NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by th

MD PHEV/EV ARRA ProjectData Collection and Reportin

Led by:Kevin WWith suppLaurie RAdam DBen RosNREL/PR-5410 Janu

CA

Miles Driven in Each State

OR MD

OH

VA

GA

MO

IN

TX

DCNYKSFL
Background

• ARRA funds helped deploy vehicles and EVS

- Four awards total:

• Smith• Navistar• SCAQMD/EPRI• Cascade Sierra Solutions

• DOE’s Vehicle Technologies Program (VTP) 

NREL to collect and analyze commercial fleedeployment data

- Part of Advanced Vehicle Testing Activity (AVTA- Planned under VSST Activity, FY10-12- Monitoring performance and energy utilization- Reporting effort similar to INL AVTA LD program

PROJECT

2
Smith Electric Vehicles

~500 Newtons throughout U.S.

– Manufactured in Kansas City, MO– $32 Million ARRA award– 100 mile electric range (cycle 

dependent)

– 26 channels of 1hz data to be 

logged and delivered to NREL for analysis

– Deployment plans included 20 

launch partners

PROJECT

3

Smith Newto

1 Timestamp2 Operating Mode3 GPS Speed4 Accelerator Peda5 Brake Pedal Pos6 Battery Current7 Battery Voltage8 Battery State of C9 Minimum Cell Vo

10 Maximum Cell V11 Balancing State 12 Balancing State 13 Balancing State 14 Balancing State 15 AC Current16 AC Voltage17 GPS Latitude18 GPS Longitude19 GPS Altitude20 Minimum Battery 21 Maximum Batter22 Motor Temperatu23 Power Electronic24 Motor Speed25 Heater State26 Auxiliary Battery 
Navistar, Inc.

Up to 950 EVs throughout U.S. 

– Manufactured in Elkhart, IN– $39.2 million ARRA award– 100 mile range (cycle dependent)– 12,100 lb GVWR (class 3)– 32 channels of 1hz data being logged 

and delivered to NREL for analysis

PROJECT

4

Navistar e

1 Timestamp2 GPS Latitu3 GPS Longi4 GPS Altitud5 Ambient Te6 Auxiliary Ba7 Odometer8 Operating M9 Vehicle Sp

10 Accelerator 11 Brake Peda12 Battery Cur13 Battery Vol14 Battery Sta15 Battery Dis16 Battery Cha17 Battery Cel18 Battery Cel19 AC On20 AC Current21 AC Voltage22 AC Power 23 AC Charge 24 AC Dischar25 Battery Bul26 Minimum B27 Maximum B29 Charger Te29 Heater Stat30 Shifter Pos31 Transmissi
SCAQMD + EPRI

Vehicles to be deployed across the US:F-550 based PHEV utility “Trouble Truck” application + an E-450 based Shuttle Bus

– EPRI is the primary partner– $45.4 million ARRA award– ~40 channels of 1 hz data proposed for logging 

and delivery to NREL/DOE

– Charge depleting range is cycle dependent

PROJECT

5
Shorepower Truck Electrification 

• Expecting 50 sites w/25 connections per site 

to report eventually

• Up to 5000 trucks to utilize system• Capture vehicle electrification data and 

truckstop pedestal data

• Monitor and report usage patterns

PROJECT

6
IP Protected

• Raw data sent securely to NREL• Agreements for 3-year storage of proprietary data• ~25-40 parameters protected

PROJECT

7
Commercial Fleet Data Center (C

Server

PROCESS Data Relay Network

NREL FTP

0110101101010001010101111011

01010101111011

01010101111011110101010101111011

011010110101000101010

0110100101111011

OEM

Or

3rd Party 

Telemetry

Reports

Storage

8

~ once per week
Automated Transfer and 

• Planning to collect over 300 GB/month (peak)• Three secure FTP sites set up and running to 

Commercial Fleet Data Server (CFDS) curren

- Tape Backup- 2 Storage Arrays

 Up to 25 TB data

- HP DL360 G7

 6-core, 2.66 GHz

PROCESS

9
Automated Fleet Analysi

Filter, Analyze, Characterize and Store

– DRIVE (drive cycle tool) Calculates over 200 unique 

driving statistics (Appendix A)

– Fleet Analysis Toolkit has unique algorithms 

developed for each set of variables from mfg.

• Requires significant effort to understand each fleet

Visualize

– Displays graphs, tables, and histograms of data– Automated production / common templates

PROCESS

10
PROCESS Multi-Step Analysis

11

Raw 

Data

Convert to 

MATLAB

Raw Data

Time 

Zone 

Shift

Time-adjusted Data

Mode Align

(capturing full overnight 

charge cycles)

Driving Data

.CSV format.MAT format

Charging Data

Powertrain 

Analysis

Duty Cycle 

Analysis

Electronics 

Analysis

Battery 

Analysis

Sort Pl

P

P

Report Analytics Summary

Quarantine
Quality Control

• Each file is checked for “usability” using a proprietary 

process with a ‘quarantine’ function

• All quarantined files will be revisited and re-examined 

coordination with the OEM to attempt to recover or intvia alternative methods.

• Raw data is never deleted... only moved between qua

valid locations

• Empty data records (with no value logged) within eac

marked “unusable.”

PROCESS

12
Sample Data Quality Out

13

0

0.5

1

1.5

2

x 104

Data Amount (MB)

Comprehensive Quality

TotalUsable

0

4

8 12 16 20 24

05

10152025

Speed Data Duration (Hrs)

% of Files

Speed Data Duration Distribution

0

0

102030

% of Files

0 20 40 60 80 100

0

20406080

100

% of Mode Data Available in File

% of Files

Mode Data Availability Distribution

0

2

4

6

8 10 12

0

10203040

Original Filesize (MB)

% of total data

Available Data by filesize (MB)

Available DataUsable Data

0 

0

20406080

100

% o

% of Files

SOC 

Sample Output

PROCESS
Typical Data Products Avai

1 Time in Service Total days of valid data2 Vehicle Range Miles traveled per trip3 Fuel Efficiency DC energy out of the battery with respect to total miles 

4 Battery Pack & Cell Voltage Average voltages at pack and cell levels5 Battery Degradation Average voltages for fleet each 1000 miles (or 1000 cyc

6 Battery Soak Temperatures Time spent parked at various temperatures7 Time Spent Charging Total hours spent charging per vehicle per mile traveled8 Arriving/Departing SOC Binned SOC % recorded when plugging-in and unplugg9 Battery Resting SOC Time spent at each range of SOC

10 Charging Time of Day Local time when plugging-in

11 Powertrain Efficiency Compare road-load demand (assuming various GVWs) 

12 Charging Efficiency Total AC energy in (from the charging cord) vs. total DC 

13 Duty Cycle Impacts to Range Variation in energy efficiency (Wh/mi) with respect to K14 Idling Statistics Idle time (key-on zero speed) and power demand durin15 Drive Temperatures Trip duration at various ambient temperatures 

16 Drivetrain Temperatures Motor/power electronics temperatures at various DC po17 Air Conditioner Energy Impacts Fuel efficiencies with air conditioner on and off and dura18 Charging Location Map of locations where vehicle charge (with bubbles siz

19 Effective Vehicle Range Estimate total range availability using fuel efficiency and 20 Voltage Transients Second-by-second deviations in pack voltage21 Energy Cost Savings Estimate electricity cost by location with respect to dies

and more to come...

PRODUCT

14
Quarterly Data Published

15

PRODUCT

3-4 Page Quarterly Reports Include: vehicle background, trip/equivalent mpg, driving styles, drive and charge metrics

Sample Data Outp
Sample Automated Data Pr

16

Time Stamp and 

Data Description

Sample Output

PRODUCT
Sample Automated Data Pro

17

Length of bar ind

frequency of oc

Sample Output

PRODUCT
Sample Automated Data 

18

Sample Output

PRODUCT
Sample Automated Data 

19

Sample Output

PRODUCT
Status / Next Steps

20

PLANS

• As of Dec 2011, approximately 122 Navistar e-Star veh

and reporting data

• As of Dec 2011, approximately 169 Smith EV’s delivere

data

• Cascade Sierra currently has multiple Shorepower TSE 

operational and over 2000 trucks enrolled and operating 

• AQMD ‘trouble trucks’ and shuttle buses will be delivere• 1st quarterly Report on Smith Vehicles will be published 

• 1st quarterly Report on Navistar Vehicles will be publish• 1st quarterly Report on Cascade Sierra will be published 

2012

• AQMD ‘trouble trucks’ and shuttle buses 1st quarterly re

published in late 2012
Thanks!

21

Acknowledgement:

This work is supported by the U.S. Departme

Energy’s EERE Vehicle Technologies Progr

For More Information:

www.afdc.energy.gov

Contact: Kevin.Walkowicz@nrel.gov