Hybrid Powertrains R&D Vehicle Engineering Thalavai …tntdpc.com/automotive-2017/Thalavai Venkatesan .pdf · mature markets, and ... 2 targets will be achieved via a system approach,

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Hybrid Powertrains – R&D Vehicle Engineering

Thalavai Venkatesan

www.continental-automotive.de Powertrain

Public

CII Autmotive R&D Trends 2017

2

March 09, 2017

Thalavai Venkatesan, © Continental AG

Continental Powertrain’s Vision & Main Drivers

Introduction to Electrification

Electrification Tailored to Fit

1

2

3

Agenda

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March 09, 2017


Powertrain Our Vision: Clean Power

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Powertrain Main Drivers

March 09, 2017


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March 09, 2017


Continental Powertrain OutlookGlobal PV/LV Engine Production (2015-2030)

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Powertrain VisionPeak Combustion Expected Latest in 2025 - 2027

6

Global PV/LV Production*

Propulsion Split (Standard Scenario)

Global PV/LV Production*

Electrification View (Standard Scenario)

[mn. vehicles]

40

60

80

100

120

0

20

2030

89

103

2015

118

2020

112

2025

Gasoline48VEV

PHEV

DieselM/FHEV

CNG/LPG

26.0

8.3

13.0

FHEV 48VEV PHEV

2030202520202015

Peak

› Vehicle electrification is

making a decisive step

forward “Peak

Combustion” expected

2025

› Cost optimized 48V

solutions will be found in

each mid class car in

mature markets, and …

› …pure EV will win the

race against heavy hybrid

solutions

* Source: Powertrain Outlook 2030 (May 2016)

** US, China, Japan, EU

3,5

March 09, 2017Thalavai Venkatesan, © Continental AG

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March 09, 2017





1

2

3

Agenda

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March 09, 2017


Brief History of Electrified Vehicles

More electric

vehicles

than gasoline

engine cars

on the road

1888

Since 1912

decreasing

electric vehicle

sales

1899 1990

1990s: New

attempt with

electric vehicles

2015

Today: Promising

successes through

combination of

combustion engine

and electric motor

Future

?

Source: Wikimedia; Continental

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March 09, 2017


Electric Vehicle (EV) and Plug-in Hybrid (PHEV) Electric Driving on a Daily Basis

› 50 km electric range sufficient

for 60 to 70% of the vehicles

› Attractiveness increased through:

› Comfortable and fast charging

› Increasing energy density of batteries

› Intelligent route planning and driving strategy considering low emission zones, charging spots, dy-namic traffic data,...

30

Nu

mb

er

of

Ve

hic

les

[%

]

< 10

Daily Mileage [km]

75 to 10050 to 7525 to 5010 to 25

25

20

15

10

5

0

Germany

USA

Source: Continental Mobility Study 2011

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March 09, 2017


Electric Vehicle (EV) and Plug-in Hybrid (PHEV) Increasing Demand on Power and Fast Charging

› Option 1: Double voltage

› Accelerate charging

› Requires 1200 Volt IGBT

› Option 2: Double current

› Cables with larger diameter

› Dedicated connectors

› More IGBT

500

Ele

ctr

ic P

ow

er

[kW

]

Past

300

200

100

0

Now Future

Option 1:

800 V

450 A

Option 2:

400 V

900 A400 V

450 A

400 V

225 A

x2

x2

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March 09, 2017





1

2

3

Agenda

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March 09, 2017


12 Volt Micro Hybrid Hybridization for Small Engines

› CO2 reduction of 3.5% on top

of Stop/Start

› Major lever for CO2 reduction:

Engine Off Coasting and Recuperation

› Stabilized boardnet enables the

simplification of components

› Pumps and actuators can react

faster, reduce weight and costs

Hybrid boardnet11...16 Volt

Stabilized boardnet11...14 Volt

Dual Battery Manager

› Controls energy flow

› Ensures minimum voltage level

› Enables Engine Off Coasting

LeadAcid

Battery

Li-Ion Battery

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March 09, 2017


48 Volt Mild HybridMarket Starts with Belt Starter Generator Configuration (P0)

› 15 kW Belt Starter Generator› 3 kW DC/DC Converter› 0.5 kWh Li-Ion Battery

Configuration: › Market introduction of 48V Mild Hybrid starts

with Belt Starter Generator, replacing the12V alternator

› 13% CO2 saving in NEDC, mainly by

recuperation

› In real driving: Active coasting (20 to 25% of

driving time) leads to additional 8% CO2 saving

› Fast and comfortable engine start

› NOX reduction (Diesel: 10% in NEDC)

› 48 Volt consumers enabled

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System Approach with 48 Volt Mild HybridCovering Engine, Transmission and Exhaust Aftertreatment

Mild Hybrid

Down Speeding

Shift operation point

Exhaust Management

Thermal Management

Combustion Optimization

7.0%

4.5%

2.5%

1.5%

1.0%

0.5%

› Enhanced Stop/Start, recuperation

and engine off coasting

› Electric energy completely

generated in recuperation phases

› Additional torque during acceleration

› Turbo gap closed by 48V E-Motor or

› 48V super-charger

› Engine operating point shifted

› Higher efficiency, and reduced

wiring with additional 48V consumer

Possible levers with 48V Mild Hybrid:

Example: CO2 savings measured w. the Gasoline Technology Car:

CO2 saving in total: 17% (based on a 3 cyl. Engine)

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March 09, 2017


Connected 48 Volt Mild Hybrid SystemEfficient Driving Strategy by Connected Energy Management

› Further CO2 reduction in real driving

› Optimized driving strategy

› Enhanced energy management

› Maximize coasting and recuperation

› Efficient engine operation points

Sp

ee

d [km

/h]

Road [m]

100

Coasting

60

Recuperation

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P2 – Side Attached BSG Concept

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March 09, 2017


TransmissionCombustion

engine

Front Rear

P2

P4

P3

Example: Front Mounted, Rear Drive, longitudinal drive orientation

P0 – BSG HP Gen1

14 kW

53Nm

15 kW

53Nm

GTC2 demo

vehicle

P1/P2 – ISG L25

Up to 25 kW

Up to 200Nm

OEM discussions

for series

P3 / P4 Concepts

20-30 kW

55-100Nm

Concept Studies

P2 – BSG L16

16 kW

55Nm

Series order

expected

P0

Indicated peak power and peak torque in generator mode

SOP

end 2016

48V Mild Hybrid MotorsTopology & Applications Continental

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SOP

SOPDC/DC Converter 3.2kW48V – 12V, bi-directional, ASIL-C compliant

DC/DC Converter Gen 2

DC/DC Converter 1.6kW48V – 12V, bi-directional, ASIL-C compliant

Basis / 2015 2016 2017 2018 2019 2020

SOP

SOP Possible SOPStart of production (SOP) SOP

48V DC/DC ConverterProduct Roadmap

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Plug-in Hybrid DriveSave Fuel and Drive on Electricity – for Everyday Driving

Brake

Control

Unit

Engine Control Unit HMI

(Human

Machine

Interface)

Electrical Machine

Electric

Vacume

Pump

Electric Vehicle

Controller

Transmission

Control Unit

Electric Water

Pump

Accelerator

Force

Feedback

Pedal

Li-Ion High

Voltage Energy Storage

Conti

eContact

Tires

Inverter,

DCDC

Converter

March 09, 2017

18Thalavai Venkatesan, © Continental AG

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Pure Electric DrivingZero Emissions

Brake

Control

Unit

HMI (Human

Machine Interface)

Electrical

MachineElectric

Vacume

Pump

Electric

Water Pump

Accelerator

Force

Feedback

Pedal

Inverter, DCDC

Converter

Electric

Vehicle

Controller

Conti

eContact

Tires

Li-Ion High

Voltage Energy Storage

March 09, 2017


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CII Autmotive R&D Trends 2017 March 09, 2017


Motor

Reducer

Reducer

Inverter

Motor

Inverter

Signal-Input

Rotating

axis output

High Voltage-Input

Parking

Lock

Continental Axle Drive System Integrated E-Motor Solution for PHEV and EV Applications

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CII Autmotive R&D Trends 2017 March 09, 2017


PlatformEMR Gen. 3

Base

Stator active OD (fix) 190mm 190mm

Stator active L (scalable) 125 - 175 - 225 mm 175mm

Rotor active (selectable) PSM, MagRM or IM PSM

Cooling Water jacket Water

Weight ~67kg … ~87kg ~75kg

Housing Customized

InverterGen. 2.8

450A … 550A

Gen. 2.8

450A

Software EPF 2.8

Safety Level ASIL C(D) ASIL C(D)

Gear Ratio (scalable) 7.5 – 12.5 ~9.3

Parking Lock (optional) Yes Yes

Decoupling device

(optional)Yes -

Max. EM Speed ≤ 14.000rpm ≤ 14.000rpm

Max. EM Torque 190Nm … 420Nm ~270Nm

Max. EM me. Power 80kW … 140kW ~120kW

Continuous Power 40kW .. 65kW ~60kW

Dimensions 400x500x320mm

Highlights

› Highly integrated Electric Drive System with inverter,

electric machine and reducer

› Reduced efforts at customer for integration, sourcing,

validation

› Variable rotor/stator length and gear ratio enables

scalable performance

› Re-use of proven technologies like power electronics

ensures high maturity

› High power density provides compact packaging

Platform Axle Drive System Gen.3System Overview

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Hybrid SystemsSolution Tailored to Fit

Customerbenefit

Hybridization will become a common feature in all vehicle segments – adapted to the respective needs

Modularsystemsolution

Vehiclesegment

Systemcost

› There is not one hybrid solution for the entire market

› CO2 targets will be achieved via a system approach,

including vehicle, engine and transmission

› Energy management optimization will be

supported via navigation system and connectivity

› Charging comfort and time will be optimized

via inductive charging technology

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March 09, 2017


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Your questions?

March 09, 2017


Documents

Hybrid Powertrains R&D Vehicle Engineering Thalavai …tntdpc.com/automotive-2017/Thalavai Venkatesan .pdf · mature markets, and ... 2 targets will be achieved via a system approach,