Report

CARB Tech. Review Sept. 2006

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1 1 Toyota RAV4 Toyota RAV4 - - EV Driver Experience EV Driver Experience A Survey of Capability, Reliability, A Survey of Capability, Reliability, and Failures and Failures Ron Freund, EAA Chairman Ron Freund, EAA Chairman Presented to the CARB Technical Review Presented to the CARB Technical Review Sacramento, September 27, 2006 Sacramento, September 27, 2006 http://www.eaaev.org http://www.eaaev.org Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 2 2 Results: Usage Patterns Results: Usage Patterns Surveyed: 132 vehicles Surveyed: 132 vehicles (incl. 16 fleet) 2001, 2002, 2003 (incl. 16 fleet) 2001, 2002, 2003 Total ZEV miles: 5,051,064 Total ZEV miles: 5,051,064 Average Annual Miles: 10,000 Average Annual Miles: 10,000 Car purpose: Car purpose: Range: 103.1 mi, Range: 103.1 mi, Commuter: 24% 11.6 mi.

standard deviation Commuter: 24% 11.6 mi. standard deviation Primary: 66% Primary: 66% Sole vehicle: ~10% Sole vehicle: ~10% Even when ICE is available Even when ICE is available 3 3 avg. use: 80.4% of all miles driven avg.

use: 80.4% of all miles driven High mileage: 105,135 High mileage: 105,135 Average odometer: 37,978 miles Average odometer: 37,978 miles Low Mileage: 4,100 Low Mileage: 4,100 Locations: Initially all in CA, now in FL, MD, PA, IL, LA, CO, Locations: ... more. less.

Initially all in CA, now in FL, MD, PA, IL, LA, CO, NJ, NJ, Nova Scotia etc. Nova Scotia etc. Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 3 3 Results: Power sources used Results: Power sources used Regular home Regular home - - based grid charging: more convenient based grid charging: more convenient Solar: 48% of respondents drive Solar Solar: 48% of respondents drive Solar Powered Vehicles (SPV) Powered Vehicles (SPV) BEVs can use renewables today.<br><br> BEVs can use renewables today. Solar, Wind, Green Certificates, Methane Solar, Wind, Green Certificates, Methane Public infrastructure is enjoyed by >90% Public infrastructure is enjoyed by >90% Extended driving horizon: 34.6 X/yr, avg. Extended driving horizon: 34.6 X/yr, avg.<br><br> Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 4 4 Results: Failure/Defect Analysis (1 of 2) Results: Failure/Defect Analysis (1 of 2) Failure defined: Failure defined: Anything that was not expected and that resulted in inability Anything that was not expected and that resulted in inability to continue without outside assistance to continue without outside assistance BEV Technology related versus routine: nothing remarkable BEV Technology related versus routine: nothing remarkable noted noted Significant is 10 Significant is 10 - - year year - - old design, well executed, mature old design, well executed, mature technology technology No repeated BEV technology related failures, only routine No repeated BEV technology related failures, only routine maintenance issues noted maintenance issues noted Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 5 5 FRU Frequency of Occurrance 0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O Results: Failure/Defect Analysis (2 of 2) Results: Failure/Defect Analysis (2 of 2) Defect counts from 132 samples Defect counts from 132 samples A A Charge port fan Charge port fan B B Traction pack Traction pack C C Heat pump Heat pump D D Electric Pwr. Steering Electric Pwr. Steering E E Rectifier Rectifier F F Rear Wiper motor Rear Wiper motor G G Traction Motor inverter Traction Motor inverter H H Battery Mgmt ECU Battery Mgmt ECU I I Motor seal leak Motor seal leak J J Main relay Main relay K K Regen caused cut Regen caused cut - - out out L L Dash Brake Lamp on Dash Brake Lamp on M M Tires misaligned Tires misaligned N N Master cylinder Master cylinder O O Overcharging Overcharging Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 6 6 Results: Support services Results: Support services Problems with Toyota Problems with Toyota While a few dealerships gave exemplary service, some had not While a few dealerships gave exemplary service, some had not seemed fully on seemed fully on - - board board Problems with Toyota obtaining parts Problems with Toyota obtaining parts Yes = 24%, 76% said Yes = 24%, 76% said c c not needed or no not needed or no d d Many parts had long lead times, 4 Many parts had long lead times, 4 - - 6 weeks after crash/impacts 6 weeks after crash/impacts Problems with the home charger Problems with the home charger (included with vehicle) (included with vehicle) None = 77% 4 roll None = 77% 4 roll - - aways; generally CFC Inc.<br><br> repaired; once aways; generally CFC Inc. repaired; once they refused for a known problem they refused for a known problem Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 7 7 RAV4 RAV4 - - EV Traction battery EV Traction battery Panasonic EV Panasonic EV - - 95 NiMH performs admirably, 26 kWh capacity 95 NiMH performs admirably, 26 kWh capacity Specs: Three rows, ~1000 lbs., 26 kWh >100 freeway miles Specs: Three rows, ~1000 lbs., 26 kWh >100 freeway miles Regeneration: 20 Regeneration: 20 - - 33% additional energy recaptured and 33% additional energy recaptured and available thru use of available thru use of 8 8 B B 9 9 , , 8 8 EB EB 9 9 and anticipation and anticipation 91% reported no change in capability, 9% reported some range los 91% reported no change in capability, 9% reported some range los s. s.<br><br> Of those 9%, the loss was less than 10%. Of those 9%, the loss was less than 10%. No long term self No long term self - - discharge noted.<br><br> discharge noted. Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 8 8 Tool employed: RAV4Info S/W on PDA Tool employed: RAV4Info S/W on PDA 3 3 rd rd party development party development Taps into OBD Taps into OBD - - II data stream on car II data stream on car Software: protocol emulator, Software: protocol emulator, data interpretation, presentation data interpretation, presentation How well do people drive? How well do people drive?<br><br> DC energy used per mile driven DC energy used per mile driven 245 wH/mile average, A/C largest 245 wH/mile average, A/C largest secondary load secondary load High: 340, Low: 112 High: 340, Low: 112 Regeneration provides range boost Regeneration provides range boost (>20%) (>20%) Driving for efficiency becomes a goal Driving for efficiency becomes a goal Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 9 9 Drivers Drivers 9 9 Overall Perception of RAV4 Overall Perception of RAV4 - - EV EV Owners overwhelmingly appreciate: Owners overwhelmingly appreciate: - - vehicle functionality and reliability vehicle functionality and reliability - - predictability and durability of the NiMH battery technology predictability and durability of the NiMH battery technology - - measurably lower fuel cost, time saved by home charging measurably lower fuel cost, time saved by home charging - - not buying gasoline not buying gasoline - - no tailpipe emissions; lower carbon footprint no tailpipe emissions; lower carbon footprint - - unexpected investment asset unexpected investment asset - - very short learning curve very short learning curve - - extremely simple to operate extremely simple to operate No technology limitations seen in this implementation No technology limitations seen in this implementation example example All failures and defects are significantly less, or in rare case All failures and defects are significantly less, or in rare case s, s, at worst at worst - - very comparable to the gasoline version of car very comparable to the gasoline version of car Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 10 10 RAV4 EV Drivers' Survey RAV4 EV Drivers' Survey Conclusions Conclusions RAV4 RAV4 - - EV provides drivers w/ good value and pleasant driving EV provides drivers w/ good value and pleasant driving experience. experience. The manufacturing process demonstrated by Toyota is The manufacturing process demonstrated by Toyota is mature and well executed mature and well executed As natural and easy to use as a gas car As natural and easy to use as a gas car Textbook example of manufacturing quality control; failures Textbook example of manufacturing quality control; failures below 3% maximum for worst component below 3% maximum for worst component Technology is over 10 years old, over 100,000,000 ZEV miles Technology is over 10 years old, over 100,000,000 ZEV miles in real in real - - world consumer use world consumer use Frequent comments: Frequent comments: c c best car ever owned best car ever owned d d , etc.<br><br> , etc. Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 11 11 RAV4 EV Drivers' Survey RAV4 EV Drivers' Survey Backup slides Backup slides RAV4 EV Driver Survey Electric Auto Association Electric Auto Association 12 12 Biographical overview Biographical overview Professional Hardware Design Engineer Professional Hardware Design Engineer Actively employed as engineer in tech. industry Actively employed as engineer in tech.<br><br> industry Driver of electric vehicles since Feb. 1998 Driver of electric vehicles since Feb. 1998 Renter of GM EV Renter of GM EV - - 1 from EV 1 from EV - - Rentals at LAX in 2001 Rentals at LAX in 2001 Purchased 5th RAV4 Purchased 5th RAV4 - - EV from Toyota in Palo Alto, 2002 EV from Toyota in Palo Alto, 2002 Lead EAA since Feb.<br><br> 2001, CA 501(c)(3) w/ >1000 members in 43 Lead EAA since Feb. 2001, CA 501(c)(3) w/ >1000 members in 43 states and 10 foreign countries states and 10 foreign countries EAA represents drivers as a public benefit education organizatio EAA represents drivers as a public benefit education organizatio n n with several special interest groups with several special interest groups Details on website Details on website http://www.eaaev.org http://www.eaaev.org Electric Auto Association Electric Auto Association RAV4 EV Driver Survey 13 13 RAV4 EV Drivers' Survey RAV4 EV Drivers' Survey Approach used Approach used Decided what data to collect Decided what data to collect Created an email survey Created an email survey Requirement < 10 minutes to fill out and return Requirement < 10 minutes to fill out and return >132 vehicles represented (of ~330 privately held) >132 vehicles represented (of ~330 privately held) Tabulated responses via spreadsheet Tabulated responses via spreadsheet Electric Auto Association Electric Auto Association RAV4 EV Driver Survey

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