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Electric Vehicle Benchmarking S outhwest Research Institute® (SwRI®) is initiating a benchmarking program for the new generation of electric vehicles. With more than 60 years of experience serving the automotive industry, SwRI has the in-depth expertise, broad experience, and extensive facilities and equipment required to evaluate and benchmark new vehicle technologies. Competitive vehicle benchmarking is a standard practice among vehicle manufacturers and has great value for evaluating state-of-the-art technologies. Tesla Model D Inspection and Instrumentation D019818 The next electric vehicle to be evaluated at SwRI is the Tesla Model D with all-wheel drive and two drive motors. The vehicle and battery pack will be heavily instrumented to gather in-depth data pertaining to on-road vehicle baseline performance and chassis dyno laboratory testing. A variety of vehicle battery parameters will be mapped to provide insight into the battery management system (BMS). Results of this project will be provided to each program member. Cold box evaluation on dynamometer D019819 • Vehicle inspection ◦◦ Powertrain layout ◦◦ Battery pack layout (modules, cells, sensors) ◦◦ Cooling system ◦◦ Physical layout of power electronics and switching ◦◦ Wiring and diagnostic port locations ◦◦ Compatibility with aftermarket diagnostic reader devices ◦◦ Owner manuals • Vehicle and pack instrumentation ◦◦ Pack-level current, voltage and temperature ◦◦ Contactor switching ◦◦ Module-level current, voltage and temperatures based on series/parallel configurations ◦◦ Cooling system operation (flow, temperature, pump power) ◦◦ Current, voltage and temperature across electrical junctions Tesla Model D Testing • Baseline (accelerations, regenerative braking, constant speed, coast-down, creep, etc.) • Break-in (settling of adaptive calibrations) • Static capacity sweep across temperatures and currents • Pulse power sweep across temperatures • Continuous power Vehicle charging port • Open circuit voltage mapping • Range testing per EPA standards • Range testing under various driving cycles • Storage testing (self-discharge rate, battery thermal management, etc.) • Charge testing (110, 240 and supercharger) Southwest Research Institute technology data sheet Battery pack instrumentation Program Deliverables multiple tests ◦◦ Charge and discharge battery pack management strategy across multiple tests ◦◦ Binary and ASCII files on ftp site as data is being generated ◦◦ Component photographs ◦◦ Conclusions + - D019820 modes of operation ◦◦ Envelope of battery operation across Coolant fow • Data sets • Final report ◦◦ Event and trend analysis across different Thermocouples Current sensors on pack Voltage sensors on series strings only Subscriber Benefits • Data sets and the final report will be provided to all subscribers of this benchmarking program. • Program subscribers obtain benchmarking data at a fraction of the cost of in-house testing or individual purchase. • SwRI can present benchmarking data on site or subscribers may visit SwRI’s facilities in San Antonio, Texas, to test drive program vehicles. SwRI Office of Automotive Engineering • Certified to ISO 9001:2008, Quality Management Systems – Requirements • Accredited to ISO/IEC 17025:2005, General Requirements for the Competence of Testing and Calibration Laboratories We welcome your inquiries. • Certified to ISO If you are interested in becoming an early subscriber or would like additional information, please contact: D019838 Dustin Kramer Senior Research Engineer Energy Storage Technology (210) 522-3843 [email protected] 14001:2004, Environmental Management Systems Inspection and instrumentation of battery packs electricvehiclebenchmarking.swri.org electricvehiclebenchmarking.swri.org swri.org Southwest Research Institute is an independent, nonprofit, applied engineering and physical sciences research and development organization using multidisciplinary approaches to problem solving. The Institute occupies 1,200 acres in San Antonio, Texas, and provides more than 2 million square feet of laboratories, test facilities, workshops, and offices for nearly 3,000 employees who perform contract work for industry and government clients. Southwest Research Institute • 6220 Culebra Road • PO Box 28510 • San Antonio, TX 78228-0510 Find us on SwRI Business Development San Antonio, Texas (210) 522-2122 [email protected] © 2014 Southwest Research Institute. All rights reserved. An Equal Opportunity/Affirmative Action Employer Minority/Female/Disabled/Veteran Committed to Diversity in the Workplace Designed & printed by SwRI MPS 03-1114 JCN 250685 tp