MINNESOTA STATE,
MANKATO’S PLUG-IN
HYBRID VEHICLE PROJECT
Minnesota Plug-In Hybrid (PHEV) Task Force Meeting
11/17/2006
Dr. Bruce Jones & Dr. Vince Winstead
Minnesota Center for Automotive Research (MnCAR)
Minnesota State University, Mankato
MINNESOTA CENTER FOR
AUTOMOTIVE RESEARCH

To provide industry and government
with technical expertise in automotive
research and product development

To provide undergraduate students the
opportunity to become directly involved
in comprehensive research projects
MSU PLUG-IN TEAM

Automotive Engineering Technology Undergraduate Students
Cliff Backler
Eric Esselman
Jon Liu
Luke Markham
Nate Starkson

Christopher Bahn
Jacob Kriesel
Tony Reichel
Jacob Wilson
Capstone Senior Design Project
One Year Project

Faculty Advisors
Dr. Bruce Jones – Automotive Engineering Technology
Dr. Vince Winstead – Electrical & Computer Engineering and Technology
PARTNERS

Corporate Sponsor


Xcel Energy
Public Partners



Minnesota Travel Management
Minnesota Department of Natural Resources
Minnesota Department of Transportation
MnCAR EMISSION LAB
PLUG-IN HYBRID PRIUS

WHAT

Multi-phase project started as a senior design project
in the Automotive and Manufacturing Engineering
Technology Department (Fall 2006)

Modify a stock Toyota Prius Hybrid with the goals of
demonstrating increased fuel economy coupled with
flexible fuel (ethanol blended) capability without
increasing tailpipe emissions
PLUG-IN HYBRID PRIUS

Specific Goals
 Average
fuel economy of 100 MPG
 Operation on E-85 fuel
 No negative impacts to drivability
 No increases in stock vehicle emissions level
(as measured based on drive cycle test
measurements)
PLUG-IN HYBRID PRIUS

Enablers
 100
MPG
– Increased battery pack capacity through use of
higher energy density chemistries and/or via
increased pack size
– Plug-In* capability to enable battery pack
charging when the vehicle is not in use
*Although energy gained from the “grid” is not free, its equivalent fuel cost can be relatively low and hence
it can greatly improve average fuel economy.
PLUG-IN HYBRID PRIUS

Enablers
 Flexible
fuel capability
– Materials compatibility testing
– Consideration of fuel pump and injector capacity
constraints
PLUG-IN HYBRID PRIUS

Enablers
 Drivability
– Placement of battery cells to distribute the
increased mass within the frame and interior
constraints
– Design of enclosures and mounting to reduce
relative movement between the vehicle and the
added mass components
– Close adherence to weight and balance
constraints.
PLUG-IN HYBRID PRIUS

Enablers
 No
impact to drive cycle emissions
– Increased usage of battery capacity over the drive
cycle (allows electric only operation*)
– Base-lining and emissions lab familiarization for
repeatability
– Extensive tailpipe emissions test and
measurement
*This becomes an optimization problem since other vehicle systems are effected during engine off conditions
such as catalyst cooling, etc.
PLUG-IN HYBRID PRIUS

Vehicle Modifications

After baseline testing for fuel economy, emissions and
drivability, the vehicle will be modified with a
number of enhancements

The next few slides show the anticipated progression
of modifications…
FLEXIBLE FUELED VEHICLES

Ability to Use ANY
Blend of 0% to 85%
Ethanol




Larger Fuel Injectors
Some Different Fuel
System Materials
Some Vehicles Use a
Special Sensor
Others Let the Computer
“Learn” the Type of Fuel
In-Line Fuel Sensor
PLUG-IN HYBRID PRIUS

“Intelligent” Controller
PLUG-IN HYBRID PRIUS

Analyzing Controller Area Network
(CAN) Traffic
PLUG-IN HYBRID PRIUS

Current case studies and decision matrices
Battery Matrix
Weight and Balance Study
PLUG-IN HYBRID PRIUS

Current case studies and decision matrices
Battery cell distribution
E-85 HYBRID
2006 Toyota Prius
Insert flex-fuel kit to run on ethanol.
Material compatibility testing will be done
to see if ethanol corrodes or erodes the
components of the fuel system, such as
the fuel rail and fuel pump.
PCM
FUEL
TANK
ELECTRIC
MOTOR
ENGINE
GENERATOR
E-85 HYBRID

Conversion components
QUESTIONS
?