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Page 1: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

CPT Confidential and Proprietary Information. Do not reproduce without permission.

Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability

September 2013 Nick Pascoe, CEO

To help protect your privacy, PowerPoint prevented this external picture from being automatically downloaded. To download and display this picture, click Options in the Message Bar, and then click Enable external content.

Page 2: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Themes

Convergence of Global standards for fuel economy/CO2

Kinetic Energy Recuperation:

• the next focus for CO2 reduction

• ....at 48V?

Exhaust Gas Energy Recuperation

• feasibility and benefit validation?

Maintaining the Momentum in a Technology Driven, UK based SME.

Page 3: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

CPT Created March 2007 • Products, Technology and Facilities acquired from Visteon Corporation,

December 2007. • Development facilities in Laindon, Essex and Coventry. • Strategic Partnership with Nidec SR Drives Ltd., Harrogate. Organisation • ~45 employees including 36 engineers. • German Office added mid-2010. • VTES business sold to Valeo December 2011. Competencies • Powertrain. • Power Electronics, Control Electronics and Software. • Automotive Industry Design and Validation.

Page 4: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Drivers for Change Legislation

Continuing Global Convergence of Standards

Page 5: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

2015 EU Target

2020 EU Target

Drivers for Change Brand Image vs European Legislation

Average Emissions and Emission Targets 2015 / 2020 (Data sources: eea.europa.eu, data published Dec 2012)

Page 6: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

(Data source: International Energy Agency)

Powertrain Solutions Light Vehicle

Electric

Fuel Cell

Internal Combustion Engine volumes increasing through to 2040

Page 7: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Hybrid Technology Options System ► Metric ▼

Micro Hybrid

Mild Hybrid

Full Hybrid

Plug-in Hybrid

Voltage 12V 24-130V 200-600V 300-400V e-Motor Power 3kW 10-15kW 20-50kW 60-70kW

Regen. Power 0.5-3.0 kW ~10 kW ~20 kW 20 kW +

Launch Assist 0 <15kW >15kW >60kW

e-Drive Range 0 0 ~ 2 km ~ 30 km Customer on-

cost €200 - €900 €3000 - €5000

€6000 - €8000

€12000 - €15000

CO2 Benefit % 3 -7 % 5-10% 10-15% 15%

Customer Cost/ Benefit

€40 - 300 /1%

€300 - 1000 /1%

€400 - 800 /1%

€800 - 1000 /1%

future

Excludes potential additional engine down-speeding/ down-

sizing benefits (eg 30% smaller = -15% CO2)

and/or alternative fuel (eg CNG)

Target Market <60 volts

Page 8: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

CPT SpeedStart®

Integrated Starter/Motor & Generator

TIGERS Exhaust Gas Energy Recovery

Turbine

COBRA Heavy Duty, Water Cooled

Electric Supercharger

CPT Product Portfolio

Integrated Electronics

• Control electronics • Power electronics

(water cooled)

Page 9: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

1. Simple Construction for Motor Robustness

2. No Requirement for Permanent Magnets

3. Flexible, Configurable Electronics

4. Highly Programmable

5. Practical Installation Solutions

SR Motors

Page 10: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Electrical Energy Usage • Vehicle energy demands already exceeding 12V/3kW alternator.

– Powertrain & Chassis Systems – Passenger Safety, Security & Comfort Systems

• Hybridisation includes the use of controllable, electrical devices to reduce energy demands:

– Cooling fans, – Water pumps, – Electric Power Assisted Steering, etc.

• Higher power electrical devices would benefit from higher voltage systems but:

– >60V requires much greater safety consideration..... – ...leading to significant cost increase.

48V provides an ideal compromise for performance and cost.

Page 11: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Kinetic Energy Recuperation

CPT SpeedStart®

Page 12: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

48V Specification for Motor/Generator

Specification still evolving but real pressure to conclude quickly.

Page 13: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Energy Harvesting & Usage

Recuperation energy potential in NEDC

[vehicle mass 1450kg; parallel braking with travel dead end]

Page 14: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Application Driven Specification 48V Electro-Magnetic Optimisation

High mass vehicle

Transient Generation focus

Low mass vehicle

Transient Motoring focus

Single Design for Packaging. Multiple Variants.

Multiple Applications.

Page 15: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Electric Launch Assist and/or Drive with Load Point Moving Example for Electric Launch Assist (Acceleration) in NEDC

0 20 40 60 80 100 120 140 160 180Time [s]

Vel

ocity

[km

/h]

-20

0

20

40

60

80

100

120

140

EM

Mec

hani

cal P

ower

[kW

]

-8

-6

-4

-2

0

2

4

6

8

EM

Mot

Max

Pow

er [k

W]

-8

-6

-4

-2

0

2

4

6

8

Threshold for max. E-Machine power

Selected electric launch events

Simulation results courtesy of AVL Schrick GmbH

Page 16: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Electric Launch Assist and/or Drive with Load Point Moving Example for Electric Drive Event in NEDC

0 20 40 60 80 100 120 140 160 180Time [s]

Vel

ocity

[km

/h]

-20

0

20

40

60

80

100

120

140

EM

Mec

hani

cal P

ower

[kW

]

-8

-6

-4

-2

0

2

4

6

8

EM

Mot

Max

Pow

er [k

W]

-8

-6

-4

-2

0

2

4

6

8

Threshold for max. E-Machine power

Selected electric drive events

Simulation results courtesy of AVL Schrick GmbH

Page 17: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Recuperation by Electric Brake Assist Example for Recuperation in NEDC

Threshold for max. generating power

Simulated electric brake assist

Simulation results courtesy of AVL Schrick GmbH

Page 18: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

2011 VW Passat 1.4TSI Bluemotion 12V architecture.

Revised gear ratios & increased engine torque output.

CPT SpeedStart® rapid stop-start, efficient generation & 3kW regeneration.

Valeo VES (formerly CPT VTES) electric supercharger

ALABC Lead Carbon,12V*, 2x50Ah battery pack.

Provector Battery Management System (BMS)

ALABC/LC SuperHybrid

Page 19: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

6

7

8

9

10

11

12

13

14

90 110 130 150 170 190

Acc

eler

atio

n (

0-6

2m

ph

, se

con

ds)

CO2 (g/km)

Performance vs Fuel Economy

1.8l TFSi

1.4l TFSi

Gasoline

Diesel

Source: Company websites & LC SuperHybrid testing & simulation

ALABC/LC SuperHybrid

2.0l TDi

1.4l TFSi 48V LC SuperHybrid

1.4l TFSi 12V LC SuperHybrid

48V SpeedStart

48V (7x3 cell) lead carbon batteries

Page 20: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

12V Starter-Generator

48V Motor-Generator

Low Mass, Motoring

Focused, Low Cost Mild Hybrid

High Mass, Recuperation

focused, Premium Applications

CPT SpeedStart® Market Evolution

12V Motor-Generator (Low Cost Micro-Mild

Hybridisation)

48V activity is increasing market interest in enhanced B-ISG functionality.

24V Motor-Generator

(Light-Medium Duty Bus/Truck)

Page 21: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Exhaust Gas Energy Recuperation

CPT TIGERS®

Page 22: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Combustion Fuel Energy Utilisation and Waste

Page 23: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Initial CPT modelling

Page 24: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

VIPER Programme Objectives

• Thermal Optimisation of the Complete Powertrain. • Included recovery of waste thermal energy considering:

– Thermo Electric Generators (TEGS). – Exhaust Gas Energy Recuperation (CPT TIGERS).

• TIGERS developments (at 12V) included: – Sensing System. – Stator and Rotor design for steady

state operation. – Low pressure ratio, high efficiency

turbine. – By-pass system

Target 4.5% CO2 reduction overall including ~2kW from TIGERS

Page 25: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

VIPER Programme Results

Measurements on-going. Drive cycle critical.

Page 26: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Wrightbus Programme (IDP1) Ultra Efficient Systems for Hybrid Technologies

TIGERS applied to Wrightbus led, TSB supported programme.

Page 27: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Considerations for Recuperation Operating Cycle

Validation Certification Customer value

Requirements definition

Electrical Architecture Voltage Energy storage technology

Control System Integration

Thermal management

Page 28: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

People Skills, Resources and Collaborations

Maintaining the Momentum in a Technology Driven UK Based

SME

Page 29: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Mechanical Development Thermal, Static and Dynamic Simulation

Assembly/Manufacture Noise/Vibration

Continuous improvement of mechanical performance.

Page 30: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

Electronics Development Thermal Simulation

Increasing Power limits of Recuperation and Motoring.

Time dependent thermal loading of Power Electronics.

Page 31: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

CPT Confidential and Proprietary Information. Do not reproduce without permission.

Vehicle road load power profile

Current profile

Control System Development Optimising for Energy Storage/Discharge

Knowledge Transfer Partnership

Development of Advanced Control Concepts utilising SR Capabilities

Page 32: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

48V Intelligent Electrification Kinetic & Exhaust Gas Energy (IDP9)

• Awarded July 2013. Announced at LCV 2013! • Builds on the successful TSB supported, Ricardo led HyBoost programme. • First application to a state-of-the-art diesel powertrain. • Intelligent Electrification includes:

– Kinetic Energy Recuperation (SpeedStart). – Exhaust Gas Energy Recuperation (TIGERS). – Electrification of Engine Ancillary Devices. – Energy storage (48V Lead Carbon). – Energy Re-use (SpeedStart & Ancilaries). – Powertrain Simplification and Total Cost Reduction (incl.Emission

Control). <70g/km CO2 at affordable total system cost

Page 33: Low-Voltage Hybridisation for Affordable Fuel …...Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability September 2013 Nick Pascoe, CEO To help protect your privacy,

CPT Confidential and Proprietary Information. Do not reproduce without permission.

Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability

September 2013 Nick Pascoe, CEO

To help protect your privacy, PowerPoint prevented this external picture from being automatically downloaded. To download and display this picture, click Options in the Message Bar, and then click Enable external content.