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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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hofer powertrain GmbH

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

2

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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5

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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7

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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9

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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ow

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su

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ly, …

En

vir

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ffic

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om

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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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su

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ly, …

En

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om

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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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Joerg.Neugaertner@hofer.de

+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

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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

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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

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tera

ctio

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ly, …

Range extender >20/30kW for Golf class as option

Cooperation with energy supplier needed

Base for invest is the legislation boundary conditions