More Electric Powertrain - Next Generation Hybrids & EV 04 June 2015 Glasgow, UK - NMI
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DRAFT CREATED BY CMB (07/08/2014)
More Electric Powertrain
Next Generation Hybrids & EV
04 June 2015
Dr Will Drury Glasgow, UK
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 1
Agenda
• Introduction
• Hybrid & electric vehicles
• The importance of power electronics developments
• AESIN More Electric Powertrain work-stream
• Conclusions
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 2
Introduction to Ricardo
Ricardo’s Hybrid and Electronic Systems Engineering
Assisting OEMs and Tier 1 Suppliers meet the challenges of vehicle
hybridization and electrification – More than 200 project completed to date
Pre-Concept Concept Development Pre-Production Post Launch
Hybrid and Electrical
Systems Engineering
Passenger Car -- Commercial Vehicles -- Motorsport -- Off Highway -- Agriculture -- Marine -- Defence -- Rail
Flywheel Stationary
Micro to Full Range Fuel Cell Energy Charging Grid
Battery EV Energy
Hybrid Extenders Storage Infrastructure Distribution
Storage
Architecture Battery Pack & Power Hybrid Control Functional Demonstrator
eMachines
Selection BMS Electronics Strategy Safety / ISO26262 Vehicle Builds
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 3
Agenda
• Introduction
• Hybrid & electric vehicles
• The importance of power electronics developments
• AESIN More Electric Powertrain work-stream
• Conclusions
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 4
Hybrid & electric vehicles
Fuel economy regulations for light duty vehicle markets are
converging and for some regions the targets are aggressive
Global regulated & planned targets for CO2 & fuel economy
270
US-LDV California-LDV
Grams CO2 per kilometer, normalised to NEDC
250 Canada-LDV EU
Japan China
230 EU requires 2.6%
S. Korea Australia
annual reduction to
210 achieve target by 2024
190 China proposing
aggressive targets
170
US requires 4.7%
150 annual reduction
130
US 2025:
Solid dots and lines: historical performance China 109
110 Solid dots and dashed lines: enacted targets 2020: 117
Solid dots and dotted lines: proposed targets Japan 2020: 105
Hollow dots and dotted lines: unannounced proposal
EU 2020: 95
90
2000 2005 2010 2015 2020 2025 Gradual global
convergence of
[1] China's target reflects nationwide gasoline fleet scenario. If including other fuel types, the target will be lower.
[2] US and Canada light-duty vehicles include light-commercial vehicles. targets
Source: ICCT
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 5
Hybrid & electric vehicles
xEV Market Snapshot
Light Duty/Passenger Car Global Market Trend 2013 - 2020
Source: Navigant Research via The chart shows the actual figures for hybrid sales
http://www.greencarcongress.com/2013/06/navi-ev- in the US from 2000 to 2006, compared with the
20130611.html
actual sales of PEVs in 2011 and 2012 - then Pike
Research’s projected sales through 2017.
Source: Forbes Magazine
http://www.forbes.com/sites/pikeresearch/2013/02/06/dying-
ev-industry-set-for-growth/
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 6
Hybrid & electric vehicles
xEV Sales Targets
Source: Global EV Outlook – Electric Vehicle Initiative, April 2013.
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 7
Hybrid & electric vehicles
Hybrid & electric vehicles: Key system components
Traction
On-board Energy
inverter eMachine
charger Storage (+ boost)
240 Vac
Fast Charger dc/dc Axillary
converter loads
Hybrid Terminology:
HEV : Hybrid Electric Vehicle
PHEV : Plug-in Hybrid Electric Vehicle
RE-EV : Range Extended Electric Vehicle
(B)EV : (Battery) Electric Vehicle Source: Modified diagram from US DOE APEEM May 2013:
http://www4.eere.energy.gov/vehiclesandfuels/resources/merit-
Hybrid Architectures: review/sites/default/files/ape00a_rogers_2013_o.pdf
P1 : eMachine integrated on engine crankshaft Images
P2 : eMachine integrated between engine and gearbox http://delphi.com/images/mediaRoom/photos/2011/hires/Delphi-Portable-Electric-Vehicle-Charger.jpg
http://www.brusa.biz/uploads/tx_userbrusaproducts/NLG513W__0057_frei_rgbweb700px_01.jpg
P3 : eMachine mounted on gearbox output http://www.mclarenp1-thestory.com/#/default/default-page5.html
P4 : eMachine integrated on axel input http://www.bosch-presse.de/presseforum/details.htm?locale=en&txtID=5159
http://gm-volt.com/wp-content/uploads/2010/01/GMElectricBattery035.jpg
https://www.global.tdk.com/csr/ecolove/sup_pw07.htm
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 8
Hybrid & electric vehicles
Advanced combustion engines & electrified powertrains -
The future of light duty vehicles
SHORT TERM: ~2015 MEDIUM TERM: ~2025 LONG TERM: ~2050
Boosting & downsizing Extreme downsizing with 2 Plug-in/Hybrid and
– Turbocharging & 3 cylinder engines Battery electric systems
Combined turbo/ dominate
– Supercharging
supercharging systems – Very high specific
Low speed torque
Advanced 48 volt hybrid power ICE’s
enhancements
systems dominate 50% lower weight
Friction reduction
PHEV’s in premium & Range of application
Advanced thermal systems
performance products specific low carbon fuels
Stop/Start & low cost
EV’s for city vehicles Exhaust & Coolant energy
Micro Hybrid technology
Significant weight reduction recovery
Niche Hybrid, PHEV’s &
High Efficiency Lean Advanced thermodynamic
Electric Vehicles
Stratified Gasoline Cycles
Weight reduction (5-10%)
Advanced low carbon fuel – Split Cycle?
formulations – Heat Pumps?
Increasing Importance
Source: Ricardo Technology Roadmaps, Ricardo Analysis
of Electrification
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 9
Hybrid & electric vehicles
Operating cycle efficiency is more important in specification of
components than peak values
• System efficiency should be rated over the
operating cycle of the vehicle
• Peak efficiency of systems, whether or not at
maximum power point, is not the right way to
specify or design the most efficient system
• Using WLTP drive cycle it is shown that the
majority of the operating time is spentHybrid & electric vehicles
US DOE TARGETS for system cost & power density
Source: US Department of Energy APEEM 2013
http://www4.eere.energy.gov/vehiclesandfuels/resources/merit review/sites/default/files/ape00a_rogers_2013_o.pdf
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 11Agenda
• Introduction
• Hybrid & electric vehicles
• The importance of power electronics developments
• AESIN More Electric Powertrain work-stream
• Conclusions
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 12The importance of power electronics developments
The development of an inverter is not solely based around
electronics and software capability
• It is important to note that the development of an
inverter is dependant on more than power
electronics
• The software is essential for optimum control of Power
electronics
the electrical machine and for the functional
Functional Power
safety of the inverter and hence vehicle safety passives
• Exacting design of the control electronics is
required keeping the BoM cost down and
performance maximised
System Control
• Thermal design directly impacts semiconductor integration Inverter electronics
selection, efficiency and volume so is considered
by some as the single most important aspect of
the design
Software &
• The mechanical packaging for the vehicle has to Mechanical
Firmware
be robust and suitable for the environment
Thermal
• The final design must be able to be integrated into
the final system and operate as expected
• Functional safety is paramount to this component
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 13The importance of power electronics developments
Inverter Architecture Summary
• In general there is no one architecture that is right, each application should consider all
of those available and trade-off the benefits and the challenges
• The standard 6-switch VSI inverter is still the default choice and we believe it will stay
this way until we start to explore higher voltage batter packs >600V
• Multi-level inverters may have cost benefits, allowing high volume manufactured
MOSFETS to be used in higher voltage applications
• Switched reluctance motors are currently very topical and there is ongoing research
into these
– They have a reputation for being noisy and depending on where the reference
comes from this can be believed or no; it really is application and design specific
• Non PM machines such as induction machines and synchronous reluctance machines
have advantages, but they also have the advantage they use a conventional inverter
topology with modified control software
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 14The importance of power electronics developments
Current developments in power electronics show a good trend
towards more efficient systems using emerging semiconductors
• Increased use of Wide Band Gap devices -
integrated inverters with machines using
SiC and GaN devices
– Additionally these devices may lead to
smaller passive components and
migration into 105°C coolant circuit
[1]
• Passive component development is in dc-
link capacitors - they strongly influence the
size, cost and durability
– Continued improvement in performance
[3]: Integrated machine &
inverter (60kW) – Current trend is towards film capacitors
• Significant size, weight and cost savings
are possible by co-locating all the power
electronics systems to share common
[2] [4] overhead components
[1, 2]: www.a2mac1.com
[3]: http://www.mitsubishielectric.com/news/2014/0213-d.html
[4]: Toyota / Denso
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 15The importance of power electronics developments
SiC and GaN are now emerging to be real competitors to the Si
incumbent in niche areas of the automotive space
Silicon Carbide Gallium Nitride
• There are drawbacks to the use if SiC • GaN has lower breakdown voltage than SiC as
– Large forward voltage meaning the it is a lateral device; there is ongoing research
applications it is applicable for are generally into vertical devices
high voltage (>600Vdc) – In a lateral device, the hold off voltage is
– Cost is significantly greater than for Silicon determined primarily by the distance
between the gate and drain
– Production in automotive volumes has still
not been achieved – As this is extended to achieve higher
operating voltage the switch on-resistance
• Fast switching gives reduced losses but also is increased
increased EMC considerations
– Breakdown through the epitaxial layer to
• There may be a cost trade-off between SiC the Si substrate is determined by the
and Si that would include the thermal cooling thickness of the GaN epitaxial layer
system (currently typical breakdown voltages of
– Currently the packaging is the limit to SiC ~1000V hence the popular 650V devices)
temperature capability but if it could run • Development in GaN devices have given them
hotter then potential to work from air cooled credibility in the industry although they are still
system in their infancy
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 16Agenda
• Introduction
• Hybrid & electric vehicles
• The importance of power electronics developments
• AESIN More Electric Powertrain work-stream
• Conclusions
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 17AESIN More Electric Powertrain work-stream
Introducing…
AESIN work-stream 2: More Electric Power Train
• Continual development of a More Electric
Powertrain is critical to ongoing development
of xEVs
• The key topics being considered are from an
industry led group with key stakeholders being
informed
– Automotive council
– Power Electronics UK
• Topics must align with the Automotive Council,
APC, PEUK and will inform the road-mapping
process
• This has been developed on the back of the
success of the “Connected Corridors” work-
stream
• The aim is not to start a fresh but utilise work
form ongoing research programs (EPSRC,
InnovateUK, etc…)
Source: http://www.greenoptimistic.com/wp-content/uploads/2014/01/transmission-Audi-A3-e-tron-drive-unit.jpg?f8f832 (Accessed 04 Jun 2015)
Source: A2MAC1 (www.a2mac1.com) (Accessed 04 Jun 2015)
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 18AESIN More Electric Powertrain work-stream
Although still in the scoping phase for the new work-
stream, initial concepts being considered...
WBG devices enabling compact powertrains
Electrical machine topology assessment
Wireless Charging
Architecture analysis
Integration of electronics and machine drive
Integration with future transmission technology
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 19Agenda
• Introduction
• Hybrid & electric vehicles
• The importance of power electronics developments
• AESIN More Electric Powertrain work-stream
• Conclusions
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 20Conclusions
Conclusions
• The power electronics and e-drive market is growing fast
– Power electronics in the automotive sector will flourish as there will multiple variants of
xEV in the future (HEV, PHEV, RE-EV and FC EV)
• Still need to overcome significant commercial and technical challenges
– Reducing cost and improving reliability, while increasing power density and efficiency
– Thermal engineering is critical to development
• AESIN is looking to drive forward the More Electric Powertrain and this initiative is looking to
solve the OEM / Tier 1 driven technical issues
– This will leverage ongoing UK research programs
– Work cross sector, through the industry and with academia
– More information will be published soon!
• Power electronics in this sector is exciting and continues to push boundaries and embrace
emerging technologies
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 21Any questions?
Ricardo UK Ltd. – Cambridge Technical Centre,
400 Science Park, Milton Road,
Cambridge, CB4 0WH, UK
Dr Will Drury MEng PhD CEng MIET MIEEE
Team Leader – Electric Machines & Power Electronics
Hybrid and Electronic Systems Business Unit
Direct Dial: +44 (0)1223 223 265
Reception: +44 (0)1223 223 200
Mobile: +44 (0)7525 197 906
Fax: +44 (0)1223 223 300
will.drury@ricardo.com
www.ricardo.com
Unclassified - Public Domain 4 June 2015 © Ricardo plc 2015 22You can also read
