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48V Architectures for Enabling High Efficiency

Brian McKay, Ph.D. Powertrain Technology & Innovation

www.continental-automotive.com Powertrain Division

Introduction Innovation is Accelerated by CO2 & Emission Regulations

Driving Innovation Workshop Washington, DC

September 13, 2016 Dr. Brian McKay, © Continental AG

› GHGandfueleconomyregula1onsare“DrivingInnova1on”

› 48Voltsystemsnotconsideredviablelessthan5yearsago

› Four1mesthepowerof12V,saferthanfullhybrids(<60Vlethalthreshold),lessexpensiveelectricalcomponents

› Brings70%ofthebenefitsoffullhybridat30%ofthecosttobothgasolineanddieselvehicles

› ManysuppliersandOEMscommercializing48Vtechnology

›Firstcommercialintroduc1oninAudiSQ7dieselinEuropemorein20171meframe

180

130

80

280

230

2000 2005 2010 2015 2020 2025

gCO

2/km

Worldwide Vehicle Volumes [Millions]

4

13

2

6

11

1

3

0

10

20

30

2020

11

2015 2025

27

3 <1

Battery Electric Vehicle Plug-in and Full Hybrid 48 Volt Mild Hybrid

2

Electrification – Tailored to Fit the Need Scalable Modules for Different Customer + Market Demands

48 V Eco Drive

12 V Start-Stop

Full Hybrid

Plug-in Hybrid

Electric Vehicle

Electrification

CO

2 Sa

ving

Pot

entia

l NED

C * Fuel saving

with low voltage technology

Fuel saving and electric driving

100% electric driving

< 5kW

< 5%

6 - 20kW

7 – 10%

20 - 40kW

20 - 30%

50 - 90kW

50 - 75% 50 - 90kW

100%

* Saving Potential Tank-to-Wheel in NEDC, w/o Eco Innovations

High voltage

3 Driving Innovation Workshop Washington, DC

September 13, 2016 Dr. Brian McKay, © Continental AG

48V Hybrid System Component Overview

› 48V electric motor › Belt starter generator (BSG, 7-15 kW) › Integrated starter generator (ISG)

› DC/DC converter links 12V and 48V systems › 0.5 kWh Li-Ion Battery

Fewer simple components control costs

› Features:

4

› Energy recuperation › Engine-off coasting (sailing) › Torque assist and electric driving › Power 48V devices (electric turbo)

Driving Innovation Workshop Washington, DC

September 13, 2016 Dr. Brian McKay, © Continental AG

P2 configuration

› Side attached BSG or ISG

› Higher cost › More recuperation

› Additional hybrid functions

P3 & P4 Configurations

› P3: eMotor torque on transmission

› P4: eMotor torque directly on axle drive

› Highest energy recuperation potential

48V System Configurations Mild Hybrid System Roadmap

P0 configuration

› Low cost integration

› Belt Starter generator

› Torque limited

Driving Innovation Workshop Washington, DC

September 13, 2016 Dr. Brian McKay, © Continental AG 5

P1 Configuration

› Crankshaft mounted

› High torque

48V System Configurations Fuel Economy Benefit

-7.4%

-8.7%

-10.7%

-13.2%

+35%

CO2 Reduction Potential Cost per gCO2/km Ratio

P0+P

4

6

P0 BSG P1 BSG P2 BSG P4

Recuperation, electric torque assist,

engine-off coasting

!" !" !" !"

Engine-off A/C x x !" x

eCreeping/ Sailing

x x !" !"

Driving Innovation Workshop Washington, DC

September 13, 2016 Dr. Brian McKay, © Continental AG

100m/10s

30m/5s

Accelera1onfrom800rpmto~3000rpm2ndGear

Accelera1onfrom800rpmto~3000rpm3rdGear

Theelectrictorqueassistwaslimitedto50Nmoncranksha]Improvedlow-end-torque

26m/5s

86m/10s

48VP0HybridTransientPerformance15%Accelera1onBenefitfromElectricTorqueAssist

Source:Ford

September 13, 2016 7 Dr. Brian McKay, © Continental AG

Driving Innovation Workshop Washington,DC

48V Allows for Auxiliary Component Electrification More Efficiency and Further Benefit

4 kW 5 kW (max.) Power

25%

50%

75%

100%

Pow

er-O

n Ti

me

100 W 300 W 500 W 750 W 1 kW 2 kW 3 kW

Possible 48 Volt Devices

Front Wiper Window Lifter 4x

Radiator Cooling Fan

Front Window Heating

Water Pump

Rear Window Heating

High Beam Front Seat Heating 2x

A/C Compressor

PTC Heater

Power Steering

Blower

Dynamic Roll Stabilization

Electric Booster

Variable Valve Train

Variable Compression Ratio

Electric Vacuum Pump

(Transmission) Oil Pump

Engine Oil Pump Twin Drive

≈≈ ≈

Electric Valve Train

8 Driving Innovation Workshop Washington, DC

September 13, 2016 Dr. Brian McKay, © Continental AG

48 Volt Technology – More than a Mild Hybrid Benefits Over and Above CO2 Reduction

› 48 Volt electrification is driven by CO2 and emission reduction regulations.

› Future 48V powertrain designs will enabling even greater CO2 savings.

› Recuperated energy can be utilized for safety, comfort, and efficiency functions.

› Auxiliary components can be electrified to reduce power load on engine.

› Rapid development to commercialization in next few years

9 Driving Innovation Workshop Washington, DC

September 13, 2016 Dr. Brian McKay, © Continental AG