Second Generation Electric Vehicle Development at the University of Kansas

Abstract

Due to more stringent emissions and fuel economy standards, many automotive manufacturers are implementing more electric and hybrid vehicles into their model fleets. Hybrid and purely electric powertrains offer more sustainable transportation methods; however, larger sport utility vehicles and trucks occupy a significant majority of the vehicles on the road in the United States. To this end, this work covers the development of a second generation electric sport utility vehicle at the University of Kansas. Chapter 2 of this thesis outlines the use of CAN bus in the automotive industry throughout the evolution of the Electronic Control Module. Chapter 2 also showcases the different types of control modules installed in vehicles. CAN bus theory of operation, message formats, error handling, wiring techniques, and additional vehicle networking methods are also discussed. Lastly, electric vehicle case studies at the University of Kansas are presented to illustrate the importance and benefits of implementing CAN bus. Chapter 3 focuses on the development of the JimmE-V. The JimmE-V serves as a research vehicle that has features similar to EVs available to consumers. In order for the vehicle to generate research quality data, vehicle operation and systems integration are discussed. CAN bus communication allows components to be controlled, calibrated, and monitored in real-time allowing the JimmE-V to be adjusted for a variety of research studies. Safety information is also provided due to the high voltage potential when working with EVs. The different causes for vehicle failure are additionally included in this chapter. Chapter 4 examines the complete energy and emissions produced by the JimmE-V. This chapter highlights the energy used in the vehicle manufacturing process in addition to examining the benefit of reusing vehicle components. Furthermore, a Life-Cycle Analysis (LCA) was generated using Argonne National Laboratory’s Greenhouse Gasses, Regulated Emissions, and Energy Use in Transportation (GREET) model. The LCA provides estimations for the JimmE-V’s energy use and emissions produced throughout the vehicle’s lifetime use. Accompanying this information is information regarding the iv production and recycling of LiFePO4 batteries. This work’s LCA efforts for the JimmE-V are compared to the previous LCA efforts for the VW Beetle. Drive cycle data was collected to examine the efficiency of the JimmE-V, and to compare the results to the VW Beetle. Lastly, the solar generation capabilities of the newly built (2013) Hill Engineering Research and Development Center are presented. Lastly, Chapter 5 focuses on the conclusions of the JimmE-V project mainly highlighting the author’s main contributions to EV projects at the University of Kansas. The author’s main contributions were centered on the powertrain of the JimmE-V including the motor, controller, ECM, and battery pack. This chapter additionally focuses on the vehicle’s future impact as a research platform.