Refining Control, Charging, and Battery Chemistry for CO2 e Savings in Heavy-Duty Off-Road Plug-In Series Hybrid

Goodenough, Bryant; Czarnecki, Alexander; Robinette, Darrell; Worm, Jeremy; Subert, David; Kiefer, Dylan; Heath, Matthew; Brunet, Bob; Kisul, Robert; Latendresse, Phil; Westman, John; Black, Andrew

doi:10.4271/14-14-02-0009

Refining Control, Charging, and Battery Chemistry for CO₂ e Savings in Heavy-Duty Off-Road Plug-In Series Hybrid

Journal Article · Wed Feb 26 04:00:00 EST 2025 · SAE International Journal of Electrified Vehicles

DOI:https://doi.org/10.4271/14-14-02-0009· OSTI ID:2530165

Goodenough, Bryant ^[1]; Czarnecki, Alexander ^[2]; Robinette, Darrell ^[2]; Worm, Jeremy ^[2]; Subert, David ^[2]; Kiefer, Dylan ^[2]; Heath, Matthew ^[2]; Brunet, Bob ^[2]; Kisul, Robert ^[2]; Latendresse, Phil ^[3]; Westman, John ^[3]; Black, Andrew ^[4]

Michigan Technological University, Houghton, MI (United States); Michigan Technological University APS LABS
Michigan Technological University, Houghton, MI (United States)
Pettibone/Traverse Lift LLC, Baraga, MI (United States)
Soli Consulting LLC, Hancock, MI (United States)

With current and future regulations continuing to drive reductions in carbon dioxide equivalent (CO₂e) emissions in the on-road industry, the off-road industry is also likely to be regulated for fuel and CO₂e savings. This work focuses on converting a heavy-duty off-road material handler from a conventional diesel powertrain to a plug-in series hybrid, achieving a 49% fuel reduction and 29% CO₂e reduction via simulation. Control strategies were refined for energy savings, including a regenerative braking strategy to increase regenerative braking and a load-following hydraulic strategy to decrease electrical energy consumption. The load-following hydraulic control shuts off the hydraulic electric machine when it is not needed—an approach not previously seen in a load-sensing, pressure-compensated system. Furthermore, these strategies achieved a 24.1% fuel savings, resulting in total savings of 61% in fuel and 41% in CO₂e in the plug-in series compared to the conventional machine. Beyond control strategies, this study evaluated battery chemistry and charging strategy refinements for total cost of ownership (TCO) and lifetime CO₂e. LFP batteries emerged as the most cost-effective and least emitting due to their longer lifespan, which reduced replacement frequency. Charging comparisons showed that Level 2 charging (L2C) typically resulted in lower TCO but higher lifetime CO₂e than DC fast charging (DCFC). DCFC costs were heavily influenced by local demand charges, and DCFC emissions were heavily influenced by local grid emissions.

View Accepted Manuscript (DOE)

Research Organization:: Michigan Technological University, Houghton, MI (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: EE0008800

OSTI ID:: 2530165

Journal Information:: SAE International Journal of Electrified Vehicles, Journal Name: SAE International Journal of Electrified Vehicles Journal Issue: 2 Vol. 14; ISSN 2691-3747

Publisher:: SAE InternationalCopyright Statement

Country of Publication:: United States

Language:: English

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