power or driving speed.

The key to the results of the simulation is the behavior of the real drivers represented in the data set. The data contains widespread and significant driving at power levels and speeds beyond that represented by the urban driving schedule.

Savagian2
Net battery energy versus distance driven, compared to the requirements of the three different cycles. Click to enlarge.

GM calculated the driving intensity—the net energy per mile (kWh/mile)—required by the urban cycle, the highway cycle, and the much more aggressive US06 cycle, then compared these to the RTS data. (See diagram at right.) They found that while only 3% of the real-world drivers fit within the urban cycle and 21% fit within the highway cycle, fully 97% fit within the requirements of the US06 cycle.

In the study, GM found that:

  • An E-REV is more than ten times as likely to finish the day as an EV than an urban-capable PHEV derived from an HEV, when operated in the actual application, as represented by the RTS data set.

  • Similarly, an E-REV will consume, on average, less than half of the petroleum of a PHEV in the real world, if overnight charging is assumed.

  • An E-REV will reduce regulated emissions that are due to initial trip starts by more than 70% when compared to a PHEV in the actual application.

  • “Electric range” when operating on the urban schedule is not a direct measure of a plug-in vehicle's ability to run with the engine off, ability to displace petroleum or ability to reduce regulated emissions in the actual application. Rather, the ability to run with full performance on electric power alone leads to improvements which would be realized in actual application.

We conclude that electrification that enables E-REVs may be well worth the effort. Specifically designed electric powertrains, incorporating higher power motors and thermal systems, higher energy batteries and integrating them into vehicle structures specifically designed for that purpose will be rewarded with societal benefits realized in real world use.

—“The Electrification of the Automobile”

While PHEVs can make improvements when compared to HEVs, an E-REV appears to realize a much greater portion of societal benefits.

During the SAE presentation, Savagian noted that GM designed the Volt with the intention of delivering 40 all-electric miles on the urban schedule. Driven under the more aggressive US06 scenario, he said, the Volt would deliver about 32 all-electric miles.

GM plans to produce and sell HEVs, PHEVs and E-REVs.

Resources

Comments

Lulu

GM's study says bigger battery is better, which I agree. However, the cost of battery is not zero, so there are other factors to consider. I mentioned cost, and there is also time to market.

DS

HEVs,PHEVs and E-REVs...Oh my!
Reminds me of the phrase "If you can't impress them with the facts, baffle them with BullShite".
What are they saying, that in most cases a series hybrid has better mileage than a parallel hybrid. That's not news to me.

Patrick

Real world mileage of 32 miles all electric.

I wonder what Toyota's pitiful 7 mile AER would be on a more realistic driving cycle...

Patrick

Make that Toyota's proposed future 7 mile AER

Patrick

nah, they are trying to attack Toyota and others that might produce a parallel PHEV.

Let's see, I can lease a civic for 3 years and get out of the lease just in time for a Volt...if it sucks or is too high of a price I'll just go with Toyota, Honda, or Mitsubishi's electric offerings (of course Mitsubishi never brings their "good" stuff out of the Japanese market).

Henry Gibson

If GM had not shredded all of the working EV-1s they could have had many E-REVs on the road many years ago. They sold the battery factory to an oil company. They did not offer to sell a single EV1, so they did not have any idea how well they would sell. Their leasing policy contract should have offended all people. Nothing can be said about the salability numbers of a car that was only leased in small numbers with performance far inferior to the battery technology available even back then. Never did GM introduce any other car that required leasing. Throw an OPOC or a Honda generator in the back of an EV1 and for a hundred pounds including fuel you have a range of 400 miles. The ZEBRA battery was ready and available for the EV-1 to give it a range of a hundred kilometers. Fuel cells will never be cheap enough to power any production automobile, and the majority of hydrogen has to be produced from hydrocarbons at less overall efficiency than the oldest operational coal fired power plants in commercial service. Why not reenable a museum EV1 and put it on the road. COATES LTD makes a remarkable high power long life modification to motorcycle engines for much higher power. Or use an OPOC. SHADENFREUDE is the term to use how I feel about GMs EV1 adventure and their present losses. They could have had their E-REV in almost instant production if they had not spent billions to eliminate the CARB ZEV requirements by weak advertising and lawsuits and lobbying or worse; and promoting fuel cells as a diversion with no economic returns possible before hydrogen fusion is producing all of the electricity in the US...HG....

AES

"they are trying to attack Toyota and others that might produce a parallel PHEV."

They are producing one themselves in the form of the plug-in saturn vue.

I do agree, however, that the definitions game gets wearisome. Regardless if the ICE assist is in series or in parallel, difference between PHEV and E-REV is essentially one of "Mine is bigger than yours".

John Taylor

So ... now we know ... Electric automobiles are more energy efficient ... And GM knows.

But the GM Volt will deliver about 32 all-electric miles, not the 300 miles it could be designed to give.

The E1 lesson is that we can't trust GM to make a useful Electric car, and must support other companies.

Lucas

Sure am glad GM told GM all of this.

Anyone around here would feel stupid if they didn't know it at least five years ago.

Healthy Breeze

It sounds like GM is pointing out that series hybrids never run the gas motor at suboptimal RPMs, which is goodness. That doesn't make it most efficient though, depending on how the PHEV is designed.

I thought UC Davis concluded that a through-the-ground parallel hybrid with a big electric motor and an ICE just big enough to maintain highway cruise speed was the best you could do for efficiency. It gets all the benefits of electric for starting and regenerative brakes. It avoids the conversion losses of powering a generator, charging a battery and then going through the electric for highway steady highway speeds where ICE is most efficient.

I think GM is also saying, "See, we shouldn't have to use big costly batteries!" Dunno if I agree with that.

Rafael Seidl

Keep in mind that the concept of "fuel economy" still refers strictly to the rate of consumption of hydrocarbons stored on board.

Electricity may be cheap compared to on-road fuels and, it offers certain emissions advantages. However, it still has to be produced - in the US that usually means a coal-fired powerplant. THe sum of direct and indirect CO2 emissions due to your driving an E-REV may well be down relative to a conventional vehicle with comparable performance, but not by nearly as much as the above graph implies.

DS
If GM had not shredded all of the working EV-1s they could have had many E-REVs on the road many years ago.

They could have put one of these in the truck of an EV1 back in 1999.

GreyFlcn

GM has figured a way to bring this CO2 reduction back up to the status quo
http://greyfalcon.net/coskata

Gerald Shields

Wow. They haven't shipped the Volt so who cares?!

dodacrazy

What baffles me is why back in the mid 70's when there was a carb. that would let us get 50 miles or more on one gallon of gas that was proven then all at once it disappeared !Well common sence tells me the gas Companys purchase this system and hide it some were criminals in big business wonder who?

mahonj

Charge them on night rate Nuke electricity (if you are lucky enough to have it).
If you are feeling green, build lots of windmills / solar and design a time variable charging system / wireless protocol to control the charging when there is excess power.
Also, make the cars fairly small - don't do this with 6000 lb monsters.

2 - 3000 lb vehicles should do most people.

Some people need the ability to move heavy things, some people like the ability to accelerate fast, the trick is not to insist on combining them (like SUVs).

mahonj

Charge them on night rate Nuke electricity (if you are lucky enough to have it).
If you are feeling green, build lots of windmills / solar and design a time variable charging system / wireless protocol to control the charging when there is excess power.
Also, make the cars fairly small - don't do this with 6000 lb monsters.

2 - 3000 lb vehicles should do most people.

Some people need the ability to move heavy things, some people like the ability to accelerate fast, the trick is not to insist on combining them (like SUVs).

mahonj

sorry about that - browser locked up - JM

Jim G.

DS,

I believe the full quote is "if you can't dazzle them with dexterity, baffle them with bull----" (surely one of the funnier lines ever spoken)

Does seem like they are attempting for some bizzarro GM reason to consign the word "hybrid" to Toyota and rebrand their own (still alleged) effort as an "electric car". Yet another stupid decision piled on top of all the others IMO. What about the more direct and obvious strategy:
A) make a better hybrid than Toyota's (i.e. a real car)
B) sell it as "the best hybrid you can buy anywhere" or something similar

Instead they seem to be selling first figuring out how to deliver later. Sadly in recent times this has become more the norm than the exception. I guess it works for a handful of risk taking charlatans but they'll never ever touch Toyota if they play the game like that.

AES

Pointing out that electrical energy has its own carbon footprint (usually), is sort of a Captain Obvious thing. It would be nice to see that sort of metric figured more prominently in this study, especially since most intelligent readers aren't Captain Oblivious.

Possible caveat to the E-REV vs. PHEV duality - aren't some HEV-based conversions able to get up to 60mph by virtue of their beefed up electric motor, e.g. MG2. Sure it's not the same grunt as a Tesla or EV1 motor, but it still covers a lot of highway speeds.

That said, it's good that GM honestly admits that US06 would deliver 32, not 40 miles. Gives us some perspective.

At the end of the day I'm still thinking "Viva la Volt" in my head though.

Healthy Breeze

Hey, let's look at this another way.

GM is admitting that they can double the fuel efficiency of virtually any car model.

So...they will be happy with raising CAFE standards to 50mpg by about 2018, right?

RhapsodyInGlue

One thing that GMs analysis doesn't take into account is the possibility, hopefully required for future PHEVs, of having an EV only button. In that mode the acceleration and top speed would be limited to what the electric only could handle and I'm sure the results would be much more comparable to REV. Their analysis is undoubtedly putting people in standard cars and simply seeing how often in that unconstrained environment the drivers accelerate or drive too fast for whatever parallel hybrid configuration they are modeling. I think many people who would consider buying a PHEV would also consider using such a mode for a lot of driving if it were available.

One would probably learn how to avoid the engine cut-in thresholds even without a EV only mode... but why not simply put it in the car?

RhapsodyInGlue

One thing that GMs analysis doesn't take into account is the possibility, hopefully required for future PHEVs, of having an EV only button. In that mode the acceleration and top speed would be limited to what the electric only could handle and I'm sure the results would be much more comparable to REV. Their analysis is undoubtedly putting people in standard cars and simply seeing how often in that unconstrained environment the drivers accelerate or drive too fast for whatever parallel hybrid configuration they are modeling. I think many people who would consider buying a PHEV would also consider using such a mode for a lot of driving if it were available.

One would probably learn how to avoid the engine cut-in thresholds even without a EV only mode... but why not simply put it in the car?

fred

GM lost how many $billions this year and they have the audacity to suggest that the Volt will be the greatest thing since sliced bread. I dont beleive their calculations can be trusted. Methinks I will wait until they prove it, as I expect the Volt they produce will be a cross between a Vega and a golf cart, cheap enough they can make millions of them yet small enough they wont take up too much room in the landfill two years later when they fall apart.

Herm

" a cross between a Vega and a golf car".. that is cruel Fred :)

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