powertrainpowertrainelectrification / electrification ... · hybrid and electric vehicles, energy...

Hybrid and electric vehicles, energy storage technologies Hybrid and electric vehicles, energy storage technologies Hybrid and electric vehicles, energy storage technologies Hybrid and electric vehicles, energy storage technologies

and control systemsand control systemsand control systemsand control systemsNational and international R&D-projects, research institutions and funding programs

Vienna, October 21st 2008 in cooperation with and

PowertrainPowertrainPowertrainPowertrain electrification / electrification / electrification / electrification / hybridisationhybridisationhybridisationhybridisation

---- potentials & potentials & potentials & potentials & complextitycomplextitycomplextitycomplextity

Wolfgang Kriegler Wolfgang Kriegler Wolfgang Kriegler Wolfgang Kriegler

2Rethinking Propulsion.

Why electrification of powertrain?

1st Statement:

Electric powertrains are nothing new!

Lohner Porsche HEV ~1900, Wheel hub motors

Electric powertrains have been build already 1900 due to

„environmental“ reasons!They are lokally emission free !!! (= most important advantage!)


ContentContentContentContent

Introduction

Motivation

Electrification

Conventional applications

Battery

Prerequisite for power train electrification

Hybrids

Hybrid architectures – electric all wheel drive

Hybrid versions & operational strategies

Example

HySUV Architecture – Highlights of the control system

Potential & Results


IntroductionIntroductionIntroductionIntroduction

Source: Agenda 21Source: Goldmann Sachs

Development in Asia increases energy demand & emissions

Climate change is felt as a big threat Main reason is CO2 increaseSource: bpb

Just one quarter of the climate change is due to traffic

Source: DiStatis

Power Generation 29%

Deforestation, slash & burn: 15%

Industry 18%Transportation

22%

Heating

7%

Agriculture

6%

Miscellaneous

3%


Threat to environment: COThreat to environment: COThreat to environment: COThreat to environment: CO2222

Development of earth population correlates with the CO2-content in atmosphere

*

*without countermeasures

Development of earth populationGlobal warming – forecast *

Temperature Increase °CDeveloping Countries

Industrial Countries


Technical Solutions in the Vehicles:

• Efficiency increase with standard gasoline & diesel engines

• Mixing with bio fuels (20%)

• Developm. / Introduction of synthetic fuels from various sources

• Developm. / Introduction of hydrogen technology (FC/ H2-Engine)

• Developm. / Introduction of combined (Hybrid) or pure electric drives

Traffic Restrictions:

• Speed limits

• Bigger pedestrian areas • Zone-Models, e.g. City-Toll (London, Stockholm, Berlin)• Complete locking of areas for „emitting“ vehicles• Strict traffic guidance

• Increased pressure to use public transport

Legislation:

• Continuously tightening up exhaust gas and noise emissions limits (CO2-Emissions, Dust, etc.)

Measures against Climate ChangeMeasures against Climate ChangeMeasures against Climate ChangeMeasures against Climate Change


0 50 100 150 200 250

COCOCOCO2222 Reduction PotentialReduction PotentialReduction PotentialReduction Potential

Hydrogen ICE (CGH2 out of CNG)

Fuel Cell (CGH2 out of wind power)

0 50 100 150 200 250

161

9

14

17

104

186

125

164

141

196Gasoline ICE

Hybrid (gasoline ICE)

Diesel ICE

Hybrid (Diesel ICE)

Diesel ICE (BTL)

Fuel Cell (CGH2 out of CNG)

Fuel Cell (CGH2 out of bio mass)

Reference: Compact sedan, NEDC

-28%

-16%

-36%

-91%

-46%

-93%

-95%

-5%

Source: EUCAR/CONCAWE/JRC, 2005

-18%Natural-gas ICE (CNG)

GHG Emissions [g CO2 eq/km]

It is worth to develop hybrid vehicles!


HEV/ EV Market HEV/ EV Market HEV/ EV Market HEV/ EV Market ConsiderationsConsiderationsConsiderationsConsiderations / / / / CARBCARBCARBCARB----ViewViewViewViewMSF ProjectsMSF ProjectsMSF ProjectsMSF Projects

Source: CARB May 2007

Mila EVPure electric

Mila EVw. Range Extender/ Plug-In

HySUV4WD Full Hybrid


Electrification Roadmap

Level of Electrification

Hybrid 1st Gen

Full Hybrid

HySUV

Plug-In-Hybrid

Flexible E-Drive platform / propulsions

Electric VehicleZEV

NiMhd 2 kWh Li-Ion 4 kWh Li-Ion 15 kWh Li-Ion 25 kWh Li-Ion 40 kWh Storage capacity

2003 2007 2010 2012 2015

x000 EUR 3000 EUR 8000 EUR … EUR ... EUR Batt. Module cost

50 kg 60 kg ca. 150 kg ca. 220 kg ca. 300-350 kg

EV / ZEV

EV withRange Extender /PHEV

Extension ofFull HEV

Development speed depending on battery

development

Weight


Motivation ElectrificationMotivation ElectrificationMotivation ElectrificationMotivation Electrification

Increasing energy demand Increasing energy demand Increasing energy demand Increasing energy demand –––– exploding pricesexploding pricesexploding pricesexploding prices

Shortage of resourcesShortage of resourcesShortage of resourcesShortage of resources

Environmental protection (climate change COEnvironmental protection (climate change COEnvironmental protection (climate change COEnvironmental protection (climate change CO2222, dust emissions), dust emissions), dust emissions), dust emissions)

Legal limits, restrictions in citiesLegal limits, restrictions in citiesLegal limits, restrictions in citiesLegal limits, restrictions in cities

Becoming energy independentBecoming energy independentBecoming energy independentBecoming energy independent

Energy ConsiderationsEnergy ConsiderationsEnergy ConsiderationsEnergy Considerations

Energy consideration of the complete life cycleEnergy consideration of the complete life cycleEnergy consideration of the complete life cycleEnergy consideration of the complete life cycle

Recuperation of kinetic energyRecuperation of kinetic energyRecuperation of kinetic energyRecuperation of kinetic energy

Utilizing lossesUtilizing lossesUtilizing lossesUtilizing losses

Vehicle to GridVehicle to GridVehicle to GridVehicle to Grid

Motivation Motivation Motivation Motivation ConclusionConclusionConclusionConclusion


PowertrainPowertrainPowertrainPowertrain Electrification Electrification Electrification Electrification ““““ConventionalConventionalConventionalConventional”””” ApplicationsApplicationsApplicationsApplications

Electrification of comfort auxiliaries:

• Window lifter

• Seat heatings

• Air conditioning• Info-tainment

Electrification of power train components (Drive by wire components):

• Power steering pump• Brake / Brake assist power

Electrification with ic- engines:

• Water pump ∆be = 2 – 3% especially after cold start• Valve train depending on patent; ∆be up to 15%• Oil pump tbd

Magic Wording: Operation on Demand !


ElectrificationElectrificationElectrificationElectrification of of of of iceiceiceice----componentscomponentscomponentscomponents

Electric water pump

CWA 50 Pierburg Pump Technology

• Fully flexible valve train ΔΔΔΔbe : up to 15 % depending on Concept

∆be = 2 – 3% especially in warm up


ElectrificationElectrificationElectrificationElectrification of of of of drivedrivedrivedrive traintraintraintrain componentscomponentscomponentscomponents

„Drive by Wire“ Components:

• Electric Steering • Electric Brake assist

• Electric water / Oil pumps for cooling& lubrication

Fully-electric Steering

Electric Comfort-Components:

• Window-Lifter etc• Seat-Heatings• Electric (HV) Air condition • „Info-tainment”



Introduction

Motivation

Electrification


Battery


Hybrids



Example


Potential & Results


Prerequisite for Prerequisite for Prerequisite for Prerequisite for powertrainpowertrainpowertrainpowertrain electrification:electrification:electrification:electrification:Battery TechnologyBattery TechnologyBattery TechnologyBattery Technology

NiMH:

state of the art; up to

70% less energy and

power density on system

level; worse life time as Li-Ion

Sp

ecific

Po

we

r, W

/kg

at

Ce

ll L

eve

l

Pb Technology

For Micro Hybrid

Applications only

SuperCaps:

highest specific power; limited for applications

due to poor energy density

Li-Ion:

high power and energy density;

preferred technology at some point

in the future

1

100

10.000

100.000

Specific Energy, Wh/kg at Cell level1

10

1.000

20 40 60 80 100 120 140 160 180 200

DLC

Pb

Ni-Mh

Li-Ion

Future Li-Ion ?


Selection of LiSelection of LiSelection of LiSelection of Li----Ion technologyIon technologyIon technologyIon technology

Li-Ion technologies (Cathode Selection)

LiNiCoAlO2

� most proven but most thermally unstable at high SOC; Ni/Co expensive metals

LiNiCoMnO2

� gaining momentum; not many durability data yet available

LiMn2O4

� life time problem at elevated temperatures has not been solved yet

LiFePO4

� most thermal stabile; lower voltage and energy; life and cost are highly promising

but yet not fully evaluated

Blends� promising for the future


HEV & EV Battery Systems HEV & EV Battery Systems HEV & EV Battery Systems HEV & EV Battery Systems ---- StatusStatusStatusStatus

NiMHNiMHNiMHNiMH TechnologyTechnologyTechnologyTechnology

• Cylindrical and prismatic designs in productionCylindrical and prismatic designs in productionCylindrical and prismatic designs in productionCylindrical and prismatic designs in production

• Over 1 Million vehicles are in the fieldOver 1 Million vehicles are in the fieldOver 1 Million vehicles are in the fieldOver 1 Million vehicles are in the field

• Limited power and energy densityLimited power and energy densityLimited power and energy densityLimited power and energy density

• High costs is the prime concernHigh costs is the prime concernHigh costs is the prime concernHigh costs is the prime concern

LiLiLiLi----Ion TechnologyIon TechnologyIon TechnologyIon Technology

• Cylindrical and prismatic designs developedCylindrical and prismatic designs developedCylindrical and prismatic designs developedCylindrical and prismatic designs developed

• Safety concerns have led to design improvementsSafety concerns have led to design improvementsSafety concerns have led to design improvementsSafety concerns have led to design improvements

• Provides weight, volume, life time and longProvides weight, volume, life time and longProvides weight, volume, life time and longProvides weight, volume, life time and long----term cost advantageterm cost advantageterm cost advantageterm cost advantage

• First serial production implementation begins in 2009First serial production implementation begins in 2009First serial production implementation begins in 2009First serial production implementation begins in 2009


Low voltageconnection(LV)

High voltageconnection(HV)

Bus (CAN VEHICLE, CAN HYBRID)

Low voltageconnection(LV)

High voltageconnection(HV)

Bus (CAN VEHICLE, CAN HYBRID)

Battery Architecture

Contactor

switches

Electrical interconnections

CS

C

Cell

system

Co

oli

ng

Sensors

LIN

CAN HYB

HV

LV

BMS

SW

Battery Body

LV

LV

LVHV HV

Contactor

switches

Contactor

switches

Electrical interconnectionsElectrical interconnections

CS

CC

SC Cell

systemCell

system

Co

oli

ng

Co

oli

ng

CANCAN VEH

HV

LV

Cooling

circuit

BMS

SW

Master EMS

SWSW

Energy Storage SystemEnergy Storage System

LV

LV

LVHV HV

Sensors


MAGNA STEYR’s Battery Pack PortfolioE

ne

rgy/

[kW

h]

0

1

10

100

Power/ [kW]1 10 100 1000

MILD

FULL

TRUCK/BUS HEV*

PHEV*

EV*

Energy Battery10 – 30 kWh30 – 120 kWprismatic cells (20- 40 Ah)SOP: 2011

Power Battery0,8 – 3,0 kWh10 – 60 kWprismatic cellsSOP: 2010

Heavy Duty Battery2,5 – 7 kWh60 – 180 kWcylindric cellsSOP: 2009

A wide range of alternative vehicles will be on

the world-wide market in the future

A modular approach resp. right cell

geometry and technology key for the success

EV* Electric Vehicle

PHEV* Plug In Hybrid

HEV* Heavy Duty

serial productionheavy duty battery

systems

SOP energy battery

systems

SOP power battery

systems

2006 2007 2008 2009 2010 2011

1st generation Li-Ion battery

system

2nd generation Li-Ion battery system

1st to market



Introduction

Motivation

Electrification


Battery


Hybrids



Example


Potential & Results

Rethinking Propulsion.

Battery

Inverter

VKM

Transmission E-Motor

Battery

InverterInverter

IC Engine

E-MotorGenerator

Series-Hybrid Parallel-Hybrid

Basic Hybrid StructuresBasic Hybrid StructuresBasic Hybrid StructuresBasic Hybrid Structures

Battery

IC-Eng.

Inverter

Generator

Power Split Transmission

EE--MotorMotor

Power Split Hybrid


Parallel & Parallel & Parallel & Parallel & powersplitpowersplitpowersplitpowersplit subvariantssubvariantssubvariantssubvariants bybybybyDaimlerDaimlerDaimlerDaimler


Electric Rear Axle

Battery

Power-electronics

AMT

ICE

AC AC

DC

BIGS (belt driven generator)

Genera

tor

E-

moto

r

Front Rear

HV HV

Solution for Hybrid 4WD & Solution for Hybrid 4WD & Solution for Hybrid 4WD & Solution for Hybrid 4WD & EVsEVsEVsEVs


Hybrid Hybrid Hybrid Hybrid versionsversionsversionsversions dependentdependentdependentdependent on on on on dimensioningdimensioningdimensioningdimensioning

× (limited)×Electric driving

limited×Brake recuperation

×Boost

optional×Electric 4WD

×Load-shift

Start / Stop

Power HybridFull HybridMild HybridMicro Hybrid

Operation


Target of the operational strategy:To control all active parameters that an overall efficiency maximum can be achieved and all other requirements regarding dynamics and comfort can be fulfilled.

Hybrid operational Hybrid operational Hybrid operational Hybrid operational strategiesstrategiesstrategiesstrategies

Macro Strategies:a) Charge depletion mode (EV Operation / Range)b) Charge depletion mode with ice assist (ice on/off mode)c) Charge sustaining mode (hybrid mode)d) Driver/Guidance selection mode

> “Real life” strategies are a combination of above modes!


Hybrid operational mode 1 Hybrid operational mode 1 Hybrid operational mode 1 Hybrid operational mode 1 ––––FCFCFCFC----reductionreductionreductionreduction potentialpotentialpotentialpotential

Start / Stop Strategy:

Shut down ice Shut down ice Shut down ice Shut down ice –––– Intermittent engine operationIntermittent engine operationIntermittent engine operationIntermittent engine operationIce is switched off in phases of low efficiency (idle, part load); restart in case of better expected efficiency, dynamic and/or battery SOC requirements


ICE Load-shifting:

Shifting of operating points Shifting of operating points Shifting of operating points Shifting of operating points in the engine map to higher torque to receive

higher efficiency (better specific fuel consumption) and recover SOC or

store energy




Recuperative Braking: : : :

a) a) a) a) BatteryBatteryBatteryBattery ChargingChargingChargingCharging duringduringduringduring motoringmotoringmotoringmotoring

b) b) b) b) BatteryBatteryBatteryBattery ChargingChargingChargingCharging duringduringduringduring brakingbrakingbrakingbraking


Hybrid operational mode 4 Hybrid operational mode 4 Hybrid operational mode 4 Hybrid operational mode 4

ICE „Boost“:

Short Short Short Short assistassistassistassist of of of of thethethethe EEEE----motormotormotormotor forforforfor betterbetterbetterbetter accelerationaccelerationaccelerationacceleration;;;;

AllowsAllowsAllowsAllows „„„„ICE ICE ICE ICE DownsizingDownsizingDownsizingDownsizing““““ !!!!!!!!

>>>> FC >>>> FC >>>> FC >>>> FC ReductionReductionReductionReduction potential potential potential potential fromfromfromfrom 5 to 25 %5 to 25 %5 to 25 %5 to 25 %



Introduction

Motivation

Electrification


Battery


Hybrids



Example


Potential & Results


Hybrid Example Hybrid Example Hybrid Example Hybrid Example

HySUVHySUVHySUVHySUV (TM)(TM)(TM)(TM) ––––

Power train conceptPower train conceptPower train conceptPower train concept


HySUVHySUVHySUVHySUV Hybrid Hybrid Hybrid Hybrid –––– Components / ComplexityComponents / ComplexityComponents / ComplexityComponents / Complexity

HV A/C Compressor

E-power steeringTire-fit &

Compressor

Manual Autom. Transmission

PDU

MicroautoboxHEV-Controllerfor transmission & E4WD Module

E4WD-Module rear: EM2 (50kW/500 Nm)

DC/AC-Converter

E4WD Module front: EM1 (50kW/350 Nm)

14V-Battery

DC/DC-Converter

Li-Ion Battery70kW, 200-410V

Battery Cooling

Heat Exchanger, Compensation TankVacuum Pump

for Brake

HV-Harness


5-6%

HySUVHySUVHySUVHySUV (TM)(TM)(TM)(TM) ---- PotentialsPotentialsPotentialsPotentialsFuel consumption reduction by intelligent electrification

of the power train and auxiliaries

AMT


n [U/min]

M [

Nm

]

n [U/min]

M [

Nm

]

Efficiency Map ICE ML350 Efficiency Map ICE HySUV

HySUV™ - Result

ML350: 14.66 l/100km HySUV™™:: 11.1 (-24%) l/100km

Consumer cycle (mixed urban & extraConsumer cycle (mixed urban & extraConsumer cycle (mixed urban & extraConsumer cycle (mixed urban & extra----urbanurbanurbanurban)---- Distance: 20 km- Mass ML350: 2387 kg- Mass HySUV™: 2714 kg- Battery SOC balanced


contact

Dipl.Ing. Wolfgang Kriegler

MagnaSteyr

Fahrzeugtechnik AG & Co KG

address: Liebenauer Hauptstrasse 317

8041 Graz, Austria

tel: +43-664-8840-7725

fax: +43-316- 404- 3039

web: www.magnasteyr.com

email: [email protected]


thank you for your attention !!!!!

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