TECHNOLOGY REPORT
ELECTRIFICATION
Studies show cold temps cripple EV range
It was a tough winter in much of the US.
Even normally temperate seasonal re-
sions like San Diego, Los Angeles and
Las Vegas were hit wth harsh and, in
some cases, record cold this year. That's
particular bad news for the growing
number of owners of battery electric
vehicles (EVs) who have discovered the
impact extreme temperatures can have
‘on both range and charging times.
iim consistently seeing a 30% degra-
dation” in range on cold days, said
Henry Payne, an automotive reviewer
far The Detroit News and oviner of 2
Tesla Model 3. He's by no means alone.
"can get 270 miles [range] no prob-
lem from his Chevrolet Bolt EV with a
fresh and fully charged battery, said
Timothy Grewe, chief engineer at
General Motors electric propulsion lab
But Grewe notes that when tempera-
tures fell into negative territory, "I got
around 170"
The issue of cold-weather range has
been a subject of concer among BEV
owners for some time, and a frequent
topic on social media, But several new
studies have attempted to quantify the
effects, The results are significant, show
ing that some vehicles lose more than
50% of their range in sub-freezing tem
peratures, though drivers can mitigate
the losses if they're willing to limit their
use of cabin heating.
Percent Change in Combined Rance
Percent
es change in
AAA study
“We found thatthe impact of tempera
ture on EVs is significantly more than we
expected,” said Greg Brannon, AAA's
lector of automotive engineering. “’s
something all automakers are going to
have to deal with as they push for Fur
ther EV deployment because it's some~
thing that could surprise consumers”
The organization tested five separate
models: the BMW i3, the Chevrolet Bolt
EV, the Nissan Leaf, Tesla Model S and
Volkswagen e-Golt. AAA engineers sub-
Jecting each car to both 20-degrees F
‘Percent charge nos for 100 Mes of Combined Urba/Hiahay
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10 May 2019
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cold and 95-degrees F heat
The vehicles proved surprisinaly simi
lar in their response tothe thermal con-
ditions, said Brannon. He noted that, on
‘average, they ost about 12% oftheir
range on the cold side. That was a rela-
tively modest decline, but it dd not in-
clude the use of any form of cabin heat-
ing. When HVAC systems were activat-
4, the range degradation averaged
40%. In other words, a BEV with an EPA-
rated range of 200 milas would get only
18 miles between charges.
‘nd those numbers dont fly reflect
potential range los, as they dont factor
in the use of seat or steering whee! heat-
ers or headlights during winter com-
‘mutes. The impact is felt by motorists in
Various ways. Nat only can they travel
less per charge, but tney also pay more.
‘AAA estimated a typical American BEV
owner would pay an extra $2427 per
11000 miles when t's cold
Consumers Union study
‘The AAA findings were largely echoed
by a separate study conducted by
Consumers Union, the publisher of
Consumer Reports magazine. t focused
‘on two EVs—the Tesla Model 3 witha
310-mile EPA range rating, and the 151-
mile version of the Nissan Leaf. Testing
was conducted at the CU track on days
ALTOMOTIVEENGINEERING‘BMW's 8s demonstrated th ighest-
percentages of ding range in cold
‘weather, according toa AAA study.
\when the outside terperature averaged
between 0 to 10 degrees F
The Tesla used up the equivalent of
121 miles to cover 64 actual miles of
criving, leaving it with a displayed
range remaining of 189 miles. The
Nissan fared even worse, “burning” 141
miles of stated range to travel those 64
miles. At the end ofthe test, the sec
‘ond-generation Leaf had oniy 10 miles
showing on its range display.
Electric habitable zone
Part of the problem, said the AAAS
Brannon, is that “lithium-ion batteries
lke the same sort of temperatures that
we do, around 70 degrees” Much be-
low that and the chemistry used to
store energy runs into various prob-
lems. Among other things, batery
components develop increased resis-
tance that limits how much power they
can hold, as wel as how fast a battery
pack can be charged or discharged,
explained GM's Grewe.
A decidedly unscientific test ofa
Hyundai Kona on a 20-degrees F day in
Detroit found it was only able to go
from 31 to 110 displayed miles after be-
ina plugged in for 45 minutes to a 50-
KW SAE Level 3 charger. That’ barely
half what the automaker normally
promises under ideal conditions.
‘Adcitional information on methodology
can be found at https//wmwaea cory
|AAA/common/AAR/Ties/AAA-Electic-
Vehicle-Range-Testing-Report
Paul A Eisenstein
AUTOMOTIVE ENGINEERING
TECHNOLOGY REPORT
aNuFACTURING
Ford demos latest
digital tools at flagship
transmission plant
Ford recenty provided macia with 3
look at some of its latest digital manu
facturing tools, opening up the floor at
Cone ofthe work! largest transmission
plant to showcase the quality: and pro-
ductivity-drivenintitive. The tour of
Ford's Livonia Transmission Piant (LTP)
\Was part of a Detrot-area Manufacturing
In America conference hosted by
Siemens. Though showcasing the latest
tools in use today, Ford stressed that this
was a journey that began in earnest over
a decade ago—andis ony ust beginning
tobe leveraged,
The daital systems Ford is employing
permit a more efficient path between
its computer-aided engineering (CAE),
the creation of production/supply sys-
tems and the assembly process itself,
improving quality by validating metrics
in real time and gathering a swarm of
data for analysis. Exceptional granular-
ity nits component traceability pro-
vides a wealth of on-site data to im=
prove quality, but leveraging such data
in the cloud also can improve vehicie-
specific characteristics at distant, fnal-
assembly locations
"What we showed off here today was
the evel of technology that we're de-
ploying in our engineering factory and in
‘ur physical factory, with the idea that
eventually those two areas will merge,”
said Mike Bastian, Ford digital systems
integration manager for powertrain
‘manufacturing. “We've done that based
off of high degrees of standaraization
and integration to enable data analytics,
and going forward have set the future
Up for artificial nteligence:”
Hardware + Network + Software
= Function
‘According to Bastian, the digital trans-
formation of Ford's production acceler=
ated in earnest in 2008, with the adop-
tion of global control standards, fol+
lowed by locking down its network
architecture in 2009 and the massive
deployment of ethernet to the plant
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