BOARD MEETING DATE: May 10, 1996

AGENDA NO.8

PROPOSAL:

Execute a Contract to Cost-Share the Development and Demonstration of an Electric Vehicle Range Extender

SYNOPSIS:

The first electric vehicles to be offered for sale will have lower-than-desired travel range due to battery limitations. AC Propulsion of San Dimas has proposed to develop and demonstrate an EV range extender that will enable EVs to be used for long trips. The availability of such units should enhance the marketability of EVs and increase their number in the vehicle fleet. The cost of this program is $675,000 of which the AQMD would cost-share in an amount not to exceed $296,000.

COMMITTEE:

Technology, April 10, 1996, Recommended for Approval

RECOMMENDED ACTION:

Authorize the Chairman to execute a contract with AC Propulsion to develop and demonstrate an electric vehicle range extender for an amount not to exceed $296,000.

James M. Lents, Ph.D.
Executive Officer

CSL:ARA:MXB

Background

The AQMP calls for the accelerated introduction of zero-emission electric vehicles (EVs) as an air quality attainment strategy. ARB regulations require the major automotive manufacturers to offer EVs for sale in California in 2003. Although there is no production requirement for years 1998-2002, ARB has established a Technology Partnership intended to place as many as 3,750 advanced EVs on California roads in the interim. As a result, General Motors will introduce limited production of its EV1 in 1996. Several other manufacturers also are planning to introduce EVs over the next few years. Although vehicle and battery technology is developing rapidly, these initial EVs will have some range and recharging-time limitations compared with conventional vehicles. These EVs will be quite adequate for short trips up to 90 miles, but will have no utility for extended trips. For the longer term, either advanced long-range batteries or fuel cells will be required for EVs to broadly penetrate the vehicle fleet.

The range limitations of these early generation EVs have spawned the development of EV range extenders by two companies, AC Propulsion and Fisher Electric Motor Technology. Current range extender designs consist of gasoline-engine-driven generator sets mounted on torque trailers which provide essentially unlimited electrical energy and range for EVs. However, tongue trailers are difficult to back up and do not have emission controls on their internal combustion engines.

User-friendly, low-emission range extenders have the potential to improve EV marketability by addressing the energy limitations associated with current-technology batteries. Consumers will be more likely to purchase EVs knowing that they can be driven on cross-country trips using range extenders that could be rented from EV dealerships or equipment rental businesses. Range extenders can also be designed to achieve very low, ULEV-equivalent emissions.

Proposal

AC Propulsion proposes to develop a lightweight, high-power, user-friendly, low-emission range extender based upon experience gained with two successive range extender designs. Their proposed design will use a space-frame trailer with a close, rigid bumper mount to the EV. A motorcycle engine, using either gasoline or propane, will power a high-efficiency, lightweight alternator. Emissions will be controlled to very low levels through the use of a three-way catalytic converter and electronic engine control. The development and demonstration of the range extender will include: the design of the alternator and charging subsystem; development of the engine and emission controls; design of the trailer chassis, enclosure and noise control; subsystem integration; and testing of the range extender.

This proposed project is included in the Technology Advancement Plan for Clean Fuels Program as Project MS-13, “Development and Demonstration of Advanced EV Technologies.” In terms of direct emission reductions, an EV using the range extender will be at least as clean as an ULEV during periods when the range extender is operating. When the range extender is not operating, during all-electric use of the EV, emissions will be zero. On a per-mile basis, power plant emissions attributable to EV use are about 100 times lower than ULEV emissions, as estimated by the ARB. Thus, while an EV using the range extender will not offer the full emissions benefits of a pure-electric EV, the overall operating emissions will be significantly lower than a ULEV. Moreover, range-extender operation and the associated emissions, will probably occur mostly out of the Basin when it is needed for long trips.

Availability of the range extender can help expedite EV deployment in the Basin. Consumers will be more likely to purchase EVs knowing that they will have the option to rent an range extender and drive the EV on vacations and long trips. Such EVs will replace conventional vehicles with much higher emissions. Although there are no emission benefits during the brief demonstration period of this project, the goal is to develop technology which will encourage the acceptance and purchase of EVs. If successfully demonstrated, the resulting range extender technology will become commercially available for use in Southern California with commensurate emission benefits through the greater use of EVs.

Sole Source Justification

Section II, Step 3(C) of the Consultant Selection Policy and Procedure, identifies four provisions under which the Executive Officer may award a sole-source bid: (1) cost to prepare documents exceeds cost for consultant; (2) delay would result in the endangerment of public health; (3) services are only available from sole-source; and (4) other circumstances exist identifying sole-source as in the best interests of the AQMD. This request for sole-source bid is made under provision (4).

In September 1995, the AQMD issued Program Opportunity Notice (PON) #9596-001. The objective of this PON was to solicit interest in and identify potential proponents for a cost-shared program to develop and demonstrate a user-friendly, low-emission range extender. This solicitation encouraged the use of various types of engines including small gas turbines or motorcycle engines, high-power lightweight alternators, advanced emission controls, and alternative fuels such as propane.

The PON was sent to 403 different businesses around the world, of which 107 were located in California. Three pre-proposals were received in response to the PON: AC Propulsion of San Dimas, Alturdyne of San Diego, and Virginia Polytechnic Institute. One pre-proposal was expensive, and the other two involved the use of tongue trailers and heavy systems. Each proposer was requested to revise its proposal to better meet the scope of the intended project. AC Propulsion and Alturdyne revised and resubmitted their pre-proposals; Virginia Polytechnic did not resubmit.

The redesigned Alturdyne range extender did not use a tongue trailer and was much reduced in weight. However, this redesigned unit did not contain a fuel tank, would require a special lift for installing the range extender into the rear bumper of an EV, and would likely cause vehicle handling problems. Thus, this proposal was deemed technically unacceptable.

AC Propulsion revised its proposal to develop a bumper-mounted, dual-caster-wheel tubular space frame trailer with suspension and a retractable third wheel for off-vehicle maneuvering and parking.

Staff believes the proposal submitted by AC Propulsion represents a viable approach to development of a consumer-acceptable EV range extender. AC Propulsion, a small business located in San Dimas, California, has extensive experience in developing high-power, high-efficiency EVs, EV drivetrains, and EV battery recharging and monitoring systems. The company has developed two generations of range extenders, and has practical experience with two cross-continent trips and over 15,000 miles of travel with a range extender.

Resource Impacts

Total estimated cost of the development and demonstration project is approximately $675,000; cost to the AQMD will not exceed $296,000. The funding breakdown is as follows:

Sufficient funds are available in the Fiscal Year 1995-96 Budget.

BD13:5-96D