Performance Testing of the Extended-Range (Hybrid) Electric G Van

This paper presents the results of performance characterization testing of the extended-range Conceptor G Van electric vehicle (EV). Testing was performed at the Electrotek Electric Vehicle Test Facility (EVTF) as part of the Electric Power Research Institute (EPRI)/Electrotek EV Program. This extended-range EV (XREV) is based on the electric G Van, which is a GMC full-sized van converted to electric propulsion by Conceptor Industries of Newmarket (Toronto), Ontario. A 7-kW Onan gasoline engine/generator (E/G) set was retrofitted into the vehicle by McKee Engineering of Lake Zurich, Illinois. The XREV utilizes tubular-plate lead-acid batteries and dc powertrain components furnished by Chloride EV Systems of Redditch, England. Testing was conducted according to the EPRI/Electrotek EV Test Plan and included measurement of driving range on the SAE J227a C Cycle, on the Electrotek-defined Chattanooga City Cycle (CCC), and at four constant speeds from 56 km/h to 80 km/h. The C Cycle and CCC tests were performed with the E/G switched on at different battery states of charge (SOC) from 100% to 25% to determine the effects of the E/G on driving range and battery behavior. “Limp-home” tests were also conducted over these cycles by driving the XREV on pure-electric power to 0% SOC, turning on the E/G for a one-hour battery charge, and then continuing the cycle under both battery and E/G power. It was found that use of the E/G increased driving range significantly for all cases. Additional tests were performed to determine the dc energy consumption of the XREV over the C cycle and at various constant speeds. Data is presented which includes driving test results as well as calculated costs for different combinations of electric and gasoline operation.