Chrysler Recalling Prototype PHEV Fleet Due to Li-Ion Battery Concerns

[xcel]

Maybe it is a good thing Chrysler chose to produce a “prototype” fleet instead of a consumer available one?

Wayne Gerdes - CleanMPG - Sept. 22, 2012

Chrysler is withdrawing from service its test fleet of advanced plug-in hybrid-electric vehicle (PHEV) prototypes to conduct a Li-Ion battery-pack swap.

The PHEV Ram’s are part of the national demonstration fleet of 140 vehicles that will be used during the next three years to evaluate customer usage, drive cycles, charging, thermal management, fuel economy, emissions and impact on the region’s electric grid. In addition to NV Energy, seven other partners across the United States are slated to receive vehicles for demonstration and testing purposes.

Strictly a DOE funded demonstration program, there are no plans for a production version of the PHEV trucks.

The Ram 1500 PHEV includes a liquid-cooled 12.9 kWh Li-Ion and a 6.6 KW on-board charger. Additional features include AC power generation of up to 6.6kW; directional charging; reverse power flow and full regenerative braking used to capture braking energy. For fuel economy improvements, the front axle of the four-wheel-drive automatic transmission can be disconnected when not needed. The powertrain also includes a 5.7L HEMI V-8 engine and a two-mode hybrid transmission. The 5.7L Hemi is equipped with a Fuel Saver technology that improves fuel efficiency at highway speeds by shutting down fuel delivery to up to four cylinders.

The battery pack is located under the second-row seat of the pickup and is liquid cooled to help maintain a consistent battery temperature. For on-the-job electrical power tools, a 240 volt/30 amp four-prong outlet and 120volt/20amp duplex outlet power strip is located in the rear box.


We have done a few stories on RAM 1500 PHEVs to date including the following:

San Francisco to Receive 14 PHEV_Ram Pickups

Not For Sale and Not Going to Be Sold RAM 1500 PHEVs in the News ...

The RAM P/U Truck of the Future

Ram Trucks Pull the Plug on Hybrids

Chrysler Making Waves With Big Fuel Economy Improvement Project ...

Electrovaya Awarded $5 Million from SDTC for PHEV_Battery ...

Dodge Ram PHEV

2010 Dodge Ram Two-Mode Hemi Hybrid Still On Track

The Problem

According to the Chrysler release, three of the fleet’s 109 pickups equipped with the PHEV powertrains sustained damage when their prototype 12.9 kWh Li-Ion traction batteries overheated. Chrysler stated that there were no injuries and the incidents occurred when the vehicles were unoccupied.

The 23 PHEV minivans experienced no similar issues but are being withdrawn from service for the swap just in case.

A different battery chemistry will be used in the projects' next phase, which should provide improved safety.

The PHEVs were being evaluated for durability and other attributes by 16 partner organizations -- municipalities and utility companies across 20 states. The fleet accumulated more than 1.3 million miles of service in various conditions, from high-altitude Colorado to Arizona’s searing desert.

The HEMI equipped PHEV pickups Advanced Technology Partial Zero-Emissions Vehicles (AT-PZEVs) emissions certified with a recorded peak average fuel-economy of 37.4 mpg, while the minivans delivered 55.0 mpg.

The batteries are said to be produced without environmentally any harmful NMP solvent used in most battery-manufacturing processes.

Funding for the program in part is provided by the American Recovery and Reinvestment Act of 2009 through the Transportation Electrification Initiative sponsored by the DOE. The grant, totaling $48 million from DOE and $49.4 million from Chrysler Group LLC, was designed to develop vehicles that will be cost efficient for consumers, satisfy safety concerns of daily travel without recharging and help reduce dependence on foreign oil.

While that is not really occurring, it is a way for Chrysler to get their feet wet while readying their engineering for the future direction of the automobile.

[2RR2NV]

[quote=xcel;356511]
The HEMI equipped PHEV pickups Advanced Technology Partial Zero-Emissions Vehicles (AT-PZEVs) emissions certified with a recorded peak average fuel-economy of 37.4 mpg, while the minivans delivered 55.0 mpg.

QUOTE]

are you KIDDIN me? holy cow! I'm actually excited if they were to build that.

now, if they were to put that tech in the new RAM with 25mpgs already on the table. oh YEAH!!!

[waltermlee]

A liquid cooled Li-ion pack sounds like Chrysler is experimenting with very high power drain levels which is probably why the MPG went up like that but that the cooling system either failed or was inadequate for the power levels that Chrysler is aiming for so the battery pack overheated. Even if the Li ion battery packs don't burst into flames, their lifespan can be shortened signficantly when they overheat - given the cost of a li-ion battery pack - not a good thing.

I too am glad that Chrysler is learning these very expensive lessons on an experimental fleet.

Is there a reason why none of the major truck manufacturers has not just redesign the body of the traditional pickup truck to be more aerodynamic so it can get higher MPGs at higher speeds?

[xcel]

Hi Waltermlee:

Both the Ford F-150 and upcoming RAM 1500 have had a number of aero work instilled in their latest designs. The RAM 1500’s Cd is down to just .360 which for a pickup is pretty damn amazing. IIRC, the F-150 Crew Cab had a Cd of .375 or thereabouts?

Wayne

[herm]

Could have been anything, even a contaminant when they cells were built. The Volt's 16.5kWh pack is used at a 150hp power level without issues.. thats almost a 7C continuous discharge rate. Obviously you can only do that in a racetrack.

[EdwinTheMagnificent]

Is there a reason why none of the major truck manufacturers has not just redesign the body of the traditional pickup truck to be more aerodynamic so it can get higher MPGs at higher speeds?

That's an easy one. Pickup buyers are more about tradition then ANY vehicle buyers. If one manufacturer offers a true "aero" design , most of their "loyal" customers will go elsewhere. I can hear them saying " That don't look right".
Of course I'm clueless about pickup trucks and can only offer my opinion.

[herm]

What little I know is this: a huge chrome plated plastic grill is expected, plus dangling large chrome plated testicles at the back.. it has to look manly or it wont sell. Also, an unwritten rule is that you will need a ladder to reach over the sides of the bed... also a minimum of 300hp.

[Indigo]

A Chrysler recall? Say it ain't so! Seriously, this company needs to learn how to build rock-solid conventional cars and trucks first before it dabbles into that "newfangled sciency stuff". My guess is that the LiIon vehicles started having trouble at 36,001 miles of use.

I REALLY wish that our government would stop throwing R&D money at Chrysler. The company just isn't ready for prime time. Obama was justified in saving GM, but he should have let Chrysler die. Or, better yet, assign Chrysler's production facilities to GM and Ford so that the Chrysler executives would be out of a job but American workers wouldn't be.

[2RR2NV]

well, how else ya gonna test something... at least they weren't production vehicles and THEN get recalled. i'd rather they test, make it right, and then sell it.

justified saving GM? oh my... definitely not in the truck catagory....

[EdwinTheMagnificent]

It's probably a good thing that Chrysler is working on deveoping this technology. Toyota,Ford, or GM won't share it with them and why should they ? Eventually Chrysler buyers will demand technology , and I'm talking bout stuff that WORKS.