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Energy Efficient Powertrain and Storage Systems
Energy Efficient Powertrain and Storage Systems
Presentation 01st of April 2009
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Energy Efficient Powertrain and Storage Systems Presentation content
F Market Driver – future challenges
F CO2 Legislation and consumption
F Technology Improvements – New Technologies within the last years
F Energy Efficient Powertrain
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F Simulation methods – real world and test driving
F Electrification of Powertrain
F Storage System
F Application examples
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Energy Efficient Powertrain and Storage Systems Main Market driver / Challenges Powertrain
Worldwide - different requirements
Emissions legislation
Leg
isla
tio
n
2003 2012 2020 (PLAN)
CO2 (g/km)
Consumption – CO2
90 g/km
170 g/km
Legislation: e,g. Europe fleet average
130 g/km
Worldwide - different requirements
Legislation: e,g. Europe PM limit
NMOG/HC
CO
PM
NOX
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System valuePerformance / Torque / Drivability
Mark
et … engine torque built up… fun to drive (no turbo lag)
… 60 … 100kW /l (w/ downsizing)
… usable engine speed range … convenience … service costs … customer costs
… real life consumption … customer at pump
… lifetime … durability
… repair costs … insurance cost
…system costs … vehicle price
… driving range (autonomy range > 450km)
… up to 200Nm/l (Otto) / 220Nm/l (Diesel)
… usable engine speed range … convenience
Energy Efficient Powertrain and Storage Systems
Status (EU cars manufactured in 2006)
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130@MY2012
Energy Efficient Powertrain and Storage Systems New Technologies introduced with last years
Gasoline Diesel
Turbo charging
up to 26bar PME
Direct injectionVariable Valve train 2stage charging
… up to 2000bar Rail pressure
… up to 200bar Rail pressure
BMW Vanos BMW Valvetronic
Cooled / high EGR
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Downsizing
i.e. 2,2l -> 1,6l displ.
TREND:Downsizing, Direct injection Downsizing
FUTURE DEVELOPMENT FOCUS:
Emission, Costs, …Fuel consumption, Costs, …
SCR: Picture IAV
Controlled Water pump
Controlled oil pump
Optional :
stratified combustion
Optional :
Lean Nox aftertraetment
DPF aftertreatment
DeNox aftertreatment
Energy Efficient Powertrain and Storage Systems Further CO2 potentials – Example Otto Engine
F Rough indication (base MY2006 engine design)
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Energy Efficient Powertrain and Storage Systems Further CO2 potentials on different Powertrain areas
Energy storage
… up to 5%
Combustion Engine
Example: Otto engine
… up to 15%
Gearbox
…up to 10%
Torque trans. / axle
… up to 4%
Up to 15% - 25% in NEDC expectedi.e. Otto engine mid size sedan 1,8l Turbo DI - 7,9l/100km
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Ø Vehicle Mass (roughly 100kg ~ 0,5l / 100km in NEDC)
Ø Real world driving: Usage by customer (+0,5 … +1,5l/100km)
Ø Real world driving: Traffic conditions (+1 … +1,5l/100km)
Ø …
~ 2l/100km best case
Energy Efficient Powertrain and Storage Systems CO2 reduction – test cycle vs. real world cycle
F Different driving cycles ww
F Focus on Technology development for the next years
F Example: Downsizing Otto engine comparison NEDC vs. Real world driving cycle
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Source: Ford
Energy Efficient Powertrain and Storage Systems Limitation System cost add on – Examples only
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Energy Efficient Powertrain and Storage Systems Hybrid Drivetrain Concept
F System design choices per vehicle class, segment- assuming typically driving performances, user profiles and preferences
F Impacted by legislation requirements / targets – market = country dependent
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Energy Efficient Powertrain and Storage Systems Area of Tension – technical Challenges
EconomyValue for customer and OEM
Infr
astr
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reIn
tera
ctio
n w
/ p
ow
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su
pp
ly, …
En
vir
on
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t
Tra
ffic
/ C
om
. S
yste
ms …
450km autonomy, 0… 100km/h, Tambient -40 … +55°C…
Weight increase, Packaging constrains
Auxiliaries energy consumption, Air conditioning …
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User expectationPerformance, acceleration … up to Autonomy
Infr
astr
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reIn
tera
ctio
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/ p
ow
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su
pp
ly, …
En
vir
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Tra
ffic
/ C
om
. S
yste
ms …
… # of variants, scalability, modularization
…NVH phenomena, driving noise, lifetime issues
…Interface to environment/infrastructure, protection
…System costs, infrastructure at service, education
Energy Efficient Powertrain and Storage Systems The next generation – Pure Electrical Vehicles ?
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… Required Vehicle Key parameters:Reduced Cargo load: < +10% max. by weight add on (i.e. Hybrid System)
Towing capacity: up to vehicle mass
Refuel time: <10–15min.
Vehicle Autonomy: >450km – 550km
Picture source AMS 2008
Energy Efficient Powertrain and Storage Systems Overview Battery Store Technology
Energy Density [Wh/kg]
Batteries
Super Capacitors
Electrolyte Capacitors
cycle time
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Our Expectation: Future development focus on Li-Ion Batteries
(mix of high Power and Energy density with high no. of cycles) + i.e. Double
Layer capacitor as a fast storage device
Source: MIT Journal, 10/2008
Power Density [W/kg]
Energy Efficient Powertrain and Storage Systems Alternative Storage Systems
F mechanical
Rotational
chemicalElectro /
chemicalmechanical pneumatic hydraulic …
Fuels Batteries
Super capacitors
F hydraulic
F Hydraulical storage
Rough Ranking of Systems
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F Rotational
F …
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F Hydraulical storage device
F …
i.e. KERS for F1 series i.e. BOSCH Rexroth RHB System
Energy Efficient Powertrain and Storage Systems Success factor Powertrain Architecture of Functions
F Perfect solution designed from Tank to Wheel based on
F System Simulation
F Total System simulation
F Engine, Transmission, E-Machine, Storage
F Performance , Fuel economy, Lifetime, NVH, energy flow, costs
F Functional Powertrain architecture
F Scalable and extendable
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F Scalable and extendable
F Modular and configurable
F Applying standard interfaces
F Reusable
F Trained for customization
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Energy Efficient Powertrain and Storage Systems Examples – Micro E-Hybrid Powertrain to Full Hybrid
F Micro Hybrid
F Belt driver Starter / Generator
F STOP/START & START/STOP
F Asynchronous Machine 4-8kW
F Integrated electronics
F Full hybrid (all wheel drive by electrical rear axle)
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Ø Electrical performance:
100kW
Ø Integrated Differential
Ø Integrated Control
electronics
Ø Electrical performance: up
55kW
Ø STOP/START and
START/STOP feature
Ø Water cooled
Energy Efficient Powertrain and Storage Systems Conclusion
F Energy Efficient Powertrain design bases on F System Simulation
F Defined functional Architecture
F Modular hardware approach
F Efficient Powertrain configured according to
F Legislation requirements
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F Legislation requirements
F Market segments
F Customer expectations
F The future Powertrain has to
F Providing similar performances for car driver
F Higher interconnectivity to environment and infrastructure
F Using multiple energy storage systems types
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Energy Efficient Powertrain and Storage Systems
Thank you for your attention.www.hofer.de
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+498456/9166-0
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Energy Efficient Powertrain and Storage Systems Backup – Battery Development challenges
EconomyValue for customer and OEM
En
vir
on
men
t
Tra
ffic
/ C
om
. S
yste
ms …
Race for best battery technology / consortium
20kW/100km for Golf class, Load cycle at >45°C or below -10°C, high currents/high # of cycles stability
Vehicle energy balance – consumption of air cond.,
Infr
astr
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ctio
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su
pp
ly, …
Gasoline / Diesel Engine play major within the next years
Electrification will come / diversity of solutions
Range extender >20/30kW for Golf class as option
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User expectationPerformance, acceleration … up to Autonomy
En
vir
on
men
t
Tra
ffic
/ C
om
. S
yste
ms …
Vehicle energy balance – consumption of air cond., heaters, lights, entertainment, …
Interface to infrastructure, Position at Car / Norms etc.
Battery exchange vs. Plug in - infrastructure density
Business model / network buffer vs. Autonomy
Infr
astr
uctu
reIn
tera
ctio
n w
/ p
ow
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su
pp
ly, …
Range extender >20/30kW for Golf class as option
Cooperation with energy supplier needed
Base for invest is the legislation boundary conditions