vehicle electrification focus and challenges · elkraftdagen 2016 - cth, electric propulsions...
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Vehicle electrificationfocus and challenges
Karl Klang
Electric Propulsion Systems, Volvo Cars
Elkraftdagen 2016 - CTH
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 2Issue date: 2016-03-22, Security Class: Public
Overview
• Introduction
• Vehicle electrification challenges of today
• Volvo cars electrification – history and present
• Q&A
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 3Issue date: 2016-03-22, Security Class: Public
Why Hybrids & Electrification? Up to today
Political and market forces limiting CO2 emissions and usage of fossil fuels
Electricity as a main track for cars and light trucks- Efficiency- Infrastructure and conversion flexibility
Global Warming
• climate change
Energy Security
• fuel availability
• delivery conditions
Electrification – image step 1
Generation 1
• Decent performance
• Slight improvement in fuel efficiency
• No revolutionaryattributes
• Huge productplacement effort!
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Electrification – Image step X
Tesla
High performance electric vehicle
Message:
Electric performance can be competible with ”normal” cars!
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Worldwide legislations on CO2 emmisions
130 g/km 2012
95 g/km 2020
CO2-development over time – new cars EU
Source: icct (the international
council on clean
transportation)
Automotive electrification today
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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• Electrification strategies adopted by many car
manufacturers and many models are already available
• Expected legislated emissions decreases steadily
• Incentive programs for electrification are ramping out
Automotive electrification today
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 8Issue date: 2016-03-22, Security Class: Public
• Electrification strategies adopted by many car
manufacturers and many models are already available
• Expected legislated emissions decreases steadily
• Incentive programs for electrification are ramping out
The “chasm”
Focus and challenges today – the MarketExtremely competitive market, relatively untested for these applications, where the standard questions are to be answered:
• What do customers want?
• How much is it worth?
• At the expense of what is it still desirable?
• How do we brand whatever level we chose to offer?
• What does customers not yet know that they want?
• How and at what time will the infrastructure adapt?
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 9Issue date: 2016-03-22, Security Class: Public
Focus and challenges today – industry vs automotive
Automotive applications requires:
• Capability to handle harsh and varying environmental conditions
• Documented fulfilment of “appropriate” standards for liability and/or legal reasons
Suppliers typically comply with industry “best practice” standards + Automotive industry standardization is lagging Brand/model unique solutions, low volumes, long lead times and expensive development
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 10Issue date: 2016-03-22, Security Class: Public
Focus and challenges today – Functional safety vs robustness
• ISO 26262 introduced as an automotive “best practice” standard
• High (documented) confidence levels are required for applications where very little quality data is available
• Failing to fulfil the required confidence levels might mean that you have to go to a safe state where the electric propulsion ability is typically either not available at all or greatly reduced.
• Consequence of lost function increases as the utilization of electric propulsion increases
• Some market enforce very strict penalties for setting faults too often while still requiring action on all present faults
• No customer is happy with a car that has highly noticeable faults (at any point)
• Limited operation strategies where some functionality is maintained even though the system is not fully operational are required!
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Focus and challenges today – Platform preparations
• Adapt the platform to enable optimized electrification from the start instead of adapting the electrification to fit the platform available
• Extremely high investments
• Uncertainties/risk due to the market situation
• Crucial in order to reduce cost and staying competitive
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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25 Years ago…. Flywheel mounted
Starter alternator
Test bench 1990
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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VCC electrification programmes and studies
1992 ECC - Environment Concept Car at Paris Autoshow
Concept:
Series Plug-in Hybrid
Gas Turbine
High Speed Generator
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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HEV 98 – Demonstration Vehicles
Integration of Hybrid systems into target vehicles.
Battery: NiMH 20 kWh
Drive system: 90 kW AC induction motor
+ 2step transm
APU: 3cyl 1,4L ICE, 30 kW generator
Onboard Charger
EL AC compressor
DCDC converterDC/AC
Converter
Field Wound
Synchronous
Generator + regulatorDrive unit
1,4 L 3 cyl
Gasoline engine
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Desiree
1998 - 2000
Concept: Power Split Hybrid
Showed at Geneva
Auto Show 1999
Performance 0-100 13,5s
Electric Range 1-2 km
Top speed 150 km/h
Base Vehicle: S40/V40
Added weight: 183 Kg
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Desiree Technology
· Engine 1.4 litres, 56 kW
· Electric motor 55 kW
· Generator 25 kW
· Battery 2.5 kWh, 300V, 55kW NiMh
Demonstration objective:
Study vehicle attributes and
system implications of
power split technology in
VCC platforms
Dual Inverter Transaxle
unit
3cyl ICE with electronic throttle Water cooled NiMH battery
DCDC converter AC compressor
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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ISG Vehicle
1998 - 2001
Concept: Mild Hybrid ISG (Integrated Starter Generator)
42V/12V Dual Voltage System
>10 Vehicles built 760/S/V40/S80/Ford (1st built 1988)
Demonstrated for 150 Journalists Seville Spain 2001
Performance: Improved – Enables downsizing
Top speed: No change 42 V Battery
Fuel tank
Integrated Starter
Generator
Base Vehicle: S80 Added weight: 60 Kg
Air
conditioning
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 19Issue date: 2016-03-22, Security Class: Public
ISG Technology
ISG Machine ISG Converter incl DCDC conv.
ISG Battery Pack ISG Automatic transmission Hybrid AC Compressor
· ISG Electric machine12 kW
· DC/AC- and DCDC-converter 140A
· Battery NiMh 36cells, 0,7 kWh 15kW
· Both manual and automatic application
Induction and PM Synchronous
technology
· Electric Air Condition during
engine stop, mechanically driven
while engine is running
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Research project to build knowledge
Focus on safety/battery packing
Test fleet
- 0-100km/h on 10.5s
- 4 seats + luggage
- safe as all Volvos
- 120 - 150km range
- max 130km/h
Volvo C30 BEV
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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DC DC converter200A @ 12V
Electrical AC-compressor 8kW
PDU (Power Distribution Unit)
Inverter
Rear battery12kWh
Tunnel battery12kWh
On board charger16A @ 230V
El. motor 82/40 kW
230V AC harness
Charge Inlet
C30 Electric-Powertrain
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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V60 PHEV D6
World-first Diesel PHEv with 48g CO2/km and 50km pure electric range
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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On the EU market 2012
Lithium Ion battery 12 kWh energy
Chargeable from power network - on board charger
Electric motor 50 kW (70 hp)
Combined with an efficient premium diesel 150 kW (205 hp)
Start/Stop system included
Regenerative braking system
Electrical air condition
Electric / hydraulic power steering
V60 Plug-in Hybrid Electric Vehicle – Tech facts
Why Hybrids & Electrification? today
Legislation and environmental impact, but also:
• Performance option
• New/improved driving attributes
• Relatively low complexity to add features
• Cost savings?
• Electric drive feeling!
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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The Plug In Hybrid Electric Vehicle - Challenges
COST
Package space
Cooling
Efficiency
Durability
SAFETY
LiFE SPAN
Integration
performance
competence
Charging time/km
XC90 PHEV - Challenges for the ”second” project
• Extremely high attribute requirements
• Platform based dimensioning of all main components
• Added flexibility and more efficient developement of vehicle near functionality – strategic SW components developed inhouse
• No pre-existing (already stabilized) platform to build on
• New and hard EMC requirements
• World wide introduction
• Compared to V60 PHEV and required to be better or equal in all categories
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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XC90 PHEV – EPS parts
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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XC90 T8 PHEV – Tech facts
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Production start in 2015
No compromise: high performance & low CO2
High performance 400 HP and 650 Nm
Low emissions that complies with Euro 6 and TZEV standards.
Low CO2 64 g/100km and fuel consumption 2,7 l/100 km.
Up to 50 km electric range
Battery capacity: 9,3 kWh
Electric AWD
“Designed around you” … three cars in one … you decide
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
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Q&A
We want you as a power engineer!