Toyota RAV4 EV
Encyclopedia
The RAV4 EV was an all-electric
Battery electric vehicle
A battery electric vehicle, or BEV, is a type of electric vehicle that uses chemical energy stored in rechargeable battery packs. BEVs use electric motors and motor controllers instead of, or in addition to, internal combustion engines for propulsion.A battery-only electric vehicle or...

 version of the popular RAV4
Toyota RAV4
The Toyota RAV4 is a compact crossover SUV from Toyota. It was the first compact crossover SUV, introduced in Japan and Europe in 1994 and beginning sales in North America in 1996...

 SUV produced by Toyota. It was leased from 1997 to 2003, and at the lessees request, many units were sold after the vehicle was discontinued. A total of 1,485 were leased and/or sold in California to meet the state’s mandate for Zero-emissions vehicle
Zero-emissions vehicle
A zero-emissions vehicle, or ZEV, is a vehicle that emits no tailpipe pollutants from the onboard source of power. Harmful pollutants to the health and the environment include particulates , hydrocarbons, carbon monoxide, ozone, lead, and various oxides of nitrogen. Although not considered emission...

. As of the second half of 2010 there are almost 750 units still in use.

Toyota is working together with Tesla Motors
Tesla Motors
Tesla Motors, Inc. is a Silicon Valley-based company that designs, manufactures and sells electric cars and electric vehicle powertrain components. It was the only automaker building and selling a zero-emission sports car, the Tesla Roadster, in serial production...

 to develop a second generation RAV4 EV, and the companies expect the vehicle to be mass produced
Mass production
Mass production is the production of large amounts of standardized products, including and especially on assembly lines...

 by 2012. The initial roll-out in the U.S is scheduled for the first half of 2012 and sales will be limited initially to California only.

First generation

The first fleet version of the RAV4 EV became available on a limited basis in 1997. In 2001 it was possible for businesses, cities or utilities to lease one or two of these cars. Toyota then actually sold or leased 328 RAV4 EVs to the general public in 2003, at which time the program was terminated despite waiting lists of prospective customers.

The RAV4 EV closely resembles the regular internal combustion engine
Internal combustion engine
The internal combustion engine is an engine in which the combustion of a fuel occurs with an oxidizer in a combustion chamber. In an internal combustion engine, the expansion of the high-temperature and high -pressure gases produced by combustion apply direct force to some component of the engine...

 (ICE) version - without a tailpipe - and has a governed top speed of 78 mph (~126 km/h) with a range of 100 to 120 mi (160.9 to 193.1 km). The 95 amp-hour NiMH battery pack has a capacity of 27 kWh, charges inductively
Inductive charging
Inductive charging uses an electromagnetic field to transfer energy between two objects. This is usually done with a charging station. Energy is sent through inductive coupling to an electrical device, which then can use that energy to charge batteries....

 and has proven to be surprisingly durable. Some RAV4 EVs have achieved over 150000 miles (241,401 km) on the original battery pack. It was also one of the few vehicles with a single speed automatic transmission
Automatic transmission
An automatic transmission is one type of motor vehicle transmission that can automatically change gear ratios as the vehicle moves, freeing the driver from having to shift gears manually...

 at that time.

Besides the batteries, controller and motor, the remaining systems in the RAV4 EV are comparable to the gasoline-powered RAV4, such as power brakes, power steering
Power steering
Power steering helps drivers steer vehicles by augmenting steering effort of the steering wheel.Hydraulic or electric actuators add controlled energy to the steering mechanism, so the driver needs to provide only modest effort regardless of conditions. Power steering helps considerably when a...

, air conditioning
Air conditioning
An air conditioner is a home appliance, system, or mechanism designed to dehumidify and extract heat from an area. The cooling is done using a simple refrigeration cycle...

, tire wear and suspension components except for the power sources involved. The power brakes use an electric pump to provide vacuum instead of deriving vacuum from the engine manifold while the power steering and air conditioning systems use electric motors instead of mechanical energy delivered by fan belts. The passenger compartment is heated electrically.

Performance

The RAV4 EV has a governed top speed of 78 miles per hour (126 km/h), a tested 0-60 time of around 18 seconds (depending on state-of-charge on the batteries) and a range of 80 to 120 miles (130 to 190 km). Mileage depends on the same factors as a traditional gasoline-powered vehicle, mainly rolling resistance
Rolling resistance
Rolling resistance, sometimes called rolling friction or rolling drag, is the resistance that occurs when a round object such as a ball or tire rolls on a flat surface, in steady velocity straight line motion. It is caused mainly by the deformation of the object, the deformation of the surface, or...

 and average speed (aerodynamic drag
Drag (physics)
In fluid dynamics, drag refers to forces which act on a solid object in the direction of the relative fluid flow velocity...

).

The RAV4 EV has 24 12-volt 95Ah NiMH batteries capable of storing 27.4 kWh of energy.

Charging

The RAV4 EV's batteries can be recharged from being fully depleted to fully charged in about five hours, and are monitored with a passive battery balancing system. Electricity is supplied via a Magne Charge
Magne Charge
Magne Charge is a largely obsolete inductive charging system, also known as J1773, used to charge battery electric vehicles formerly made by General Motors, for vehicles such as the EV1, Chevy S10 EV, and other electric vehicles. It was produced by the General Motors subsidiary Delco Electronics....

 inductive charging
Inductive charging
Inductive charging uses an electromagnetic field to transfer energy between two objects. This is usually done with a charging station. Energy is sent through inductive coupling to an electrical device, which then can use that energy to charge batteries....

 paddle
from a wall-mounted 6000-Watt charging unit on a 220 volt, 30 amp, North American "clothes dryer"-type plug.

Mileage costs

As of May 2006, charging a RAV4 EV from full-dead to full-charge, at a rate of per kilowatt-hour, costs around . As of May 2008, based on a gasoline price-per-gallon cost of and up and the non-EV 2003 RAV4 2-wheel-drive gasoline fuel efficiency of 27 miles per US gallon, the RAV4 EV costs approximately 25% as much to fully charge, and makes mileage in the RAV4 EV the cost equivalent to a 111.1 miles per US gallon small SUV.

In addition, the RAV4 EV has a charge timer built into the dashboard that enables the vehicle to start charging at a specific time. As the RAV4 EV easily becomes the main cost of electricity in an average-sized home, this enables the owner to use a Time-Of-Day Meter to reduce electricity costs. This configuration is a standard practice with RAV4 EV owners. The price of electricity at night depends on the carrier, but is usually in the range of 60% of the normal rate. In the use of charging the RAV4 EV, this equates to a cheaper cost-per-mile, roughly equivalent to a vehicle capable of 166.6 miles per US gallon, based on a price of per gallon.

The United States Environmental Protection Agency listed mileage ratings for the RAV4 EV in its yearly Fuel Economy Guide from 2000 through 2003. The 2003 model recorded city mileage equivalent to 125 miles per US gallon, and 100 miles per US gallon on the highway. Estimated combined mileage was 112 miles per US gallon.

For comparison, a reasonably modern European supermini
Supermini car
A supermini is a British term that describes automobiles larger than a city car but smaller than a small family car. This car class is also known as the B-segment across Europe, and as subcompact in North America....

 may manage motorway travel at 5 L/100 km or 6.5 L/100 km in city traffic, while an average North America
North America
North America is a continent wholly within the Northern Hemisphere and almost wholly within the Western Hemisphere. It is also considered a northern subcontinent of the Americas...

n mid-size car
Mid-size car
A mid-size car is the North American/Australian standard for an automobile with a size equal to or greater than that of a compact...

 travels 9 L/100 km, 11 L/100 km city.

Consumable items

The RAV4 EV's battery system is a consumable item. Toyota reports that battery pack replacement costs are currently higher than the value of the used vehicle. Toyota tested the RAV4 EV in Japan for 300000 miles (482,802 km) over two years before introducing the vehicle in the United States. The economies of scale
Economies of scale
Economies of scale, in microeconomics, refers to the cost advantages that an enterprise obtains due to expansion. There are factors that cause a producer’s average cost per unit to fall as the scale of output is increased. "Economies of scale" is a long run concept and refers to reductions in unit...

 are affecting the replacement cost of the RAV4 EV.

Prototyping

RAV4 EV pre-production prototypes were first released in a confidential evaluation program with electric utilities throughout the U.S. These prototypes were based on the smaller, shorter, two-door version of the RAV4. The prototypes included some versions fitted with Panasonic NiMH
NIMH
NIMH or NiMH may refer to:*Nickel-metal hydride battery, a type of rechargeable battery*National Institute of Mental Health, a part of the United States National Institutes of Health...

 batteries, and others with high-performance Panasonic lead–acid PbA batteries (the same ones that eventually found their way into the EV1 and other production GM electric vehicles). The RAV4 EV prototypes also were equipped with on-board level 2 chargers and connected via a front fender conductive charger coupling made by Yazaki
Yazaki
is a worldwide supplier of automotive equipment, gas meters and air-conditioning equipment. The main business is automotive equipment like electrical wiring harnesses, components like connectors, terminals, fuses and boxes and electronic devices such as instrument clusters.The Yazaki Group employs...

 Corporation. Both prototypes were well accepted.

The utility employee evaluators did not have to personally pay for the more costly and advanced NiMH batteries, and the NiMH RAV4 EV prototype received better reviews, due to its increased range. Its energy efficiency, however, was not as good as the PbA version. Due to the impracticality of developing two battery types for a limited volume program, Toyota opted for the higher-performance, higher-cost NiMH RAV4 EV. This resulted in a greater manufacturing cost, and higher purchase price.

A number of electric vehicle advocates voiced disappointment that the choice was made to manufacture only the NiMH version. Many electric vehicle advocates claim that automaker's choice of the NiMH battery worked against the 90's deployment of cost-effective electric vehicles based on PbA batteries, and that further development of lead–acid technology could result in performance equal to NiMH, but at a substantially lower price. Their argument is that a usable electric vehicle is possible at a substantially lower price, and that the lower purchase price would foster greater acceptance of electric vehicles.

Corporate purchasing

Initially, RAV4 EVs were only available for three-year fleet lease, not for sale and not for lease to the public, at a few dealerships beginning in 1997. From 2001, leases were made available to small "fleets of one" purportedly run by small businesses.

Public availability

In March 2002, due to a shift in corporate policy, the Toyota RAV4-EV was made available for sale to the general public, but only 328 of them sold. No one knows for certain what prompted Toyota to change their position on the RAV4-EV, since they had long since fulfilled their obligations under the MOA with the California Air Resources Board's zero-emissions vehicle (ZEV) mandate via its fleet lease program.

The MSRP
Suggested retail price
The manufacturer's suggested retail price , list price or recommended retail price of a product is the price which the manufacturer recommends that the retailer sell the product. The intention was to help to standardise prices among locations...

 was ; but in California, ZIP-grant rebates of , decreasing in 2003 to , and a credit from the Internal Revenue Service brought the price down to a more palatable ( for some 2003 deliveries), including the home charger.

By November 2002, the 328 RAV4-EV’s Toyota had committed to were sold, yet demand was continuing to build. Toyota was caught off-guard by the extent of the demand because the vehicle's retail buyers had outsold the projections far faster than the vehicles could be supplied to market - despite very little advertising, and very little public awareness of the product.

There was certainly a market for these vehicles, because many GM EV1, Ford Ranger EV
Ford Ranger EV
The Ford Ranger EV is a battery electric vehicle produced by Ford Motor Company. It was produced starting in the 1998 model year through 2002 and is no longer in production. It is built upon a light truck chassis used in the Ford Ranger. A few vehicles with lead-acid batteries were sold, but most...

 and Honda EV Plus
Honda EV Plus
The Honda EV Plus was the first battery electric vehicle from a major automaker with non-lead acid batteries. Roughly 340 EV Plus models were produced and released. The EV Plus was taken out of production in 1999 when Honda announced the release of its first hybrid electric vehicle, the Honda Insight...

 drivers had been reluctantly forced to surrender their cars – in some cases to the crusher – and had become disillusioned with the carmakers. Potential buyers were encouraged by the perception that Toyota was finally playing fair.

More RAV4-EVs were sold than had been planned for manufacture through standard assembly line techniques. Toyota filled every order despite the fact that the last few dozen vehicles had to be assembled from spare parts due to a shortfall of production components (a significantly more expensive way of building a vehicle). This unexpected development caused deliveries to trickle on into September 2003. It also caused variations in the vehicles such as heated seats, retractable antennae, mats, etc.
Once the last of the 328 EVs was sold in November 2002, the website disappeared and the EV program was unceremoniously scrapped. No additional cars could be bought because Toyota didn’t have anything to sell. The RAV4-EV was based on the 1996-2000 gasoline powered RAV4, which had since been replaced. Toyota claimed that tens of thousands of orders would have been necessary for them to resume or continue production, and development time would have been a major obstacle.

Discontinuance

Toyota discontinued the RAV4 EV program one day after the passing of new air-quality requirements by the California Air Resources Board
California Air Resources Board
The California Air Resources Board, also known as CARB or ARB, is the "clean air agency" in the government of California. Established in 1967 in the Mulford-Carrell Act, combining the Bureau of Air Sanitation and the Motor Vehicle Pollution Control Board, CARB is a department within the...

 (CARB). CARB eliminated most of the Zero Emissions Vehicle (ZEV)
Zero-emissions vehicle
A zero-emissions vehicle, or ZEV, is a vehicle that emits no tailpipe pollutants from the onboard source of power. Harmful pollutants to the health and the environment include particulates , hydrocarbons, carbon monoxide, ozone, lead, and various oxides of nitrogen. Although not considered emission...

 requirement, substituting a greater number of Partial Zero-Emissions Vehicles (PZEVs)
Partial zero-emissions vehicle
A Partial Zero Emissions Vehicle is a vehicle that has zero evaporative emissions from its fuel system, has a 15-year warranty on its emission-control components, and meets SULEV tailpipe-emission standards....

 to meet the requirement. A Super Ultra Low Emission Vehicle
Super Ultra Low Emission Vehicle
Super Ultra Low Emission Vehicle is a U.S. classification for conventionally powered, natural gas powered, or gasoline-electric hybrid vehicle designed to produce minimal emissions of certain categories of air pollution at their exhaust, typically 90% less than that of an equivalent ordinary full...

 (SULEV) category was also added. This program requirement was designed to obtain equivalent emissions reductions by substituting less expensive, more general purpose vehicles.

Continuing support

Like other manufacturers, Toyota began destroying RAV4 EVs as they came off lease, after lease continuances were denied to owners. In 2005 an agreement was struck between Toyota and DontCrush.com (now PlugInAmerica.com) to stop the destruction and facilitate the continued operation of owned and leased vehicles. While no longer sold, the vehicle is still supported by selected Toyota service centers (mainly in California) and a strong owner community.

The RAV4 EV is driven daily by hundreds of owners, now across the United States. These owners have built up an online community and have worked out ways to add options to the RAV4 EV never offered by Toyota, with the most popular being keyless door entry and cruise control.

Chevron Patent incumbrance

Whether or not Toyota wanted to continue production, it was unlikely to be able to do so because the EV-95 battery was no longer available. Chevron had inherited control of the worldwide patent rights for the NiMH EV-95 battery when it merged with Texaco, which had purchased them from General Motors. Chevron's unit won a settlement from Toyota and Panasonic, and the production line for the large NiMH batteries was closed down and dismantled. This case was settled in the ICC International Court of Arbitration
International Court of Arbitration
The International Court of Arbitration is an institution for the resolution of international commercial disputes. The International Court of Arbitration is part of the International Chamber of Commerce....

, and not publicised due to a gag order
Gag order
A gag order is an order, sometimes a legal order by a court or government, other times a private order by an employer or other institution, restricting information or comment from being made public.Gag orders are often used against participants involved in a lawsuit or criminal trial...

 placed on all parties involved. Only smaller NiMH batteries, incapable of powering an electric vehicle or plugging in, are currently allowed by Chevron-Texaco.

In July 2009, Cobasys NiMH division (Chevron-Texaco), was sold to a Bosch and Sanyo consortium, but still retained the patent rights and collect royalties on the batteries. (See also Patent encumbrance of large automotive NiMH batteries
Patent encumbrance of large automotive NiMH batteries
The patent encumbrance of large automotive NiMH batteries is the encumbrance of the commercialization of nickel metal hydride battery technology by corporate interests...

).

Second generation

Since May 2010, Toyota Motor Company and Tesla Motors
Tesla Motors
Tesla Motors, Inc. is a Silicon Valley-based company that designs, manufactures and sells electric cars and electric vehicle powertrain components. It was the only automaker building and selling a zero-emission sports car, the Tesla Roadster, in serial production...

 have been working together to develop a second generation RAV4 EV using Tesla's electric motor and batteries and Toyota's platform and body. It is being developed by Tesla and Toyota Technical Center U.S.A. in Michigan. The first prototype was built in just three weeks and was undergoing testing by July 2010. The two companies expect the vehicle to be due for mass production by 2012. According to Toyota, the initial roll-out the RAV4 EV will be available to individual consumers and fleet customers.

A second generation RAV4 EV demonstrator was unveiled at the November 2010 Los Angeles Auto Show. Toyota is building 35 of these converted RAV4s for a demonstration and evaluation program that will run through 2011. The lithium metal-oxide battery and other power train components were supplied by Tesla Motors. The RAV4 EV was one of the five finalists to the 2011 Green Car Vision Award
Green Car Vision Award
The Green Car Vision Award is an annual award granted by the Green Car Journal. In contrast with its Green Car of the Year award, which only considers production vehicles that make the most significant environmental advancements, the Green Car Vision Award considers pre-production vehicles with...

.

The second generation RAV4 EV production models use the SAE J1772
SAE J1772
SAE J1772 is a North American standard for electrical connectors for electric vehicles maintained by the Society of Automotive Engineers and has the formal title "SAE Surface Vehicle Recommended Practice J1772, SAE Electric VehicleConductive Charge Coupler”...

 charging standard, Early prototypes have a 660-pound lithium-ion battery pack with a 50 kWh total capacity, 37 kWh usable, and an estimated range
All-electric range
All-electric range is the driving range of a vehicle using only power from its electric battery pack to traverse a given driving cycle. In the case of a battery electric vehicle, it means the total range per charge. For a plug-in hybrid , it means the range of the vehicle in charge-depleting mode...

 of 80 mile.

The RAV4 EV will be assembled in 2012 at Toyota's facility in Woodstock, Ontario
Woodstock, Ontario
Woodstock is a city and the county seat of Oxford County in Southern Ontario, Canada. Woodstock is located 128 km southwest of Toronto, north of Highway 401 along the historic Thames River...

 along with the regular gasoline version. Tesla will build the electric powertrain at its plant at Palo Alto, California
Palo Alto, California
Palo Alto is a California charter city located in the northwest corner of Santa Clara County, in the San Francisco Bay Area of California, United States. The city shares its borders with East Palo Alto, Mountain View, Los Altos, Los Altos Hills, Stanford, Portola Valley, and Menlo Park. It is...

, and it will ship them to Canada. The U.S. market launch is schedule for the first half of 2012 and initially will be sold only in California.

See also

  • Patent encumbrance of large automotive NiMH batteries
    Patent encumbrance of large automotive NiMH batteries
    The patent encumbrance of large automotive NiMH batteries is the encumbrance of the commercialization of nickel metal hydride battery technology by corporate interests...

  • Chevron Corporation
    Chevron Corporation
    Chevron Corporation is an American multinational energy corporation headquartered in San Ramon, California, United States and active in more than 180 countries. It is engaged in every aspect of the oil, gas, and geothermal energy industries, including exploration and production; refining,...

  • Toyota
  • Electric vehicle
    Electric vehicle
    An electric vehicle , also referred to as an electric drive vehicle, uses one or more electric motors or traction motors for propulsion...

  • Battery electric vehicle
    Battery electric vehicle
    A battery electric vehicle, or BEV, is a type of electric vehicle that uses chemical energy stored in rechargeable battery packs. BEVs use electric motors and motor controllers instead of, or in addition to, internal combustion engines for propulsion.A battery-only electric vehicle or...

  • PZEV
  • SULEV
  • AT-PZEV
  • Energy Conversion Devices Ovonics
  • Government incentives for plug-in electric vehicles
    Government incentives for plug-in electric vehicles
    Government incentives for plug-in electric vehicles have been established by several national and local governments around the world as a financial incentive for consumers to purchase a plug-in electric vehicle....

  • List of modern production plug-in electric vehicles
  • Plug-in electric vehicle
    Plug-in electric vehicle
    A plug-in electric vehicle is any motor vehicle that can be recharged from any external source of electricity, such as wall sockets, and the electricity stored in the rechargeable battery packs drives or contributes to drive the wheels...


External links

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