System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
ARPA-E Powertrain Innovation Workshop
Industry Mobility Energy Smart Home Smart City
Vision: Connected World
1
Li Jiang
Advanced and System Engineering
Gasoline Systems
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
ARPA-E Powertrain Innovation Workshop
2
Legislative Requirements and Powertrain Trends
EPA GHG LT/MDV mpg
22.3
(24.9)
36.5
(41.6)
54.8
(62.3)
CO2
g/km
l/100
km
8.6
(7.5)
6.4
(5.7)
4.3
(3.8)
gasoline
(diesel)
130
175
EU LCV
EU PC
95
147
183 166
119
146
166
217
229
192
LEVIII LEVII NMOG 0.035 g/mi NMOG+NOx 0.1 g/mi ….. 0.030 g/mi SULEV
Phase 5 Step 2
EU5 / OBD
Phase 6 Stage1
FTP75
ULEV50/70
Phase 6 Stage 2
Beijing Drive Cycle
SULEV30, no fleet average, PN/PM limit
50
100
150
200
2010 2015 2020 2025
137 EPA LT
99 EPA PC
70 EU Com. PC (NEDC)
EPA GHG PC
PN: tbd for new cycle PN: 6*1011 1/km
WLTC ? Emissions Test: NEDC PN: 6*1012 1/km upon choice of manufacturer
China
Beijing
Phase 4
Phase 5 Step 1
EU5
Europe under Discussion
China – Beijing Phase 6 new and under discussion
US CARB
ICE Optimization
Optimization of
Conventional
Powertrain
100 China Nation
Powertrain
Electrification
PM CARB 10mg/mi 3mg/mi 1mg/mi
Brazil L7 under Discussion
Proconve L6 Proconve L7 FTP75, NMOG+NOx = 0.08g/km Proconve L5
EU7 EU6c EU5 EU6b
2010 2015 2020 2025
CO2
g/mi
80
160
240
320
US National Regulations
EPA GHG targets combined
2016 250 g CO2/mi ~ 35.5 mpg
2025 163 g CO2/mi ~ 54.5 mpg
EU Regulations
2016 130 g CO2/mi ~ 5.5 l/100km
2025 Not yet determined
China Regulations
2016 164 g CO2/km (6.9 l/100km)
2025 95 g CO2/km (4 l/100km)
Brazil Regulations
2016 136 g CO2/mi (1.82 MJ/km)
2025 Not yet determined
Increasingly stringent legislative targets pushes new technologies.
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
ARPA-E Powertrain Innovation Workshop
Evolution of Electrification
Electrification Level
PHEV
CO
2 R
ed
ucti
on
Po
ten
tia
l
sHEV
mHEV <60V
Recuperation
Coasting
Boost
Advanced Start/Stop
Start/Stop
Recuperation
Boost
e-Drive
Coasting
Recuperation
Boost
e-Drive
Coasting
A
Start
Stop 2
4 6
x 1000 / min
40
80 120
160
200 km/h
<20 0
A
Start
Stop 2
4 6
x 1000 / min
40
80
160
200 km/h 0
120
A
Start
Stop 2
4 6
x 1000 / min
40
80
160
200 km/h 0
120
A
Start
Stop 2
4 6
x 1000 / min
40
80
160
200 km/h 0
120
2 4
6
x 1000 / min
40
80 120
160
200 km/h
A
Start
Stop 0 ~0
Coasting
Start/Stop Coasting
µHEV
A
Start
Stop 2
4 6
x 1000 / min
40
80
160
200 km/h 0
~120
3
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
ARPA-E Powertrain Innovation Workshop
4
2020 Engine and Transmission Technologies Projection
Transmission Production Engine Production 2020
WEU US CN JP
(AT) Automated Step Transmission
(CVT) Continously Variable Transmission
(DCT) Double Clutch Transmission
(AMT) Automated Manual Transmission
(PG) Planetary Gear
90% of AT = AT8+
Bosch prognosis for
PC & LCV<6t (mio. vehicles) WEU US CN JP
(P)HEV,BEV
CNG
PFI
Diesel
GDI
15
mio
vehic
les
10
mio
tra
nsm
issio
ns
Production projections confirm the trend toward advanced powertrain concepts
and ramp up of electrification
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
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Powertrain System Domains
Transmission Control & Components
Improvements of up to 10% by allowing for optimal ICE operation,
mechanical and actuation efficiency
Internal Combustion Engine (ICE)
Improvements of up to 15% by downsizing, combustion concept
and operation strategy
Air
Management
Fuel Injection
& Ignition
Fuel Supply
Turbocharger
Electrification
Additional benefit of
as much as 35% by recuperation and ICE relief
Power Electronics Electric Drives
Battery incl. Control
Baseline Vehicle: • 1300kg Compact Car
• 2.0L gasoline PFI natural aspirated
• 6-speed AT
What will be the impacts of Vehicle Connectivity and Autonomous Driving?
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
ARPA-E Powertrain Innovation Workshop
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Environment Modeling
Connected Vehicle technologies provide preview into the future, enabling
determination of optimized trajectory for powertrain
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
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Roadmap to Fully Automated Driving Integrated Cruise Assist
Highway Pilot
Autonomous Driving allows decoupling of driver inputs, allowing optimized
dynamic powertrain control for improved efficiency
• Operation Strategy Optimization
• Minimize Abrupt Transient Operations in Engine
• Enable Engine Technologies with High Efficiency but Compromised
Performance
How will this complement the evolution of electrification? …
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
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Opportunities and Challenges Control
Powertrain: Engine, Transmission, Electrification
• Predictive Control
How much preview is required for real-time optimization? …
• Control Models with more details
How much details are required? Data-driven online adaptation? …
• Real-Time Vehicle Individual Optimization
On-board or off-board computation? What is the communication protocol?
OEM calibration certification? …
How to account the real-world benefits towards fuel economy certification?
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
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Powertrain Operation Strategy
The synergies among Electrification, Connected Vehicles, and Autonomous
Driving maximize fuel efficiency potentials of powertrain strategies VCR: Variable Compression Ratio | COD: Cylinder On Demand
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
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Example: Multi-Mode Combustion
Preview into the future helps avoid unnecessary combustion mode switches,
resulting in 1-2% drive-cycle fuel economy improvement
Penalty for unnecessary
switching of combustion modes
• Fuel economy
• Time / Performance
Research in collaboration with Powertrain Control Laboratory at University of Michigan (S. Nϋesch, A. Stefanopoulou)
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
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Example: Optimized Transmission
Transmission strategy optimization can enable significant fuel economy savings
Concept 1. Future vehicle speed trajectory is known
2. Transmission gear optimized for better
efficiency while still meeting upcoming
performance requirements
2. Measurement Data
Optimal strategy involves upshifting &
downspeeding where possible
Efficiency gains are significant Engine Speed
Engin
e L
oa
d
Typical Shift
Strategy
Optimal
Strategy
FTP-75 HWFET Combined
Cycle
Original [mpg] 24.0 38.5 28.9
Optimized [mpg] 27.5 40.0 32
Improvement [%] +14.6% +3.9% +10.7%
Research in collaboration with Powertrain Control Laboratory at University of Michigan (S. Nϋesch, A. Stefanopoulou)
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
ARPA-E Powertrain Innovation Workshop
12
• US market dominated by
Step-AT transmissions;
which do not inherently
support SSC (requires
design changes)
• Power-net stabilisation
needed for functional safety
and robustness (synergies
to 48V)
Example: Start-Stop Coasting
New
sy
ste
m c
ha
llen
ges
Start/Stop Coasting
Fuel Savings (real-world)
Ve
h. S
peed
Coasting
6th gear,
Fuel Cut-off
Rolling Distance
Reduced Drag Torque
Drivetrain Open/Engine Off
Roadblocks
New
sy
ste
m s
olu
tio
ns
Increased rolling distance
Engine Off Time
+27%
~10%
Start/Stop Coasting
Start/Stop
Engine Restarts
Start/Stop Coasting
Start/Stop
Stress for engine starter system and
power-net
Impact on Powertrain
+~350k
…400k
+<200k
~150k…250k ~4% Start/Stop
Start/Stop Coasting
Up to 10%
Engine Trans-
mission
Regulatory
• Certification cycles do not
support SSC (fixed speed
profile)
• Off-cycle credits can be
awarded, but data collection
needed from the real-world
fleet tests
Technical
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
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Synergies for Start-Stop Coasting and 48V mHEV BRS Features (User Experience)
Engine start: - Start quality and response time is attractive for SSC
- Enables high number of start cycles not possible with existing
systems
CO2 benefit: - Benefit of Coasting and Recuperation are typically additive
- improved regenerative braking at 48V is used to supply power net
during coasting phases
- use cases are independent from each other:
“coasting” if driver releases gas pedal, “recuperation” if driver
presses brake pedal
System requirements: - mHEV power nets are “SSC ready”:
- 2nd energy storage (redundancy)
- Robust with respect to charging/decharging cycles
- High dynamic charge acceptance (efficient recuperation)
No
ise level*
* d
B(A
)
30
40
50
60
70
80
0 1 2 3 4 time [s]
** 100 cm in front of vehicle with open engine hood
G
DC DC
Li-Ion
48V
?
PbAc
SV
S HV
14V
Simulation Baseline:
compact class, 1500kg
gasoline
7-gear DCT (dry, el-hydr)
Start/Stop
Intelligent generator control
Pel=300W (power net)
FTP75 (exploitingspeed tolerance band)
simulation validated
for 1.4l engine
IDC w/ DCT
1.5 2.0 2.5 3.0 3.5 4.0
Engine displacement [l]
CO
2 b
en
efit [%
]
0
2
4
6
8
10
12
14
16
18
20
validated for:
3.5l engine,
1900kg,
7gear-automatic
transmission w/
TC (AT)
validated for: 3.0l engine, 2315kg (SUV),
8gear-automatic transmission w/ TC (AT)
BRS w/ DCT
BRS & SSC w/ DCT
SSC w/ DCT
Independent
simulation:
3.6l engine,
2100 kg
pickup, 8 gear
automatic
transmission
w/ TC (AT)
Cycle data:
31 mi / 56 min driving
12 mi Interstate (39%)
15 mi >40mph (48%)
4 mi <=40mph (13%)
most common St/St
Highway City
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
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Start-Stop Coasting w/ DCT in Real World
DCT: Dual Clutch Transmission
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
ARPA-E Powertrain Innovation Workshop
15
Driver Impacts on Start-Stop Coasting
5.21% 5.46% 5.36%
23.89%
7.95%
16.31%
0%
5%
10%
15%
20%
25%
30%
City Highway Overall
Ch
an
ge
in
MP
G
1st Drives Instructed Coasting
38%
11%
51%
Drive Mode Distribution: Best Performer without
Instruction Coasting Stop Engine On
54%
9%
37%
Drive Mode Distribution: Educated Operator
Coasting Stop Engine On
21%
8%
71%
Drive Mode Distribution, Average Distribution
Coasting Stop Engine On
System Engineering | 5/15/2015 | This presentation does not contain any proprietary, confidential, or otherwise restricted information | © 2015
Robert Bosch LLC and affiliates. All rights reserved.
ARPA-E Powertrain Innovation Workshop
16
Gϋnter Radtke, 1974