AUTOMOTIVE ELECTRIFICATION - ELECTRIFICATION SOLUTIONS Markus Maier AVL Europe ITS
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AUTOMOTIVE ELECTRIFICATION ELECTRIFICATION SOLUTIONS Markus Maier AVL Europe ITS
AGENDA
1. Why
Why do we look into Electrification
2. What
What is an electrified car all about
3. How
How do we develop an electrified car
a. Components
b. Systems
4. Summary
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 2
WHY ARE WE TALKING ABOUT
ELECTRIFICATION TODAY
Two major reasons impose the search for alternative ways to propel a vehicle
Global Warming
§ Global warming is having a significant impact on earth, nature and mankind and CO2 is said
to be the major driver for global warming.
Pasterzer Glacier, Großglockner, Austria
1938 2000 2007 2011 2013
We are running out of Crude Oil
§ From German Newspaper SZ.de:
§ Biggest new Oil Field since the 1970s found !
§ But: this Oil Field can supply the world for 14 days of Crude Oil given todays consumption
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 3
GLOBAL REDUCTION VEHICLE CO2 EMISSIONS
270 Solid dots and lines: historical performance
Grams CO2 per kilometer, normalized to NEDC
Solid dots and dashed lines: enacted targets
Solid dots and dotted lines: proposed targets
250 Hollow dots and dotted lines: unannounced proposal
US-LDV
230
California-LDV
210 Canada-LDV
EU
CO2
190
Japan
170 China
S. Korea
150
Australia
130
China 2020: 117 US 2025:107
110
Japan 2020: 105 US PC 2025: 91
EU 2020: 95 EU 2025: 70*
90 *Recommendation
2000 2005 2010 2015 2020 2025 European Parliament
.
Source: ICCT, August 2011, US and Canada values include passenger and light duty vehicles
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 4
EU TARGETS CO2 EMISSIONS OF A FLEET
CO2 Limits vs. Vehicle Weight
500
450
400
350
CO2 Ausstoß [g/km]
300 Trendlinie
250
CO2 Vorgabe
200
150
100
50
0
600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Leergewicht [kg/Fzg]
The heavier the car, the bigger the Gap
Solution #1: massive, further improvement of combustion engine (ICE)
Solution #2: alternative methods of Vehicle Propulsion with better efficiency à Electrification
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 5
FLEET TARGET CO2 EMISSONS
170
CO2 fleet target 2015
160 CO2 fleet target 2020
150
140
CO2 Emission [g/km]
130
C220 CDI 125
Jetta 1,2TSI
120
e l
Dies
Honda CR-Z 117 Saab 9-3
119 117
Hybrid I40 - 113
Honda Insight 320d Eff. Dyn. Passat 1,4TSI
110 Hybrid 109 Ecofuel (CNG)
Focus 101
Econetic
100 500 Twin Air
I20 - 98 99 GOLF 1,6TDI BM
NISSAN Micra Polo 1.2 98 PSA 308 e-HDI PSA 3008 Hy4
TDI BM
Alfa Mito Eco 89
ybr id
90
ll H Prius Hybrid
Fu
87 85 Kia Rio
79
80 VW Up CNG
79
Yaris
Hybrid
70
60
Volvo V60
Prius Plug-in Hybrid
50 Hybrid 49 49
d
Plug-In Hybri
Plug-In
40
& REV
Chevrolet VOLT/
OPEL AMPERA
30 27
600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800
Average fleet weight; Vehicle weight [kg]
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 6
ELECTRIFICATION FOR OEMS IS KEY
Roland Berger Strategy, Ludwigsburg Forum KfZ Elektronik, 2014
§ Until 2020, CO2 emissions need to be reduced by 25% - 30%
§ Low-Hanging fruits (e.g. Stop-Start) already harvested
§ Real-Driving Emission most probably to increase the Gap further
§ The best CO2 is the one not even generated
§ Engine Off Time is Key (sailing) while maintaining driver comfort
§ Optimization Efficiency of whole vehicle
§ Electrification in the whole Powertrain as part of the solution in parallel to further optimize
the combustion engine
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 7
ELECTRIFICATION OF THE POWERTRAIN
Hybrid Technology
Micro 1 Micro / Mild 2 Mild Full / Plug-In 3 BEV / FC 4
Voltage
el. Power
12V 12V / 48V 48V .. 130V 130V .. 400V 400V .. 800V
el. Distance 0,5..3 kW 3..8 kW 10 .. 20 kW > 20 kW > 75 kW
0 km 0 km ~2 km > 20 km > 150 km
Higher CO2 Benefit vs. increasing System-Complexity and System-Cost
1 Stop-Start Systems largely introduced.
2 48V Based systems promise best ratio between cost, features and safety
3 Plug-In Hybrids very attractive for CO2 Super-Credits
4 Battery Technology is key for pure electric driving (Battery Electric)
and market for pure electric vehicles to develop along new mobility concepts
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 8
AGENDA
1. Why
Why do we look into Electrification
2. What
What is an electrified car all about
3. How
How do we develop an electrified car
a. Components
b. Systems
4. Summary
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 9
CONVENTIONAL, HYBRID AND
ELECTRIC VEHICLES
Conventional Vehicle Full Electric Vehicle
Hybrid Vehicles combine
Combustion Engine and
12V Battery All Electric Propulsion Electric Motor Charging Port
ICE Generator
Gearbox Reduction
Gearbox
Hybrid Inverter
UVW
Vehicles
Starter DC/DC
Converter
+
Charger
12V
Bordnet
Rechargeable
Battery
or
Fuel Cell
Micro-Hybrids use Starter and Battery for
Stop-Start Functionality
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 10HYBRID POWERTRAIN LAYOUTS
Parallel Hybrid Serial Hybrid Powersplit Hybrid
Planetary Gearbox
UVW
UVW
UVW
Battery
2nd Battery
Generator
Electric driven rear-axles are also
parellel Hybrids and so-called road-
coupled hybrids
Benefit Benefit Benefit
• Fairly easy to realize • ICE is operated in steady state • Allows optimum combination of
• Allows full-electric driving and has hence optimum parallel and serial hybrid
• Allows electric boosting efficiency depending on driving situation
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 11AGENDA
1. Why
Why do we look into Electrification
2. What
What is an electrified car all about
3. How
How do we develop an electrified car
a. Components
b. Systems
4. Summary
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 12NEW COMPONENTS IN HYBRIDS AND
ALL-ELECTRIC
UVW
Battery Power Electronics & Inverter Electric Motor / Generator
On Board Fast charging
Charger unit
DC/DC
converter Inverter
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 13EXAMPLE: NISSAN LEAF POWER-PACK Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 14
AGENDA
1. Why
Why do we look into Electrification
2. What
What is an electrified car all about
3. How
How do we develop an electrified car
a. Components
Battery
b. Systems
4. Summary
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 15VEHICLE PROPULSION SOURCES OF ENERGY
Internal Combustion Chemical Thermal Kinetic
Engine Vehicle Energy Energy Energy
Classification Energy Source Energy Conversion Method Energy Conversion Method
Gasoline Gasoline
(Hydrogen) Premixed Otto
(Hydrogen)
Combustion Cycle
Vehicle + Oxygen
Diesel Diesel fuel Diffusive Diesel
Vehicle + Oxygen Combustion Cycle Reciprocating Rotary
Engine Engine
Chemical Electric Kinetic
Electric Vehicle Energy Energy Energ
y
Classification Energy Source Energy Conversion Method Energy Conversion Method
Fuel Cell Hydrogen + Oxygen
Fuel Inverter 3 phase e-Motor
Vehicle (FCV) Cell DC AC
Battery Reducing Agent + (Secondary)
Electric Oxidizing Agent Battery
Vehicle （BEV）
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 16BATTERY: FROM CELL TO MODULE TO PACK
Energy Storage
Cell Module Pack
system
Voltage 2-4V 10 – 40 V 100 – 1.000 V
Peak power 0,1 – 1,5 kW 1,5 – 15 kW 15 – 750 kW
Energy 0,01 – 0,1 kWh 0,1 – 1 kWh 1 – 50 kWh
Technology Li-Ion, NiMH, Super-Caps, Lead Acid, Lithium Sulphur, etc.
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 17BATTERY AS SOURCE OF ENERGY Operating Modes § A Battery operates bi-directional: from chemistry to electrical energy and vice versa § Discharge: when supplying Electrical Energy from Chemistry § Charge: when consuming Electrical Energy and store to Chemistry In-Vehicle Operations § Propel the Vehicle: Discharging § Energy Recovery while braking: Charging Major Challenges and Goals for Battery Development 1. Power Density and overall Power 2. Performance to Charge / Discharge demands and transient Response (U, I) 3. Battery Ageing and Battery Life Extension 4. Environmental Performance (Salt, Water, Temperature, etc.) Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 18
MAJOR CHALLENGES FOR BATTERY
DEVELOPMENT 1/2
Source：ENAX HP
http://enax.jp/lib/index.html
1. Power Density and Overall Power
Internal Combustion Engine
Energy Density Wh/kg
Fuel Cell
Development Goal Li-ion Battery
§ More Power per Volume and per Kg Ni-H Battery
Lead-acid Battery
§ Power Density of Combustion Engine plus
Fuel Reservoir still far better than Li-Ion Capacitor
Battery
Power Density W/kg
Constant Constant
Current Voltage
2. Performance to Charge / Discharge
demands and transient Tesponse (U, I)
Development Goal
§ For safety reason, Li-ion battery needs a
Capacity
Voltage
fine control of charge voltage, not to
Current
exceed an upper voltage limit
§ Transient response to be optimized between
different levels of Power à how fast can the
battery supply / consume power?
Time
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 19MAJOR CHALLENGES FOR BATTERY
DEVELOPMENT 2/2
Discharge characteristics – cycle number
3. Battery Ageing and Battery Life Charge CC-CV: 1.0CA-4.2V, 3hr
Discharge current: 0.2CA
Development Goal Discharge termination voltage:
2.75V
§ Larger Number of Cycles results in Voltage Temperature: 20℃
decrease by internal resistance increase
Voltage [V]
§ Battery Capacity is much lower after a
large number of cycles hence reduces the
electric driving range significantly
§ Counter-Mechanisms include Cell Balancing,
optimized Thermo Management, etc.
Capacity [%]
Discharge characteristics - Temperature
4. Environmental Performance (Salt,
Water, Temperature, etc.)
Development Goal
Voltage [V]
§ For safety reason, Li-ion battery needs a
Discharge
fine control of charge voltage, not to
current: exceed an upper voltage limit
0.2CA
Discharge § Transient response to be optimized between
termination
voltage: 2.75V different levels of Power à how fast can the
battery supply / consume power?
Capacity [%]
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 20AVL SOLUTION FOR BATTERY TESTING E-Storage HV (High-Voltage) § 75kW to 400 kW available § 4 Systems in parallel: up to 1.600 kW § Up to 1.000Volt and 2.400 A § Market leading Performance for U & I transient § Galvanic Isolation between AC and DC § Market leading footprint § Useable for Li-Ion, Lead-Batteries, Super-Caps, Nickel-Metal-Hydrid, etc. § Easy Integration to AVL PUMA, AVL Lynx or Third Party Testbed Automation via Open CAN Interface E-Storage LV (Low-Voltage) – 48V Applications § 20kW, 32kW, 64 kW available as mobile solution § Up to 1.200 A § Galvanic Isolation between AC and DC § Useable for Li-Ion, Lead-Batteries, Super-Caps, § Nickel-Metal-Hydrid, etc. § Easy Integration to AVL PUMA, AVL Lynx or Third Party Testbed Automation via Open CAN Interface § Mobile Solution ideal for Upgrading existing Testfields Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 21
AVL SOLUTION FOR BATTERY TESTING Example for climatic Chamber for Battery Pack testing § Safety § EUCAR Hazard level assessment § Advanced safety monitoring via Gas-Sensors, Thermo-Camera, Temperature Sensors § Fire suppression via Watermist or customer specific solutions § Environmental § Optional with climatic conditioning Temperature, & Humidty § Optional Salt-Spray available § Optional Shaker (rattling, shaking) § Testing § Standard (i.e. ISO 12405, SAE, JAIR, etc…) or customer specific tests Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 22
AGENDA
1. Why
Why do we look into Electrification
2. What
What is an electrified car all about
3. How
How do we develop an electrified car
a. Components
Electric Motor
b. Systems
4. Summary
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 23ELECTRICAL MOTOR TO PROPEL THE VEHICLE
Operating Modes
§ An Electrical Motor operates bi-directional in 4-Quadrants
§ Motoring: Electrical Energy is converted to rotation and torque à Driving the vehicle
§ Generate: mechanical energy is converted to electrical energy à Recovery while braking
Torque
Generate Motoring
Speed
Motoring Generate
Major Challenges and Goals for E-Motor Development
1. Speed and Torque Control ~ 0rpm
2. Transient and Dynamic Behavior for Drivability
3. Reliability and Durability
4. Environmental Performance and Conditioning (Salt, Water, Temperature, etc.)
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 24DIFFERENT TYPES OF ELECTRICAL MOTORS
E-motors as used in powertrains of Hybrid- or Electric vehicles
Integrated Starter Axle Motors, Wheel
Belt Starter
E-Motor Generators Hub Motors, etc.
Generators (BSG)
(ISG)
Rated Power 5 kW 8-35 kW 60 kW
Maximum Power 15 kW 15-50 kW 200 kW and more
Maximum Speed 8.000 rpm * Ratio 8.000 rpm up to 20.000 rpm
Micro Hybrid Mild/Full Hybrid (P) Full Hybrid (S), EV
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 25MAJOR CHALLENGES FOR E-MOTOR
DEVELOPMENT
Source: opahansblog.wordpress.com
Electrical Motor Gasoline Engine
1. Speed and Torque Control ~ 0rpm
Development Goal
§ Electrical Motors provide full torque and
Power [kW]
Torque [Nm]
high Power at 0 rpm already
§ Controllability to improve drivability
Example: Parking at curbstone
Speed [1000 rpm]
2. Transient and Dynamic Behavior for
Driveability
Development Goal
§ The dynamic behavior of an electrical Motor
is very different to a combustion engine.
Changes in the desired load are
immediately effective and as such the
driveability must be adapted to the drivers
wish and car characteristics
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 26E-MOTOR DYNAMOMETER FOR 0 RPM TESTS
DynoSpirit 250/4.8-20 Tx
PMM
250 kW
500 Nm
20,000 rpm
0.12 kgm2
25% overload
Water cooled
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 27AVL E-MOTOR TEST SYSTEMS
TEST SYSTEM LAYOUT - SAMPLE
E-Power Measurement
Power Measurement Trolley
FEM-box Idle-/Shortcircuit Contactor Box
e-Storage
PDU
Climatic Chamber
Coolant
conditioning
InMotion Dyno
Stall brake
Converter
PUMA Open
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 28AVL E-MOTOR TEST SYSTEMS – EXAMPLES
Example:
BSG-Motor
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 29AVL E-MOTOR TEST SYSTEMS – EXAMPLES
Example:
ISG-Motor
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 30AVL E-MOTOR TEST SYSTEMS – EXAMPLES
Example:
Axle-Motor
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 31AGENDA
1. Why
Why do we look into Electrification
2. What
What is an electrified car all about
3. How
How do we develop an electrified car
a. Components
Inverter
b. Systems
4. Summary
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 32INVERTER AS THE HEART OF IT ALL
Operating Modes
§ An has basically two tasks
§ Convert 2-Phase DC from Battery to 3-Phase AC for the Motor and control Motor Power
while Driving
§ Convert 3-Phase AC to 2-Phase DC while generating / recuperating
Battery Inverter
Major Challenges and Goals for E-Motor Development
1. Optimize the Control Strategies
2. Optimize the Efficiency
3. Optimize for New Functions and Features enabled by Inverter & E-Motor
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 33MAJOR CHALLENGES FOR INVERTER
DEVELOPMENT 1/2
1. Optimize the Control Strategies
Development Goal
§ Signal conversion: convert torque command
from vehicle to 3 phase AC current command
§ Vector control (max. torque / field
weakening)
§ Power conversion: Based on the 3phase AC
command, convert DC from battery to 3 phase
AC à PWM control
2. Transient and Dynamic Behavior for
Driveability
Development Goal
§ Switching loss is power consumption,
mainly due to transient characteristics of
voltage and current in switch on/off. It
brings decrease in inverter efficiency and
increase in power transistor temperature
(lifetime)
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 34MAJOR CHALLENGES FOR INVERTER DEVELOPMENT 2/2 1. Optimize for New Functions and Features enabled by Inverter & E-Motor Example: Vibration Control § An Electrical Motor has a high dynamic Response to torque demands § A Powertrain Setup can cause vibrations due to Mass-Spring-Damper § Vibration Control can be applied to actively Damp the resulting vibrations See also ATZ 03/2013 “VIRTUAL E-MOTOR AS A TOOL FOR THE DEVELOPMENT OF POWERTRAIN CONTROLLERS” by Daimler AG Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 35
E-MOTOR EMULATOR BY AVL AS A
DEVELOPMENT TOOL FOR INVERTERS
Highlights and Functions
§ Emulation of the electrical Motor via E-Motor Modell (included)
§ E-Motor Parameters adaptable via Software
§ Failsafe Testing of Inverters
§ Shortcut and blocked Rotor testable
§ Phase failure testable
§ Out-of-Position Rotation / Position Sensor can be tested
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 36AGENDA
1. Why
Why do we look into Electrification
2. What
What is an electrified car all about
3. How
How do we develop an electrified car
a. Components
b. Systems
4. Summary
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 37ELECTRIFIED POWERTRAINS TESTING
Electrified Powertrains - Characteristics Today: Whole Powertrain
010111
001010
§ High number of operating modes (recuperation, boost,
001011
Inverter
+ -
sailing, etc.) 010111
001010
001011
Battery
§ Integration of components from different Tier-1
Generator
§ New, partially unknown technology
Belt
§ High number of interfaces to the vehicle (external loads)
Gearbox
Motor
Clutch
ICE
System Integration Test - Today
§ Integration with Combustion Engine and Gearbox to full
Powertrain and Testing on Powertrain Testbench or in
the Vehicle
Tomorrow:
Challenges 01011100
1010001
011
Subsystem Electrification
Inverter
§ one Component can block the whole testing + -
01011100
§ Debugging of faulty systems complex while in the car
1010001
011
Battery
AVL Solution
§ Integration Testbench for Electrification Subsystem Motor
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 38SYSTEM TESTBENCH OVERVIEW
DVE*
Emulated World
Battery Univ. Inv. e-ME Grid Emu Load Emu
AVL
inMotion
Automation
Multipurpose Power Switch Box
AVL
PUMA
+ -
DME, DGM
Real World
Battery Inverter Motor Charge Load
HiL Restbus
Kl15,30, CAN,LIN,FlexRay
*DVE = Driver, Vehicle, Environment
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 39SYSTEM TESTBENCH OVERVIEW
DVE
motoric Loads / Sinks Ohmic Loads
AVL e-ME
inMotion Drive Shaft
Load Unit
OR OR OR
Automation universal
electronic
universal loads
Inverter
+
Energy Storage Generator* Charger
+ -
AVL
PUMA
OR Drive Shaft OR
Restbus Load Unit
OR
Grid
Emulator
Product Development in Motion 2015 * considered as DC source Markus Maier | IST-N EU | Nov 2015 | 40HIGHLIGHTS AND POSSIBILITIES
• Realistic Simulation of Driving Cycles with different Start conditions
• NEFZ Cycle with different charging status of the battery
• Different Possibilities to inject Faults / Errors
• Network: Failure of single ECUs / Components
• E-Motor: cut single phase
• Grid Supply: Phase failure, asymmetric phases, Peaks
• Bordnet: Voltage Drops caused from dynamic loads
• HV-Bordnet: Isolation fault, cable breaks
• Excellent Comparison between Emulation and Vehicle Battery especially in
dynamic load scenarios
• Dynamic switching between emulated and real component allows different
use-cases to be tested
• e.g. driver selection switch for operating modes
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 41AGENDA
1. Why
Why do we look into Electrification
2. What
What is an electrified car all about
3. How
How do we develop an electrified car
a. Components
b. Systems
4. Summary
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 42ALTERNATIVE POWERTRAINS IN THE VOL-MIX
(Fuel cell electrical vehicle)
(Battery electrical vehicle)
(Plug-in hybrid electrical vehicle)
(Hybrid electrical vehicle)
(internal combustion vehicle)
Source: California’s Energy Future – Transportation Energy Use in
California; California Council on Science and Technology, 2011
§ As a Summary, the electrification of the Automobile is moving ahead and a lot of
development challenges are ahead of us
§ AVL can supply with the test equipment, that supports in fulfilling the challenging task
Product Development in Motion 2015 Markus Maier | IST-N EU | Nov 2015 | 43THANK YOU
www.avl.com
Markus Maier
Business Manager Electrification and Racing Test Systems
European region
Zettachring 4, 70565 Stuttgart
+49-711-45041-22
+49-171-6925831
markus.maier@avl.comYou can also read
