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Punch Powert rainThe leading independent provider of innovative clean powertrain technologies

Mechatronics in AutomotiveFrom the first electric intermittent windscreen wiper to the self driving electric car

2014 Punch Powertrain Strictly confidential. All rights such as copying and passing on to third parties reserved by Punch Powertrain.

300k

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2015 2016 2017 2018 2019

VT2/VT3 CVT transmission

VT5 250Nm Torque converter CVT

VT5 190Nm Torque converter CVT

DT1 180Nm Dual Clutch Transmission

HT1 Hybrid transmission / Hybrid powertrain

VT4 CVT for RWD or AWD

Time

Dev

elo

pm

ent

Ad

van

ced

Dev

elo

pm

ent

EV powertrainsTwinspeed EV gearboxemKERS rear axle flywheel solutionMecHybrid flywheel hybrid CVT

VT5 300Nm

Product Portfolio

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Mechatronics in Automotive

Agenda

• Historic (incomplete) overview of Automotive mechatronics

• Power steering and robotized gearboxes

• Hybrid and the electric car

• 48V and the self driving car

• Conclusion & Outlook

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Mechatronics ≠electro-mechanical designs

Mechatronics =multidisciplinary engineering

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Historic overview – icons in time

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electric car(1880-1920)

Start century of themass market petrolcar (T-Ford,1914)

electronic windscreenwiper (late 1960s-

electric powerwindow (1950s-

electronic engine controls (1980s-

mechatronic power steering (1990s-

robotized gear-boxes (2000-

Toyota Priushybrid car (1997)

• autonomouscar (2020-

• hydrogen car• solar car• ….

revival electriccar (2010-

today

48V platform (2017-

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electric power steering –early enabler of the autonomous car

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column mounted EPS

rack mountedEPS

pinion mounted EPS

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electric power steering –mechatronic system layout

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• vehicle speed• emergency• parking assist• lane keeping• ….

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Self parking thanks to EPS

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Next generation self parking…?

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Toyota Prius – first mass market hybrid

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1997, 5.6 L/100 km(US-EPA)

2004, 5.1 L/100 km(US-EPA)

2010, 4.8 L/100 km(US-EPA)

Plug-in Prius 2012 4.4kWh Li-ion, 650V 2.5 L/100km (US-city, partly EV)

4.7 L/100km (US-highway)

Toyota has sold to date:• over 7 million hybrid cars…• of which over 4 million Prius

I/B

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Robotized gearboxes – CO2 and comfort

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Dual ClutchTransmission (DCT)

AMT

DCT

Automated Manual Transmission (AMT)

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Robotized gearboxes – CO2 and comfort

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Revival electric car – now to stay

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• Do you think they stay because now, EVs look better than ever?

• Why did they disappear the first time (1910s)?

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Revival electric car – now to stay

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• Gasonline engines took smaller EV motors to use it as an electric starter • Gasoline cars had greater range • Gasoline cars had much quicker refueling times • Rapid expansion of petroleum infrastructure initiated BY THE GOVERNMENT!• So much convenience steps in such a short time, the choice for gasoline was a

NO-BRAINER at that time!• Market growth cuts the prices and accelerates further growth, etc. etc.

Birth of the mass gasoline car market, like any good product it is

CONVENIENCE for a FAIR PRICE!!

…and everybody took the noisy, shaky and stinky engine for granted…being completely unaware about the future environmental impact

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Revival electric car – now to stay

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• EV cars take a small internal combustion to use it as a range extender • Nobody uses full (800km) gasoline range in a no-stop continuous trip• SuperChargers refill the battery in less than 20 minutes (300+ km range)• Rapid expansion of (super)charger network initiated BY THE GOVERNMENT,

bold ENTREPENEURS and everybody’s electric HOME!• After 100 years of fiddling with exhaust, dampers, noise, vibration and

harshness engineering and 50 years of emission law enforcement, the electric car seems a silent, clean and convenient miracle that you can actually buy.

• …and because mechatronics are there anyway, EVs better drive themselves!• So much convenience steps exactly at the right point in time, the choice for EV

is a SMART-BRAINER!

• Market growth cuts the prices and accelerates further growth, etc. etc.

(Re)birth of the mass EV car market, like any good product it should be

CONVENIENCE for a FAIR PRICE!!

100 years later….

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48V platform –CO2 and expansion of mechatronics

• Let’s not completely rule out the engine for the next 20 yrs or so, as the price of battery technology is still (too) high and the energy density (too) low

• However, use the engine and other appliances only when necessary and with great efficiency.

• This requires far-going advances in mechatronics boosted by 48V board net

• These 48V mechatronics can stay when the engine finally leaves the car...

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48V platform –CO2 and expansion of mechatronics

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(Courtesy BMW)

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48V platform –CO2 and expansion of mechatronics

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48V platform –CO2 and expansion of mechatronics

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fair cost high cost

?

48V machine + flywheel≈ full hybrid

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Autonomous car –logical step for the connected consumer

• Why is the autonomous car coming so fast into the market (<2020)?

• Safety, fuel efficiency, transport efficiency, convenience, etc. etc.

• However, most important trigger/accelerators

from outside incumbent automotive industry:

• The next generation “drivers” are rather occupied

with connectivity than with the task of car driving.

• Consumer tech driven giants like Google, Samsung, Apple and Tesla are boosting this trend

• The CES(!) shows how highly interaction technology and automotivetechnology are colliding into a whole new product experience!

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Autonomous car –full reliance on mechatronics

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4 Levels of autonomy defined by NHTSA (excluding level 5)(Level 0 - no autonomous functions, warnings at most)Level 1 - one autonomous function such as ACC, LKA, CMBSLevel 2 - partial autonomy: multiple automations, driver still “watchdog”Level 3 - limited self-driving: Autopilot in certain conditionsLevel 4 - full self-driving: Autopilot for entire trip, car may be manuallycontrollable in case of Autopilot-disfunctionality. (Level 5 – same as Level 4, however no means for manual control)

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Conclusion & Outlook

100 years ago, the mass market petrol car market “ignited” the disappearance of the electric car, but not the electric domain

Since then electro-mechanical solutions and “mechatronics” later on has been offering an ever increasing amount of innovative car functions

Before the end of this decade, this will be further boosted by the introductionof the 48V board net platform

After 100 years of car mass market, the revival of the electric car changes the automotive industry and many other industries in unexplored directions

The (electric) car is finally becoming a real “automobile” through consecutivestages of autonomy, mechatronics is the key enabling art for this

Regardless of its maturity, the automotive industry has just begun to get trulysmart, clean and exciting!

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