How Vehicle Level Attributes Drive High

Voltage Subsystem Design

Dr. Daniel KokManager - Advanced Electrified Powertrain SystemsFord Motor Company

DESIGNING AN ELECTRIFIED VEHICLE:

International Conference on Future Mobility

Innovation in Electric and Hybrid Vehicles

8-9 November 2015, Dubai, UAE

Ford Electrified Vehicles: The Power of Choice

HEV PHEVBEVFord Fusion Hybrid

Ford C-Max HybridFord C-Max Energi

Ford Fusion EnergiFord Focus Electric

1

• There is no single electrification solution that satisfies all customer requirements• The right solution depends on individual usage profiles and needs.

2015 US Sales Status (CYTD sales as of Aug 2015)

2

0 10,000 20,000 30,000

Honda Insight

Nissan Pathfinder

Lexus NX

Honda CR-Z

Infiniti QX60

Infiniti Q50

Toyota Highlander

Buick LaCrosse

Honda Civic

Lexus RX

Subaru XV Crosstrek

Lincoln MKZ

Lexus ES

Kia Optima

Toyota Avalon

Honda Accord

Lexus CT

Hyundai Sonata

Toyota Camry

Ford C-MAX/Fusion

Toyota Prius/Prius C

HEV YTD Sales

0 5000 10000 15000

Toyota RAV4

Mercedes GLE

Honda Accord

Mitsubishi I

Porsche 918 Spyder

Porsche Panamera

Porsche Cayenne

Smart ForTwo

Ford Focus

BMW i8

Chevrolet Spark

Volkswagen Golf

Fiat 500

Toyota Prius

BMW i3

Chevrolet Volt/Cadillac ELR

Ford C-MAX/Fusion

Nissan Leaf

Tesla Model S

PHEV and BEV YTD Sales

BEV

PHEV

• Ford has sold nearly 500,000 electrified vehicles worldwide since 2005

122k sales

Source : WardsAuto.com Reference Center

Customer Requirements are Described in Vehicle Attributes

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• What vehicle level attributes are relevant for Electrified Vehicles?

– Cost of Ownership

– “Fuel” Economy / Efficiency

– Performance (Launch, Maximum Vehicle Speed)

– Noise, Vibration, Harshness

– Towing capability

– Cargo volume

– Electric Range (Plug-in HEV & BEV)

– Electric Charging Speed (Plug-in HEV & BEV)

0

5

10

15

20

1200 1400 1600 1800 2000 2200 2400

Bat

tery

Inst

alle

d C

apac

ity

(kW

h)

Curb Weight (kg)

• For PHEVs, the battery is sized to deliver EV range

FHEV

PHEV

Range Extender PHEVs

Battery Installed Capacity vs. Curb Weight

4

Higher Cost

Global Regulations

US

CAN

EU

Brazil

China

4.7%

4.7%

5.1%

3.4%

5.5%

Average Annual FE / CO2 Improvement

Required by Regulation (2015-20)

• Global CO2 Regulations are becoming ever more stringent• The average rate of improvement through 2020 is nearly 5% annually 5

0

5

10

15

20

1200 1400 1600 1800 2000 2200 2400

Bat

tery

Inst

alle

d C

apac

ity

(kW

h)

Curb Weight (kg)

FHEV

PHEV

Range Extender PHEVs

• Global regulations and competitive landscape are driving increased battery capacity• Increased battery capacity yields more EV range and reduced CO2 emissions• Luckily, battery energy and power density are continuously improving

Impact of Global Regulations

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Future

Vehicle Package

• Package of a large High Voltage battery entails a trade-off with other attributes

– Cargo area, ride height, 5 person seating, etc. are all attributes impacted

– An acceptable trade-off on one application, such as cargo space in 5-door, may not be acceptable in 4-door application

• Future vehicle platform architectures aim to package the HV battery with minimal attribute tradeoffs

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Caradvice.comKbb.com

Wot.motortrend.comMad4wheels.com

Guideautoweb.com Motorauthority.com Automobilemag.com Automobilereporter.com 7

40%

50%

60%

70%

80%

90%

100%

0 10 20 30 40 50 60 70 80 90 100

Car

go C

apac

ity

xEV

(% o

f C

on

ven

tio

nal

cap

acit

y)

EV Range (miles)

• Battery capacity is often traded off against cargo capacityand fuel tank size in BEVs and PHEVs

PHEV

BEV

8

100% = No Impact on Cargo Capacity

Worse

Better

EV Range vs. Cargo Capacity – Products in the Market

Distance Between Fuel Fill-ups

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• Long distance between fill ups gives great customer satisfaction• PHEVs can help increase distance between fill-ups

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

600 800 1,000 1,200 1,400 1,600 1,800 2,000 2,200 2,400 2,600 2,800 3,000 3,200

Cu

sto

me

r P

erc

en

tile

Distance Between Fill-ups (km)

32 km EV Range48 km EV Range64 km EV Range80 km EV Range

• The average distance between fuel fill-ups for our Ford C-Max PHEV customers is more than 1,100 km

• More EV range means less fill-ups

Based on EUROFOT customer dataAssumes 38 MPG and 14 gallon tankAssumes 1 charge per day

PHEVs with Electric EV Range Need Less Fuel Fill-ups

10

• In premium vehicles, electrification is increasingly used to deliver performance

0-60 MPH Time vs. Combined Fuel Economy (US)

11

Includes PHEVs and HEVs

15

20

25

30

35

40

45

50

55

3 4 5 6 7 8 9 10 11

EPA

Co

mb

ine

dFu

el E

con

om

y (m

pg)

0-60 MPH Time (sec)

Mainstream

Premium

High Voltage Battery Power Demand

• A common battery design between vehicles is preferred but challenging• Different vehicles & different driving styles result in different battery requirements

• High power peaks with short duration to deliver vehicle performance • Medium power with long duration to deliver EV range

0.1 1 10 100 1000 10000

Bat

tery

Po

we

r U

sage

Time Duration (sec)

Range

More BEV like operation

More blended operation

Performance

12

FHEVs, PHEVs and BEVs Use Different Battery Cell Designs

PowerCell Cathode

EnergyCell Cathode

• Vehicle Requirements drive battery cell design

• Cells can be optimized for Power or Capacity (Range)

Altenergystocks.com 13

Wide-Ranging Driving Conditions in Global Markets

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Dubai

Driving Conditions – U.A.E.

Driving Conditions• High temperature with

varying humidity

• Soak in heavy sun load

• Medium overnight temperatures

Driving Patterns• Dense traffic in rush hour

• Long idle time with AC on

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Battery Power vs. TemperatureB

att

ery

Po

wer

Lim

it

Battery Temperature

Reduced capability of battery cells

Power limiting due to battery life considerations

Optimal operating temperature

WarmCold

• Electric drive capability is impacted by extreme temperatures• Battery temperature needs to be managed carefully• A chiller is required to keep the battery cool in Dubai’s climate 16

50 °C-30 °C

• In-vehicle battery package– Chilled air from

passenger cabin is used

• Underbody battery package– Liquid is cooled by a

low-temp radiator and A/C chiller

Battery Cooling System Options

Air-cooled battery

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Liquid cooled battery

Battery Cooling System Design

Cell Face Cooling

Co

st /

Co

mp

lexi

ty

Thermal Requirements

Cell Bottom Cooling

Air Cooling

• Vehicle Usage/Package location can drive substantial differences in thermal system requirements

• Blended operation PHEV’s tend to have lower cooling requirements

Performs more like HEV

• Range Extender PHEV’s have higher cooling requirements due to higher Electric-Only usage

Performs more like BEV but with smaller battery

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HEV/PHEV Commonality With Ford Powersplit Architecture

Component HEV PHEV

High Voltage Battery

Traction Motor

Generator

Inverter (s)

Electric AC

DC/DC Converter

Regen Brakes Hardware

Transmission

Engine

Charger & Wiring

Electric Pumps / Cooling Circuits

• Ford’s Powersplit architecture enables significant sharing between HEV and PHEV hardware achieving benefits of scale

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Wrap Up

• Vehicle attributes along with operating environment drive battery requirements

– Battery is designed to be robust to operating conditions

• Designing a unique battery pack for every vehicle is not economically feasible

– Must find the right balance between attribute delivery and battery complexity

– OEMs must find commonality and scalability in battery subsystem design for use in all global markets

• Ford has High-Volume Electrified Powertrain products in select markets since 2005 and is actively developing its Electrified Products to operate in global markets

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Q & A