DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN - Gerhard Vosloo, Rimac Automobili d.o.o. IPG Apply & Innovate 2020
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DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN Gerhard Vosloo, Rimac Automobili d.o.o. IPG Apply & Innovate 2020
AGENDA
‒ Introduction
‒ Background and motivation
‒ Development process
‒ Targets
‒ Use case: longitudinal performance
‒ Use case: track performance
‒ Use case: range and efficiency
‒ Correlation and validation
IPG Apply & Innovate
2020
DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 2
WHO WE ARE
− Founded: 2009 (first employees in April 2011)
− Team today: 700+ people (400+ in R&D)
− Completed B2B projects: 30+
− Developed, produced and delivered
world’s fastest electric supercar
− Tier 1 supplier to 10 Global OEMs
− Total investment so far: ~€140M
− Deloitte technology fast 50: 10th place 3 Offices in Croatia
4 consecutive years amongst top 100
Zagreb
− Awarded as the best employer in Croatia Osijek
− European Business Award Split
- Joint Venture in China signed
- World Premiere of the - Rimac builds Nobuhiro - Dealer network expansion in
- First car delivered
Concept_One, world’s Monster Tajima’s race car three continents – North
- Intense development and
first all-electric supercar for the Pikes Peak America, Europe and Asia
- Rimac Automobili is testing of Rimac All Wheel
- 10 employees International Hill Climb. - 250 employees - Hyundai Motor Group becomes a shareholder
founded in Sveta Nedelja, Torque Vectoring System.
Croatia. - 100 employees - 500+ employees
- Porsche increases stake in Rimac
2008 09 10 11 12 13 14 15 16 17 18 19 20
- Mate Rimac converts his - Mate Rimac breaks 5 - Rimac completes its first - The Concept_One becomes FIA - Contracts with major OEMs - World premiere of Rimac’s next - Testing and
BMW E30 into an Guinness and FIA World B2B project for IDIADA. Formula E’s official Race Director - Production model of the generation hypercar, the C_Two development of
electric race car and the records for the fastest First revenues. car Concept_One introduced. - Porsche becomes a shareholder the C_Two
idea is born accelerating electric car. - First OEM projects - First production vehicle contract - Significant expansion of - 400+ employees continues
- First profitable year - A-round completed facilities - further expansion of production - More than 700
facilities employees
- Opening of offices in Split and
Osijek
- Launch of the Xianyang JV location
OEM PROJECTS
Development of an powertrain Development of an electric
system and electronics of version of Hyundai Motor’s N
Automobili Pininfarina Battista brand midship sports car and
electric hypercar. a high-performance fuel cell
electric vehicle.
Development and production of Development and manufacturing
the Aston Martin Red Bull batteries and power distribution
Valkyrie supercar hybrid battery units for the Koenigsegg Regera
system, infotainment and hypercar.
connectivity system
Development of full EV system
for CUPRA (SEAT) e-racer Developed an electric version of
prototype the iconic Jaguar E-Type, which
was used as the groom and
bride car for the Meghan Markle
and Prince Harry’s royal
wedding.
VEHICLE ENGINEERING HYPERCARS TECHNOLOGY A new approach to high performance Technology developed from the ground through technology and innovation up, driving the electric revolution
HYPERCAR |
2.5 sec 14 sec 1224 hp 355 km/h 1600 Nm 350 km
0-100km/h 0-300km/h 900 kW Electrically limited From 0 to 6500rpm On a single charge
Debuted at the 2011 Frankfurt International Auto Show
HYPERCAR | 1.85*sec 1914 hp 412 km/h 2300 Nm 550 km 0-100km/h 1400 kW Electrically limited From 0 to 6500rpm On a single charge
C_TWO • Globally homologated • 4 independently controlled electric motors power each wheel • Rimac all-wheel torque vectoring • Full carbon fibre monocoque with structurally integrated battery pack • Active Aerodynamics • Autonomous driving capabilities • Driving Coach
OUR SERVICES
BACKGROUND & MOTIVATION
‒ Hypercar EV segment
‒ Low volume
‒ Less cost conscious
‒ Incorporates latest and most advanced EV technology
‒ Electric vehicles (EV) are undergoing exponential growth and development
‒ Electric motors
‒ Inverters
‒ Battery Cells
‒ Battery pack design and cooling
‒ Architecture
IPG
Apply & Innovate
2020
DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 11THE CHALLENGE FOR EV HYPERCARS
Rapid prototyping and flexibility to adapt and include latest EV technology
… or risk being left behind by competitors!
“If you aren’t first you’re last” – Ricky Bobby
IPG
Apply & Innovate
2020
DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 12THE DEVELOPMENT PROCESS
IPG CarMaker
Design iteration
Powertrain
Overall vehicle
Performance
Targets Layout & other Battery Inverters Motors
status
Parameters
Component level test data
Subsystem (e.g. front powertrain)
Vehicle level test data
IPG
Apply & Innovate
2020
DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 13TARGETS*
*Targets listed does not represent actual targets of the Rimac C_Two
‒ Performance:
‒ Longitudinal
e.g. 10 x 0-100-0 km/h without overheating/de-rating
‒ Track
e.g. 1 lap of Nürburgring, Nordschleife without any power de-rating
‒ Range:
e.g. 550+km on WLTP
IPG
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DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 14LONGITUDINAL PERFORMANCE
Performance analysis at lower SoC
NOTE: Results are given as an example, data is not representative of current, nor previous status
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2020
DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 15TRACK PERFORMANCE ANALYSIS: Nürburgring Nordschleife
Performance comparison of different battery pack designs
Nürburgring Nordschleife
Difference in
Battery pack
Simulated Lap Time
design
[s]
1 0.0
2 -20.3
3 -6.8
4 -17.3
NOTE: Results are given as an example, data is not representative of current, nor previous status
IPG
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DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 16ELIMINATE BOTTLENECKS FOR A HOLISTIC DESIGN
Improved cooling
performance
Higher sustained Increased thermal
Higher demand on
power output and durability
rest of powertrain
from battery requirements
Improved cell
chemistry/design
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DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 17RANGE AND EFFICIENCY ON WLTC CYCLE
Consumption and identifying losses
WLTC consumption, range and losses
Consumption XXX.X Wh/km Powertrain efficiency
Range XXX.X km based on WLTC cycle
Aerodynamic Losses 23.4%
Contribution of Losses
Battery 1.5% Front Rear
Powertrain Inverters 11.8% Motor 92.0% 91.0%
Losses Motors 13.5% Inverter 96.0% 95.0%
Gearbox 6.8% Gearbox 97.6% 97.5%
Friction Brakes 2.8%
Tyre Rolling Resistance 31.9%
Auxliary 8.3%
NOTE: Results are given as an example, data is not representative of current, nor previous status
IPG
Apply & Innovate
2020
DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 18CORRELATION AND VALIDATION OF SIMULATIONS
Increased variables and complexity
COMPONENT
SYSTEM LEVEL VEHICLE LEVEL
LEVEL
• Battery • Front and/or Rear Axle • Full system integration with
all control systems
• Motor & Inverter • Controlled operating conditions
• Variable operating conditions
• Gearbox • Controlled cooling environment
• Driver in the loop
• Limited control
IPG
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2020
DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 19For any additional information you might need, feel free to contact me.
Gerhard Vosloo
Vehicle Dynamics Engineer
M +385 91 3336 506
Gerhard.Vosloo@rimac-automobili.com
Rimac Automobili d.o.o.
Ljubljanska 7
10431 Sveta Nedelja
rimac-automobili.com
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