Delphi Power Electronics - Lugar Center Forum VF · Delphi Power Electronics Delphi is the largest...

Gary CameronDirector, Forward and Advanced Power Electronics Engineering

Delphi Automotive

May 23, 2011

Serving the needs of a growing market:SAFE – GREEN – CONNECTED

� Delphi is a leading global supplier of electronics and technologies for automotive, commercial vehicle and other market segments.

� Operating major technical centers, manufacturing sites and customer manufacturing sites and customer support facilities in 30 countries, Delphi delivers real-world innovations that make products smarter and safer as well as more powerful and efficient.

Lugar Center Renewable Energy Forum on Electric and Hybrid Vehicles, May 23, 2011

Delphi Power Electronics

� Delphi is the largest North American supplier of power electronics and battery packs

� Strategic partnerships and supply agreements in place

– Lithium batteries– Lithium batteries

– Power silicon

– Electronic components

– National labs and universities

– Energy Systems Network

� Light duty and heavy duty customer base with global contracts and growing portfolio


Delphi Power ElectronicsInnovative solutions for all levels of powertrain electrification for over 20 years

Delphi ConfidentialLugar Center Renewable Energy Forum on Electric and Hybrid Vehicles, May 23, 2011

North America

China

Vehic

les P

roduced

� Full HEV/PHEV will dominate - geographic sprawl requires range

� EV in urban areas where charging infrastructure exists

� Mild hybrid provides little value proposition for consumers at low fuel prices

Heavy government funding (~$15B USD over the next decade)

Vehic

les P

roduced

HEV/EV architecture adoption will vary by global region, based partly on geography and government policy


Europe

� Heavy government funding (~$15B USD over the next decade)

� Consumer incentives and OEM/supplier funding are focused on EV

� A small part of a large market is still large !

� More aggressive emissions regulations and higher fuel prices than North America and China

� Hybrid/EV portfolio will be organized by vehicle type: EV for city cars, full hybrid for luxury and sports cars

� Current legislation doesn’t support mild hybrid

Vehic

les P

roduced

Vehic

les P

roduced

HEV/EV production comes in waves, driven by government stimulus and legislation as well as market pull

Technology

Wave 3 – Voluntary Mainstream

Wave 2 – Niche

Wave 1 – Demo and Image

Technology

Win to Production

Legislation

Wave 4 – Mandate Mainstream

Wave 1 Demo

Global Stimulus and Incentives

Win to Production

- 6.5M units/ year

2016: USCanada

2015: EUChinaJapan

2000 2002 2004 2006 2008 2010 2012 2014 2016 2018 2020+

Wave 4 – Mandate Mainstream

Technology

BEV Tech China BEV

Technology

Special Opportunities

Win to Production

Wave 5 – 2nd Generation Mainstream

Win to Production

Volume Source: Global Insight, excludes micro hybrid.

2020:EU 95g/km

Technology

Wave 6 – Mega City/Mega Corridor

Win to Production


The market driver: $$ per barrel of oil

� Oil price is driven by 2 major factors– Demand (economic growth)

– Risk of Supply (speculation, political influences, reserves)

� We are heading for continual + $ 100 / barrel oil

160

Weekly All Countries Spot Price FOB Weighted by Estimated Export Volume (Dollars per Barrel) Special Cause Events

- Crisis or Speculation


0

20

40

60

80

100

120

140

160

$ p

er

Barr

el

Trend w/ Economic Growth - Major Economies- Emerging Economies

- Crisis or Speculation

Global Recession

Data Source: US Dept. of Energy – EIA May 15,2011

Governments are subsidizing HEV/EV development at all levels of the supply chain

� Governments are encouraging suppliers to localize HEV/EV engineering, production and IP:

– US: Vehicle incentives, ARRA, DOE technology programs

– Europe: Vehicle incentives, grants and R&D support for local engineering and production

– China: Vehicle incentives 863 program, proposed foreign investment industry catalog

– Singapore: Economic Development Board grants for technology investment– Singapore: Economic Development Board grants for technology investment


The Benefits The Risks

� Acceleration of supply side technology development

� Lower price to consumers

� Jump start sales of vehicles

� Drives installation of EV infrastructure in advance of sales

� Over capacity – a bubble

� Lock in investment too soon on immature technology, obsolete before mass market

� Infrastructure may be rendered obsolete by evolving standards

Mass market HEV adoption depends on economic payback –Technology cost premium is still too high

Fuel Price ($/gal)

Annual Miles Required to Offset HEV Cost Premium in 5 Years

$7,000$5,000

$8,000 HEV Cost Premium

� At $4/gal, HEV cost premium must be less than $3,000 for >50% of the U.S. population


Average Annual Miles Driven

Cumulative % of U.S.

Population

$1,000

$3,000

$5,000

$2,000

Sources: EPA.gov, U.S. Bureau of Transportation Statistics, McKinsey Global Institute, R. L. Polk & Co., Delphi Analysis

� Current full HEV on-cost is $5,000 or greater

The challenge is cost …

� Technology– Battery chemistry

– Power electronics power density

– Powertrain Architecture

– Manufacturing innovation

The solution is:


� Business volume– Supplier Infrastructure

– Economies of scale

With industry/government partnerships, Delphi is on a path to reduce HEV/EV power electronics cost

Percent Cost by

Gate Drivers

100%

Mechanical & Integration

DC Bus Capacitors

Inverter Cost Reduction Path

6%

23%

14%


Cost by Content

Current Generation

2015

45%

Capacitors

Silicon & Silicon Packaging

14%

57%

20xx

Delphi is working with the U.S. Dept. of Energy and the National Laboratories to ensure a flow of technology

� Power Devices– GaN on Silicon

– SiC

� Capacitors– Higher dielectric constant materials and

temperature capability

� Advanced Magnetics� Advanced Magnetics– Higher Switching Frequency Magnetic Design

� Partners include:– Purdue University– IUPUI– Argonne National Lab– Oak Ridge National Lab– National Renewable Energy Lab– General Electric– Dow Corning– International Rectifier – Infineon


GaN-on-Si Power Device

Mass market vehicle volumes require mass market solutions –We must move to the 3rd market phase

TIME

Cost

2

3

Technical Maturity

1

1 2 3

Design PriorityFunctionality,

Develop Technology

Differentiation,Enhance Value,

Custom Engineering

Cost, QualityIntegrate Building Blocks

Product Families

ValueSpecialty Provider

Many EnterSupplier Consolidation,

Partnerships

Large ScaleManaged Value StreamFew Big Players Survive

Supplier Specialist KnowledgeConcentrated R&D,Increased Speed of

Development

Common Work Sold To Many OEM’s,

Use Economies of Scale


Inverters

High-Voltage Battery Pack Systems

Battery Pack Controllers

Delphi Power ElectronicsDeveloping Innovative solutions for all levels of powertrain electrification

DC/DC Converters

On-Board Battery Chargers

Supervisory Controllers

Integrated Systems

→ Power Electronics

→ Controllers

→ Commercial Vehicle Systems

→ Battery Packs

→ Battery Pack

→ Battery Disconnect

→ Controllers

Delphi is creating a global supply footprint

Indiana, USA

Suzhou, ChinaFuture

Szombathely, Hungary

TroyTroyParisParis

LuxembourgLuxembourgBomigBomig

Reynosa, Mexico→ Battery Pack

→ Battery Disconnect

→ Battery Controllers

Singapore→ Power Electronics

→ Battery Controllers

→ Power IGBT Packaging


KokomoKokomo

TroyTroy

Engineering/Customer SupportEngineering/Customer SupportManufacturingManufacturing

BangaloreBangalore

ShanghaiShanghaiTokyoTokyo

Delphi Morgan Street Operations: cost-competitive, North American power electronics manufacturing

92,800 Sq. Ft. on 19 acres in Howard County� 92,800 Sq. Ft. on 19 acres in Howard County

� Occupied in January 2010

� Launched 1st Production in July 2010

� Federal, state and local economic support for:

� Power electronics and battery pack manufacturing

� Complete validation facility

� Battery pack development and test labs


Summary

� The HEV/EV market continues to emerge– All developing regions incentivizing EV/HEV growth and technologies

– Consumers accepting the technology but watching for the value

� Stimulus and economic conditions creating ebb and flow of market but long-term trend and need is clear

� The real challenge is lowering the cost to enable greater mass market adoptionmarket adoption


Delphi,With public-private sector partnerships,

Is addressing the challenge

Delphi,With public-private sector partnerships,

Is addressing the challenge

Delphi Power Electronics - Lugar Center Forum VF · Delphi Power Electronics Delphi is the largest...

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