Individual E-Mobility System Solutions for Automotive and Off … · 2016. 2. 4. · 1 BEG/PJ-EV |...

1 BEG/PJ-EV | 15.11.2011 | © Bosch Engineering GmbH 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Bosch Engineering GmbH

Individual E-Mobility System Solutions forAutomotive and Off-Highway Applications

Dr.-Ing. Martin Lenz, Bosch Engineering GmbH



E-Mobility at Bosch Engineering

The “Powertrain-Map”

Gasoline

Diesel

Electric /range extender

Gasoline

Electric / fuel cell

DieselElectric /battery

Alternativefuels

Hybrid

Electric (battery /fuel cell)

HCCI

Diesel

Alternative fuels

Electric /range extender

Hybrid

Gasoline

1997 today future




Market Trends: Electrification Systems

2015

4,8

2,0

2020

9,0

3,3

1,4

2013

3,0

1,5

2010

1,0

[in mio. vehicles]

37%

0,8

1,1

0,40,7

0,7

37%

0,50,3

0,2

33%

0,218%

0,3

1,3

0,3

18%

15% 0,6

0,4

electric axle drive / Electric Vehicle

electric axle drive / HybrideDCT: electrified double clutch

Serial parallel hybrid

Parallel mild hybrid

Parallel strong hybrid

Power Split

Electric Axles

Parallel Types

PowerSplit

37%

non PowerSplit

• Non-Powersplit Systems gaining ground.• Parallel and Electric Axle systems w/ high shares.

1,2



“We provide individual E-Mobility solutions”





Development areas E-mobility

Prototype & demonstrator construction

E/E-architecture, control units, (CAN, Flexray), safety Chassis & brake system,

vehicle dynamics

Engineering powertrain

E-Infrastructure

Energy & battery management

Infotainment, HMI, cluster

Engineering power electronics

System definition and development



System developmentConv. ICE HEV PHEV EV REX EV

Battery HV 20-30 kWh

BatteryHV 15 kWh

BatteryHV 12 kWh

BatteryHV 1.3 kWh

Battery12 V

ChargerChargerCharger

Inverter 60kWInverter 60kWInverter 85kWInverter 20kW

Pow

ertra

inin

cl. E

MA

dd. c

ompo

nent

s





Powertrain Investigation expl. EV

...

Reference

New Technol.ESMASMPSM

EM DGear-

box (1)EM DGear-

box (1)

EM

EM

GB

GB

EM

DD

Gear-box (1)

Gear-box (1)

EM

EM

DD

Gear-box (1)

Gear-box (1)

EM

Topologies

E-Machine

TransmissionOperation Strategy

PSM: Permanent Magnet Synchronous Machine ASM: Asynchronous Induction MachineESM: Electric Induction Synchronous Machine



Bosch hardware portfolio

Li-Ion battery (SB LiMotive, joint venture Bosch with Samsung SDI)

Platform modular for various system requirements

Regenerative braking systemBased on conventional systems with adjustments for using brake energy

Vehicle control unitBased on controller from conventional powertrain systems

Motor-generator: 2 product linesPlatform development for various performance levels

Power electronics (inverter, DC/DC, AC/DC)Platform modular for various performance requirements

EVPlug-in hybridFull hybridMild hybridProducts





LFe[mm]0 50 200150

100

Do[mm]

150

250

300

200

Do: Outer stator diameter LFe: Iron length

mHEV EV

(P)HEV

SMG IMG

IMG: Integrated Motor GeneratorSMG: Separate Motor Generator

SMG 138

IMG 300IMG 290

SMG 180

100

Bosch covers major (P)HEV / EV market requirementsFlexible construction kit w/ scalable design and production line concept

20 25 30 40 60 80 [kW] HEVPm peak @ca. 250V dc

Roughestimation !

EVPm peak @ ca. 400V dc

[kW]

120

100

80

12

3

P2 HybridHEV eAD / eDCTCity / Compact EVBSG

1

2

3

Electric Machine – Product Portfolio




INV2CON

0

100

200

300

400

500

600

700

800

0 100 200 300 400 500

AC-Current [Arms]

DC

-Vo

ltag

e [V

]

900/

1200

V IG

BT

600V

IGB

T10kW30kW

50kW

70kW

90kW110kW

130kW150kW

EV

Mild**

PS-HEV*

Regenerative Start/Stop (<60V)

EVFull HEV

GEN2.2 GEN2.3

Requirements:*) Power Split

/w boost converter**) low cost system

Power Electronics Segmentation




Bosch “e-Drive” componentsSMG 180/120 INVCON 2.3

Separate Motor Generator Inverter + DC/DC-Converter

1,8-2,5 kW / 0,7 kW; unidirectionalDC/DC-converter

65 °C, max. 85 °C (flow-rate 8 l/min)Cooling

400 A (continuous) 450 A (Peak 5 s)

Phase current [A] INVCON 2.3

100-365 / 100- 430VInput voltage

< 7 kgWeight

Inverter approx. 5 l (w/o DC/DC connectors)

Volume

310 x 190 x 156 mm (w/ connectors)Dimensions L x W x H

Product specification

ResolverSensor type:

Water-jacket 8l/min 85°CmaxCooling

28 kgTotal mass

40 kW (INVCON 2.2)80 kW (INVCON 2.3)

Mechanical power max.

12,500 rpmSpeed max.

up to 200 Nm [@ 400Arms]Peak torque max.

180 mm / 120 mmActive diameter / lengths

Product specification




Vehicle control unit

RangeExtender ECU *

Vehicle ControlUnit (VCU)

HMI/Navigation * optional** DC/DC converter included

InverterControl Unit **

ABS/ESP®

Charge Controller

Battery Management System

HVAC controller

Service and diagnosis

13

Chassis system solutions E-Mobility

BEG/PJ-EV | 15.11.2011 | © Bosch Engineering GmbH 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.



Brake systems Component setup Recuperation Torque coordination

Vehicle driving dynamics Safety Traction control Torque vectoring

1414 CC/MKS-AS, CIT | 15.11.2011 | © Bosch Engineering GmbH 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Regenerative Braking Systems: Overview

Brake SystemBrake System HEV Plug-in HEVEV

ESP® w/ RBC

ESP® hybrid

ESP® hev

HAS hev

iBooster hev


Recommended CRBS for different HEV/EV types

HEV: Hybrid Electric Vehicle; PHEV: Plug-In Hybrid Electric Vehicle; EV REX: Electric Vehicle with range extender; EV: Electric Vehicle

Us

Us

Us

Us

Us

Us

Us

Us

Us

TMCECU

TMCECUECU

Us

Us

Us

Us

Us

• Combination w/ MVP or EVP• Low recuperation < 0,1g• Low cost

• Combination w/ MVP or EVP• Recuperation < 0,2g for x-split circuit• Cost & performance optimized

• Combination w/ MVP or EVP• Recuperation < 0,2g for II-split circuit• Modest cost for enhanced performance

SOP 2011

SOP 2014

mild strong

SOP 2012

SOP 2014*

SOP 2010

• Vacuum independent• Recuperation up to 0,3g• High performance

• Vacuum independent• Recuperation up to 0,3g• High perform., improved cost & package

*Target

15




Product safety and functional safety New challenges regarding product safety and functional safety

Laws and regulations (e.g. ECE R100, FMVSS 305) Standards (e.g. ISO 6469, ISO 26262) Customer requirements (e.g. HV)

We provide safety concepts for Electric shock (e.g. U~ 400V) Fire (e.g. I ~ 300A) Unintended acceleration / deceleration Battery hazards (battery fire, hazardous chemicals)

!

16

Active sound enhancement interior and exterior




Generation of a synthetic engine sound according to driving situation

Driving-noise emulation for pedestrian safety in electric / hybrid vehicles

Customer specific applications and adaptation for individual solutions



Charging systems engineering

In-Vehicle Solution Hardware Software Calibration Integration

Non-Conductive Concept Hardware ECU Software

Alternative Concept Investigation




User

Smart Connectivity Service Platform

Smart connectivity




Powertrain simulation and testing

Virtual Powertrain

ECU-Functions

TransmissionElectric Power

M

Thermal

Hybrid Test Bench

ICE

ICE Battery

Transmission Bench

G

E-machine

M




Test procedures for hybrid and electric vehicles Consumption measurement in accordance with the test procedures

ECE-R101 or CFR40-Part96 Determination of “real life” fuel consumption and optimization of the

operation strategy (drive cycle, ambient temperature etc.) Gradient profiles to verify the robustness of the electric system Efficiency measurement for different speed-load setpoints

n M o t o r [ 1 / m i n ]

M M

otor

[N

m]

0 2 0 0 0 4 0 0 0 6 0 0 0 8 0 0 0 1 0 0 0 0 1 2 0 0 0 1 4 0 0 0

- 1 0 0

- 5 0

0

5 0

1 0 0

1 5 0

2 0 0

2 5 0

3 0 0

3 5 0

4 0 0

0 . 4

0 . 4 5

0 . 5

0 . 5 5

0 . 6

0 . 6 5

0 . 7

0 . 7 5

0 . 8

0 . 8 5

0 . 9

Efficiency map Customer specific driving cycles





Engine Electricmotor

Clutch

Lifting & loweringtilting

Battery

ECU

BMS

Working hydraulics

TCU

nact

trqeng ,neng

SOC

Starter

Userinput

INV

Electric powertrain fork lift trucks

Electricmotor

Standardengine strategy

Standardhydraulic strategy

trq, ntrq‘engn‘eng

nhyd

Hydraulic

Electrically

Mechanically

Energy flow

Control

Information flow

Existing SW/HW

Additional SW/HW

ECU Engine Control Unit

TCU Truck Control Unit

BMS Battery Manage-ment System

INV Inverter

INV+ Hybrid strategy

2x




Engine Electricmotor

Battery

ECU

BMSTCU

nact

trqeng ,neng

SOC

Starter

Userinput

INV

Electric powertrain tow truck

Electricmotor

Standardengine strategy

trq, ntrq‘engn‘eng

Electrically (LV)

Electrically (HV)

Mechanically

Energy flow

Control

Information flow

Existing SW/HW

Additional SW/HW

ECU Engine Control Unit

TCU Truck Control Unit

BMS Battery Manage-ment System

INV Inverter

INV+ Hybrid strategy

2x2x

Battery

PowerSteering

BrakeBooster

DC/DC



Thank you for your attention !

Individual E-Mobility System Solutions for Automotive and Off … · 2016. 2. 4. · 1 BEG/PJ-EV |...

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