— - =
Acceleration with Battery 0 Grade |

i: |
x=

‘E2of[... —— Po]

ne} z rs |

ow 10 = a ai |
os

Pry 0

0 5 10 15 20 |

Time Sec.

IMax, Watts 208 _— Speed MPH Watts/10/ Test Date 3/13/01 |

Acceleration with Battery 4 Grade

Watts/10

Speed MPH &

Time Sec.

Max. Speed 7.24 MPH

Mon, Watte 219 —Speed MPH — Watts/10) test date ara:

Acceleration with Battery 8 Grade

]
roy 20
ae 15 { —_—_—
=o
| oz 10
gf 5
o
[-3 { |
| a ) a
! 0 5 10 15 20
Time Sec.
Mor, Watts 175. “a |— Speed MPH : Watts/10| test vate a/13/01

NASA/TM—-2001-211077 18



REFERENCES

1. “Baseline Testing of the EV Global E-Bike”, NASA Technical Memorandum 2001-
210569, January 2001.

NASA/TM—2001-211077 12



25.00

Acceleration & Range Test, Capacitor, 0% Grade, Maximum Initial Speed, Normal Mode

| —cap Vor (v)
15.00 — —_ [cap cursay |
10.00 — Sutton —
5.00 —— + ——
0.00
0 50 100 150 200 250
Time (sec)
Acceleration & Range Test, Capacitor, 0% Grade, Maximum Initial Speed, Normal Mode
35.00 ~p————~ oe ne re —
30.00 ——- ——
25.00 - - -
I. - a —
20.00 | —-. — - 1 | Mtr Temp (C)
‘Amb Temp (C}
~~ Cap Temp (C)
15.00 - —— ~ —4 Crtri Temp (C) |
10.00
5.00 —
0.00

Time (soc)

NASA/TM—2001-211077 22



Fig. 1 — EV Global E-Bike

NASA/TM—2001-211077 3




«+30
EE 20)
== 10 : ——.
> {| oT eee
= i
2°
wn
0 5 10 15 20
Time Sec.
|Max. Speed 12.76 MPH
Max, Watts 242 |—Speed MPH Watts/10 Test Date 3/13/01 |
Acceleration with Capacitors & Battery 4 Grade
2 30
x=
as
=o 20 - OOO
Ba
os 10 y— -
-%
| @ 0
0 5 10 15 20
Time Sec.

Max. Speed 7.9 MPH
[Max. Watts 230

Speed MPH &

20 l
o
= 15 }-——
ao i}
B10 po -
35] !
0 fr !
0 5 10 15 20
Time Sec.
[usr Speed tae MPH “—Speed MPH _ Watts/10) rest owe snr

Acceleration with Capacitors & Battery 8 Grade

— Speed MPH Watts/1 0. Test Date 3/13/01

NASA/TM—2001

-211077 19


Acceleration Test, Battery, 4% Grade, Maximum Initial Speed, Normal Mode

30.00 -

25.00 \ ee

20.00

15.00 += — — — —

10.00

5.00 Se

o 2 4 6 8 10 12 14 16 18
Time (sec)

Acceleration Test, Battery Test, 4% Grade, Maximum Initial Speed, Normal Mode

35.00 a . - 7 - nm

30.00

25.00

20.00

15.00 - -

5.00

0.00
° 2 4 6 8 10 12 14 16 18

Time (sec)

NASA/TM—2001-211077 25

—Bat Vor (V)

— Mtr Temp (C)

Bat Curia) |

‘Amb Temp (C)
Bat Temp (C)
Cnt Temp (C) |


Acceleration Test, Battery, 0% Grade, Maximum Initial Speed, Normal Mode

30.00 Se _

25.00 ee —. -=

20.00 |-—— - — —— —- — 4

15.00 “Bat vor (vy |

Bat Cur (A) |

10,00 — —-+

5,00
0.00 +
° 5 10 18 20 25
Time (see)
Acceleration Test, Battery, 0% Grade, Maximum Initial Speed, Normal Mode

35.00 _

30.00 | -— a — ——_—_. :

25.00 |—- -— -

20.00 ~ | ee Mt Temp (C)
|| = amo Temp (C)
| <= Bat Temp (©)

15.00 | — —|_ Cnt Temp (c)_

10.00

5.00 - i
i
i

0.00

° 8 10 15 20 25

Time (sec)

NASA/TM—2001-211077 21




APPENDIX C

DESCRIPTION OF VEHICLE DYNAMOMETER
The vehicle dynamometer used to conduct the tests described in this report is the
CompuTrainer Pro Challenge PC1 Model 8001. It is a high performance,
microprocessor controlled, indoor dynamometer designed for bicycle use. The
electronic load generator is capable of creating resistance loads from 50 to 1500 watts to
simulate road grades to 15%. The dynamometer is shown in Fig. 5.
Tests documented in this report were conducted with the dynamometer programmed to
meet the test matrix requirements.

APPENDIX D

DESCRIPTION OF TEST CYCLES

Testing of the vehicle was based on the test matrix shown in table D-1.

Table D-1 EV Global E-Bike Test Matrix

PARAMETER ‘CONDITIONS.
‘Acceleration To maximum speed at 0%. 4%, and 8% grades in the normal mode with battery energy storage,
ultracapacitor energy storage, and combination battery and ultracapacitor energy storage.
Range To maximum speed at 0% grade in the normal mode of operation with ultracapacitor energy storage.
To S mph in the economy mode of operation with ultracapacitor energy storage
Top Speed To maximum speed at O% grade in the normal mode of operation with battery energy storage.
ultracapacitor energy storage, andl combination battery and ultracapacitor energy storage

APPENDIX E
VEHICLE PERFORMANCE TEST RESULTS

A complete set of plots of the test results are included here. Table 1 identifies the tests
that were conducted.

NASA/TM—2001-211077 16



Maximum Speed

The maximum speed of the vehicle was measured to be 11.94 mph with no grade under
full power with battery energy storage. The maximum speed was measured to be 12.56
mph with no grade under full power with ultracapacitor energy storage. The maximum
speed was measured to be 12.76 mph with no grade under full power with a combination
of battery and ultracapacitor energy storage. Figure 6 indicates the maximum speeds
achieved with the various energy storage systems, as well as the various powers that
were obtained

Fig. 6 - Maximum Speed for Various Grades

Acceleration Testing Max. Speed

Speed MPH

bo

7 Battery & Capacitors
Battery
Capacitors

IX)

°

% Grade

Test Date 3/13/01

Acceleration Testing Max. Watts

250
200

150
Watts
100

_/ Battery & Capacitors
Battery
“ Capacitors

Test Date 3/13/01

NASA/TM—2001 -211077 8



35.00

30.00

25,00

20.00

15.00

10.00

5.00

0.00

5.00

35.00 4

—Veh Volt (V)
— Bat Cur (A)

_Cap Cur (A) |

Time (sec)

Acceleration Test, Battery & Capacitor, 8% Grade, Maximum Initial Speed, Normal Mode

30.00 }—

25.00

20.00

—Mtr Temp (C)

Amb Temp (C)
~~ Cap Temp (C)

15.00

Crist Temp (C)_

10.00

5.00

0.00

Time (sec)

NASA/TM—2001-21 1077 31


Acceleration Test, Battery, 8% Grade, Maximum Initial Speed, Normal Mode

25.00

20.00 —_

15.00 —

— Bat Vort(V) |

10.00

5.00 ——

Bat Cur (A)

0.00

Time (sec)

20 25

Acceleration Test, Battery, 8% Grade, Maximum Initial Speed, Normal Mode

35.00

25.00 —

————__,
Mtr Temp (C) |
‘Amb Temp (C) :

Bat Temp (C) |

10.00 +--—

Crtrl Temp (C)

5.00 —

0.00

NASA/TM—2001-211077

Time (sec)



Fig. 4 — Ultracapacitor

NASA/TM—2001-21 1077 5


Fig. 2 —- E-Bike Schematic Diagram

SEVEN
PEDALS
SPEED
[> >) Seas
RIDER
INPUT
MOTOR MOTOR
|p} contro. Lp |p
ENERGY FLOW
cancer | ENERGY VEHICLE
STORAGE }-—P} ACCESSORIES
7 > ‘SYSTEM

Fig. 3 — Battery Pack

NASA/TM—2001-21 1077

ORIVE
WHEEL

PARALLEL HYBRID SCHEMATIC DIAGRAM



l Acceleration & Range with Capacitors 0 Grade
2 3
=x 0
ae
=o 20 -
oS
28 10 /F oo
/ o
a = | \
7) 0 t
0 1 2 3 4 5
Time Min.
Max. Distance 0.71 Miles
Max. Speed 12.56 MPH i ~ —
Max. Watts 243 _— Speed MPH Ww atts/1 0 | Test Date 3/13/01

Acceleration & Range with Capacitors 4 Grade

® 30

=x i

ae

Sq 20 tO
oO 0+ : —p

0 20 40 60
Time Sec.
Max, Distance 0.11 Miles
Marwats2at Speed MPH _ W atts/10 Test Date 3/13/01

Acceleration & Range with Capacitors 8 Grade i

20
15 pe ta
10 5 T
5 t
0) t

0 20 40 60 |

Time Sec
|Max Distance 0.07 Miles if

Max Speed 5.04 MPH

(Max Watts 178 —Speed MPH

Speed MPH &
Watts/10

WwW atts/1 0 Test Date 3/13/01

NASA/TM—2001-211077 17


TEST RESULTS

Vehicle Performance
Ten tests were conducted to determine vehicle performance, per Table 1:

Table 1 — Performance Tests Conducted on the E-Bike

Test Grade Vehicle Top Vehicle Energy
Number (%) Mode Speed Source Test Mode
1 +0 Normal Maximum Battery Acceleration test.
2 +4 Normal Maximum Battery Acceleration test.
3 +8 Normal Maximum Battery Acceleration test.
| 4 +0 Normal Maximum Capacitor | Acceleration/range test.

5 +4 Normal Maximum Capacitor | Acceleratior/range test.
6 +8 Normal Maximum Capacitor | Acceleration/range test.
7 _+0 Economy 5 mph Capacitor | Range test.
8 +0 Normal Maximum Bat & Cap | Acceleration test.
9 +4 Normal Maximum Bat & Cap | Acceleration test.

10 +8 Normal Maximum Bat & Cap | Acceleration test.

A similar set of plots have been included in Appendix E for each of the vehicle tests:
a. Vehicle speed and vehicle power vs. elapsed time.

b. Vehicle battery voltage, current, and power vs. elapsed time.

c. Component temperatures vs. elapsed time.

A summary of the test results is shown in Table 2 at the end of this section.

NASA/TM—2001 -211077 7


Acceleration Test, Battery & Capacitor, 0% Grade, Maximum Initial Speed

20.00 —.—_
Veh Voit (V}
= Veh Cur (A)

Cap CuriAy

16.00

0.00

25
Time (sec)

Acceleration Test, Battery and Capacitor, 0% Grade, Maximum Initial Speed

35.00 p——~

25.00 } —

20.00 - - wir Temp (O) |

‘Amb Temp (C) |
~~~ Cap Temp iC) |
Cnt Temp (C)

18.00

10.00 +— -— - ———

5.00

0.00

Time (sec)

NASA/TM—2001-211077 23


Baseline Testing of the EV Global
E-Bike With Ultracapacitors

Dennis J. Eichenberg, John S. Kolacz, and Paul F. Tavernelli
Glenn Research Center, Cleveland, Ohio

National Aeronautics and
Space Administration

Glenn Research Center

July 2001


Summary

An overall summary of the vehicle testing is shown in Table 2.

Table 2 —- Summary of Test Results for the EV Global E-Bike with

Ultracapacitors
“Parameter —_—«|§- Configuration Test Test “Remarks |
Conditions | Results
Acceleration Times
Battery 1.10 sec
S mph Capacitor 0% Grade, 0.97 sec
Battery & Capacitor | __Normal Mode 0.97 sec
Battery 7.50 sec
10 mph Capacitor 0% Grade, 6.38 sec
Battery & Capacitor | Normal Mode 6.07 sec
Battery 18.12 sec
12 mph Capacitor 0% Grade, 11.50 sec
Battery & Capacitor Normal Mode _ 10.42 sec __|
Battery 1.16 sec
S mph Capacitor 4% Grade, 1.16 sec
Battery & Capacitor Normal Mode. 0.58 sec
Battery 12.03 sec
7.24 mph Capacitor 4% Grade, 9.87 sec
Battery & Capacitor Normal Mode 10.60 sec
Battery 1.29 sec
Smph Capacitor 8% Grade, 0.43 sec
Battery & Capacitor |__Normal Mode 0.71 sec
Battery 71.94 mph
Top Speed Capacitor 0% Grade, 12.56 mph
Battery & Capacitor | Normal Mode 12.76 mph
Range
5 mph Capacitor 0% Grade, 0.89 miles
Economy Mode 13.77 min
Maximum Speed Capacitor 0% Grade, 0.71 miles 12.56 mph maximum speed.
- Normal Mode | 4.11 min
NASA/TM—2001-211077 10



Acceleration

The average acceleration, a,, of the vehicle is computed as a change in vehicle speed
as a function of time.

an =

Acceleration times are given in Table 2.

Range

The range of the vehicle was determined from the dynamometer tests under full electric
operation with ultracapacitor energy storage. This yields a range of 0.89 miles for no
grade in the economy mode with an initial speed of 5 mph.

Fig. 7 — Range with Various Speeds and Grades

Range Testing with Capacitors

a] Oo
Miles 8% Grade Max. Speed
4% Grade Max. Speed

0% Grade Max. Speed

0% Grade 5 MPH

Test Date 3/13/01

NASA/TM—2001-211077 9


Acceleration Test, Capacitor, 8% Grade, Maximum Initial Speed, Norma! Mode

35.00

30.00

“—Cap Volt (V)
Cap Cur (A)
15.00 + -—— ——— — ——
10.00 +. -— —-—-- —. — — —--
5.00 }+——-— ——_-— ——- —- “=
0.00 -
° 10 20 30 40 50 60
Time (sec)
Acceleration Test, Capacitor, 8% Grade, Maximum Initial Speed, Normal Mode
35.00 y—~ an
30.00 |
7000 : “iMirTemp G)
H Amb Temp (C)
|| "Cap Temp (C) |
15.00 |-———- - Cntr Temp (C)
10.00 +— -
5.00 } - —_-- —-— —_—_- —
0.00
° 10 20 30 40 50 60
Time (sec)
NASA/TM—2001-21 1077 30



35.00

30.00

15.00

10.00

5.00

0.00

35.00

25.00

20.00

10.00

5.00

0.00

Acceleration Test, Capacitor, 8% Grade, Maximum Initial Speed, Normal Mode

= — —_
oe — Cap Volt (Vv)
__ Gap Cur (A)
° 10 20 30 40 50 60
Time (sec)
Acceleration Test, Capacitor, 8% Grade, Maximum Initial Speed, Normal Mode
— ~- |” —=Mtr Temp (C)
| ‘Amb Temp (C)
~~ Cap Temp (C)
| Cntr Temp (C)
Cy) 10 20 30 40 50 60
Time (sec)

NASA/TM—2001-211077


INSTRUMENTATION

The E-Bike was instrumented to measure vehicle speed, distance, and load. These data
were sent to an off-board digital data acquisition system, sampled continuously and
stored on a desktop PC. Additional channels measured the battery voltage and current,
as well as the following temperatures: traction motor, motor controller, energy storage,
and the ambient temperature. These data were sent to an off-board digital data
acquisition system and stored on a laptop PC. Power for the data acquisition system,
was derived from the Building 86 utility system. The instrumentation configuration is
described in Appendix B.

TEST PROCEDURES

The tests described in this report were conducted on a dynamometer at the NASA Glenn
Research Center in Cleveland, Ohio. A description of the dynamometer is given in
Appendix C. The tests were conducted in accordance with the test matrix provided in
Appendix D.

NASA/TM—2001-211077 6



r

=

Speed MPF
& Watts/10
oOoONnM ££ DD

Max. Distance 0.89 Miles
Max. Speed 4.76 MPH
Max, Watts 21

NASA/TM—2001-21 1077

Time Min. |

‘Speed MPH Walts/10 rest onteanam



30.00

25.00

10.00

5.00

0.00

Acceleration & Range Test, Capacitor, 4% Grade, Maximum Initial Speed, Normal Mode

Cap veil vy
Cap cura |

L
0 10 20 30 40 50 60 70
Time (sec)

Acceleration & Range Test, Capacitor, 4% Grade, Maximum Initial Speed, Normal Mode

25.00

20,00

15.00

t—-- — — - | —Mtr Temp © |

10.00

Amb Temp
/ | ‘ap Temp (C)
a 1 ‘Crt Temp (C)

5.00 +—-

0.00

10 20 30 40 50 60 70
Time (sec)

NASA/TM—2001-211077 26



TEST OBJECTIVES

Testing of the vehicle was performed at the NASA Glenn Research Center. Of particular
interest are the following characteristics: range, vehicle speed, acceleration time, and
performance over stop-and-go driving schedules. The performance of the various
vehicle components, especially the motor, controller, energy storage system, and
charger are also of interest.

TEST VEHICLE DESCRIPTION

The E-Bike is a state of the art, ground up, hybrid electric bicycle. The vehicle is shown
in Fig. 1 and described in detail in Appendix A. The E-Bike is a parallel hybrid vehicle as
shown in Fig. 2. As a parallel hybrid vehicle, power is provided to the drive wheel from
an internal electric hub motor, or through the pedals via a 7-speed derailleur, or a
combination of the two.

The standard energy storage system consists of two 12 volt, 12-amp hour sealed lead
acid, deep discharge batteries to store electrical energy. The battery charger is built into
the battery pack. The charger is rated at 24 volts, 3 amps DC. The complete battery
pack including the charger is shown in Fig. 3. The battery pack is quickly removed from
the vehicle if so desired. This permits the quick installation of another battery pack, as
well as charging of the battery pack outside of the vehicle.

The ultracapacitor energy storage system tested is rated at 400 Farads. One of the
ultracapacitors is shown in Fig. 4. This state-of-the-art technology not only has much
longer life than conventional batteries, but also provides much higher current capacity
than batteries. Ultracapacitors are maintenance free, and have excellent low
temperature characteristics.

The electric traction motor shown in Fig. 5 is a 400-Watt DC brushed electric hub motor.
This is a direct drive system with no drive train losses. A pulse width modulated motor
controller allows for efficient speed control over a wide speed range. The motor
controller includes cruise control to maintain constant speed.

The vehicle incorporates Department of Transportation specified safety features
including lights, mirror, and horn.

i

NASA/TM—2001-211077



APPENDIX A

VEHICLE SUMMARY DATA SHEET

1.0 Vehicle Manufacturer

2.0 Vehicle
3.0 Vehicle Configuration

4.0 Traction Motor

4.1 Traction Motor Configuration

4.2 Traction Motor Power
4.3 Traction Motor Cooling

5.0 Drivetrain
5.1 Traction Motor Drivetrain
5.2 Pedal Drivetrain

5.1.1 Transmission Type
5.1.2 Front Chain Ring

5.1.3 Rear Cluster
5.1.4. Gear Ratio

5.1.5 Crankarm
5.1.6 Chain

6.0 Vehicle Dimensions
6.1. Wheel Base

6.2 Frame Size (center to top)

6.3 Head Tube

6.4 Headset Stack Height
6.5 Headset Dimensions
6.6 Fork Steerer Tube
6.7 Fork Travel

6.8 Stem1

6.9 Stem 2

6.10 Handlebar Width
6.11 Handlebar Rise
6.12 Handlebar Handle
6.13 Seat Post
6.14 Seat Post Spacer
6.15 Tires
6.16 Rims
6.17 Spokes

6.17.1 Front

6.17.2 Rear
6.18 Bottom Bracket

NASA/TM—2001-21 1077

EV Global Motors Company
Los Angeles, CA

E-Bike Touring Model

Parallel Hybrid

DC brushed
400 watts
Air cooled

Direct Drive

7-speed Shimano derailleur

33 teeth

14, 16, 18, 20, 22, 24, 28 teeth
0.42, 0.48, 0.55, 0.61, 0.67, 0.73,
0.85

6.7 in (170 mm)

Ye x 3/32 x 110L

41.8 in (1062.3 mm)

16.5 in (419 om)

6.4 in (163 mm)

1.30 in (33 mm)

25.4 mm x 34 mm x 30 mm w/seal
1-1/8 in

65 mm

40 degrees, 110 mm extension
28.6 mm x 25.4 mm x 150 mm
with quill

620 mm

30 mm, 10 degrees

200 mm

350 mm x 27.2 mm O.D.

100 mm x 27.3 I.D. x 34.9 mm O.D.
26 x 1.95 in

26 x 1.5 in, 14G x 36H, double wall

266 mm, 14G stainless
with brass nipples
219 mm, 14G stainless
with brass nipples
127 mm cartridge


APPENDIX B
DESCRIPTION OF THE INSTRUMENTATION SYSTEM
A block diagram of the instrumentation system is shown in Fig. B-1.

The vehicle dynamometer has an integral instrumentation system that monitors vehicle
speed, distance, and power. These data are sampled at 3 Hz and transmitted to the
desktop PC via a serial interface. The PC logs the dynamometer data.

All other measurements were obtained with a Hewlett Packard data acquisition system,
sampling at 100 Hz. Type K thermocouples were used for all temperature
measurements. Hall effect transducers were used for all current measurements. These
data are transmitted to the laptop PC via a serial interface. The PC logs the data.

Fig. B-1
DYNAMOMETER DESKTOP
INTERFACE  -—P PC taeror
motor Teme |-—>}
BATTERY TEMP
CONTROL TEMP
DIGITAL
VEHICLE AMBIENT TEMP SIGNAL DATA
DYNAMOMETER CONDITIONER [——>} ACQUISITION
BATTERY VOLT SYSTEM
BATTERY CUR
CHARGER VOLT
CHARGER CUR}

VEHICLE INSTRUMENTATION SYSTEM

NASA/TM—2001-211077 15


BASELINE TESTING OF THE EV GLOBAL E-BIKE WITH ULTRACAPACITORS

Dennis J. Eichenberg, John S. Kolacz, and Paul F. Tavernelli
National Aeronautics and Space Administration
Glenn Research Center
Cleveland, Ohio 44135

SUMMARY

The NASA John H. Glenn Research Center initiated baseline testing of the EV Global
E-Bike with ultracapacitors as a way to reduce pollution in urban areas, reduce fossil fuel
consumption and reduce operating costs for transportation systems. The E-Bike
provides an inexpensive approach to advance the state of the art in hybrid technology in
a practical application. The project transfers space technology to terrestrial use via non-
traditional partners, and provides power system data valuable for future space
applications. The work was done under the Hybrid Power Management (HPM) Program,
which includes the Hybrid Electric Transit Bus (HETB). The E-Bike is a state of the art,
ground up, hybrid electric bicycle. Unique features of the vehicle’s power system include
the use of an efficient, 400 watt, electric hub motor, and a 7-speed derailleur system that
permits operation as fully electric, fully pedal, or a combination of the two. Other
innovative features, such as regenerative braking through ultracapacitor energy storage,
are planned. Regenerative braking recovers much of the kinetic energy of the vehicle
during deceleration. The E-bike has been tested with the standard battery energy
storage system, an ultracapacitor energy storage system, and a combination battery and
ultracapacitor energy storage system. A description of the E-bike, the results of
performance testing and future vehicle development plans is the subject of this report.
The report concludes that the E-Bike provides excellent performance, and that the
implementation of ultracapacitors in the power system can provide significant
performance improvements.

INTRODUCTION

The NASA Glenn Research Center initiated baseline testing of the EV Global E-Bike as
an excellent opportunity to transfer technology from the aerospace and military
industries to a commercial venture. The project is seen as a way to reduce pollution in
urban areas, reduce fossil fuel consumption and reduce operating costs for
transportation systems. The E-Bike provides an inexpensive approach to advance the
state of the art in hybrid technology in a practical application. The project transfers
space technology to terrestrial use via non-traditional partners, and provides power
system data valuable for future space applications.

The NASA Glenn Research Center provides overall project coordination and is
responsible for testing the vehicle. This includes instrumenting the vehicle and
developing instrumentation and control programs. Wherever practical, off-the-shelf
components have been integrated into the test configuration.

NASA/TM—2001-211077 1


Range Test, Capacitor, 0% Grade, 5 mph Initlal Speed, Economy Mode

30.00 ~

26.00

20.00

10.00

8
Time (min)

Range Test, Capacitor, 0% Grade, 5 mph Initlal Speed, Economy Mode

[Cap Vor (vj
Cap Cur (A)

25.00 = ~ —
20.00 7 - — - ‘
air Temp (C)
j ‘Amb Temp (C)
1500 | ee 1
500 — Cap Temp (Ci)
niet Temp (C)
10.00 — -
500 |
|
0.00 i
° 2 4 6 8 10 12 14 16
Time (rnin)

NASA/TM—2001-211077



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Trade names or manufacturers’ names are used in this report for
identification only. This usage does not constitute an official
endorsement, either expressed or implied, by the National
Aeronautics and Space Administration.

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1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED.
July 2001 Technical Memorandum
4. TITLE AND SUBTITLE 5, FUNDING NUMBERS

Baseline Testing of the EV Global E-Bike With Ultracapacitors

1-30-07-00

6. AUTHOR(S)

Dennis J. Eichenberg, John S. Kolacz, and Paul F, Tavernelli

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION
REPORT NUMBER

National Aeronautics and Space Administration
John H. Glenn Research Center at Lewis Field E-12916

Cleveland, Ohio 44135-3191

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSORING/MONITORING
AGENCY REPORT NUMBER

National Aeronautics and Space Administration
Washington, DC 20546-0001 NASA TM—2001-211077

11, SUPPLEMENTARY NOTES,

Responsible person, Dennis J. Eichenberg, organization code 7720, 216-433-8360.

12a. DISTRIBUTION/AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE
Unclassified - Unlimited
Subject Categories: 31, 33, and 37 Distribution: Nonstandard

Available electronically at hitps//glirs.gr¢ nasa.gow/GLTRS
This publication is available from the NASA Center for AeroSpace Information, 301-621-0390.

13. ABSTRACT (Maximum 200 words)

The NASA John H. Glenn Research Center initiated baseline testing of the EV Global E-Bike with ultracapacitors as a way to reduce
pollution in urban areas, reduce fossil fuel consumption, and reduce operating costs for transportation systems. The E-Bike provides
an inexpensive approach to advance the state of the art in hybrid technology in a practical application. The project transfers space
technology to terrestrial use via nontraditional partners, and provides power system data valuable for future space applications, The
work was done under the Hybrid Power Management (HPM) Program, which includes the Hybrid Electric Transit Bus (HETB), The
E-Bike is a state of the art. ground up. hybrid electric bicycle. Unique features of the vehicle's power system include the use of an
efficient, 400 W. electric hub motor, and a 7-speed derailleur system that permits operation as fully electric, fully pedal, or a combina-
tion of the two. Other innovative features, such as regenerative braking through ultracapacitor energy storage, are planned. Regenera-
tive braking recovers much of the kinetic energy of the vehicle during deceleration. The E-bike has been tested with the standard
battery energy storage system, an ultracapacitor energy storage system, and a combination battery, and ultracapacitor energy storage
system. A description of the E-bike, the results of performance testing and future vehicle development plans is the subject of this
report. The report concludes that the E-Bike provides excellent performance. and that the implementation of ultracapacitors in the
power system can provide significant performance improvements.

14. SUBJECT TERMS 15. NUMBER OF PAGES
Hybrid electric vehicle 16. PRICE CODE
17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACT
OF REPORT OF THIS PAGE OF ABSTRACT
Unclassified Unclassified Unclassified
NSN 7540-01-280-5500 Standard Form 298 (Rev. 2-89)

Prescribed by ANS! Std. Z39-18
298-102



15.00 }

10.00

5.00

Acceleration Test, Battery & Capacitor, 4% Grade, Maximum Initial Speed, Normal Mode

pa

Veh Volt (V)
Bat Cur (A)

2» Cap Cur (A)

25.00

—-- —mtr Temp (C)

Amb Temp (C)
| ~~ Cap Temp (C)
| oo Cntd Temp (Cc)

10.00

5.00

0.00

Time (sec)

NASA/TM—2001-211077 27


CONCLUDING REMARKS

The EV Global E-Bike as tested and described in this report with the standard battery
pack is a commercially available vehicle that is fully prepared for the mass market. The
E-Bike was also tested successfully with ultracapacitor energy storage, anda
combination of battery and ultracapacitor energy storage. The vehicle, nor the energy
storage systems, exhibited any problems under the rigorous test conditions that it was
exposed to. The performance of the vehicle proved to be excellent.

The vehicle acceleration tests were very revealing. The acceleration tests were
performed with battery energy storage, ultracapacitor energy storage, and a combination
of battery and ultracapacitor energy storage. The acceleration performance to 5 mph
and 10 mph in the three modes of operation was roughly the same with no grade. The
acceleration performance to 12 mph was greatly improved with the ultracapacitor alone
or the combination battery and ultracapacitor. The acceleration performance of the
vehicle with a 4% grade and an 8% grade with ultracapacitor energy storage, either by
itself or in combination with the battery, was far superior to that of the battery alone. The
ultracapacitor is capable of supplying the high power required to accelerate the vehicle
more quickly. The addition of the ultracapacitor to the battery conserves the battery
since it does not need to provide the high current required for acceleration, thus
extending its life.

The top speed of the vehicle with no grade and full throttle with the standard battery
pack was 11.94 mph. The top speed with the ultracapacitor alone improved to 12.56
mph. The highest top speed was achieved with a combination of battery and
ultracapacitor at 12.76 mph.

The range performance of the vehicle with the standard battery energy storage is
extraordinary. The range of 34.8 miles achieved at an initial speed of 5 mph with no
grade is almost twice the advertised range of 20 miles. The vehicle operated for 5.7
hours under these conditions. The range achieved with ultracapacitor energy storage
alone at the same conditions was 0.89 miles. The vehicle operated for 13.77 minutes
under these conditions.

The test results with a combination of battery and capacitor energy storage were very
impressive. The ultracapacitor provides the high currents required for high acceleration,
while conserving the battery. The top speed is the greatest with the battery and
ultracapacitor combination.

The baseline testing of the E-Bike with the standard battery pack was the first step in the
testing process. The baseline testing of the E-Bike with ultracapacitor energy storage
was the second step. Future plans for the E-Bike calls for the testing of the vehicle with
regenerative braking. Ultracapacitors will be used for regenerative braking, because of
their superiority to batteries in accepting high braking currents, allowing for less usage of
the mechanical brakes. A photovoltaic charging station will be assembled and tested, to
permit the effective use of the E-Bike in remote locations with no dependence upon the
utilities.

The E-Bike provides an inexpensive approach to advance the state of the art in hybrid
technology in a practical application. The project transfers space technology to
terrestrial use via non-traditional partners, and provides power system data valuable for
future space applications.

NASA/TM—2001-211077 i


6.19 Base Curb Weight
6.20 Total Weight (as tested)

7.0 Energy Storage

7.1 Battery Pack

7.1.1 Configuration

7.1.2 Battery Type

7.1.3 Battery Energy Rating
7.1.4 Battery Voltage Rating
7.1.5 Charger Input

7.1.6 Charger Output

7.1.7 Dimensions

7.1.8 Weight

7.2 Capacitors
7.2.1 Configuration

7.2.2 Capacitance
7.2.3 Energy Rating
7.2.4 Voltage Rating
7.2.5 Dimensions
7.2.6 Weight

NASA/TM—2001-21 1077 14

67 Ib
267 Ib

Two in series with integral charger
Deep discharge, sealed lead acid
12 amp hours each

12 volts each

115 volts ac, 60 Hz, 2 amps

24 volts dc, 3 amps
15inx4inx4in

22.3 Ib

Bank of 8 ultracapacitors (4 legs of
2 ultracapacitors in series)

50 F each, 400 F total

8.1 kJ each, 64.8 kJ total

18 V each, 36 V for each series leg
3.25 in x 6 in x 7 in

10.8 Ib each, 80 Ib total