low-voltage hybridisation for affordable fuel …...low-voltage hybridisation for affordable fuel...
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CPT Confidential and Proprietary Information. Do not reproduce without permission.
Low-Voltage Hybridisation for Affordable Fuel Economy & Drivability
September 2013 Nick Pascoe, CEO
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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.
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.
Drivers for Change Legislation
Continuing Global Convergence of Standards
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)
(Data source: International Energy Agency)
Powertrain Solutions Light Vehicle
Electric
Fuel Cell
Internal Combustion Engine volumes increasing through to 2040
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
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)
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
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.
Kinetic Energy Recuperation
CPT SpeedStart®
48V Specification for Motor/Generator
Specification still evolving but real pressure to conclude quickly.
Energy Harvesting & Usage
Recuperation energy potential in NEDC
[vehicle mass 1450kg; parallel braking with travel dead end]
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.
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
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
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
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
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
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)
Exhaust Gas Energy Recuperation
CPT TIGERS®
Combustion Fuel Energy Utilisation and Waste
Initial CPT modelling
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
VIPER Programme Results
Measurements on-going. Drive cycle critical.
Wrightbus Programme (IDP1) Ultra Efficient Systems for Hybrid Technologies
TIGERS applied to Wrightbus led, TSB supported programme.
Considerations for Recuperation Operating Cycle
Validation Certification Customer value
Requirements definition
Electrical Architecture Voltage Energy storage technology
Control System Integration
Thermal management
People Skills, Resources and Collaborations
Maintaining the Momentum in a Technology Driven UK Based
SME
Mechanical Development Thermal, Static and Dynamic Simulation
Assembly/Manufacture Noise/Vibration
Continuous improvement of mechanical performance.
Electronics Development Thermal Simulation
Increasing Power limits of Recuperation and Motoring.
Time dependent thermal loading of Power Electronics.
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
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
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.