Synthesis, Analysis and Evaluation of Drive Concepts12th International CTI Symposium, December 2013, Berlin Dr.-Ing. Bartosch Czapnik, Volkswagen Group Research

Agenda

Motivation and objectives

Systematic synthesis of drive concepts

Application of methodology

1886 1950 1970 1990 20101769

Motivation and objectivesBandwidth of alternative drives

Motivation and objectivesDrive concept in a very early phase

Drive conceptsTechnologies

Motivation and objectivesProcedure in methodology

METHODOLOGY

Synthesis Analysis Evaluation

aver. = 90%mspec.= 1.6 kg/kWvspec. = 0.4 l/kWkspec. = €35/kW

ELECTRIC MOTOR

RESULT

Diesel drive

Compressed-air driveHydraulic drive

Hydrogen drive

Flywheel drive

Battery drive

…

…

REQUIREMENTSvmax = 170 km/htacc = 11 s

s = 400 kmtcharge = 300 min

Base vehicle

TECHNOLOGY LIBRARY

Vdrive,max = 400 l

Mechanical energy

Systematic synthesis of drive conceptsMain function of a vehicle drive and basic parts of drive energy chain

Available energy source

Energy Infrastructure Vehicle

Drive energy chain

Changing the type Changing the time Changing the size Changing the location

Energy transducer

Energy storage

Energy transmitter

Energy transformer

Output

Input

mechan. Energie

hydraul. Energie

chemische Energie

thermische Energie

nukleare Energie

elektrische Energie

Strahlungs-energie

magnet. Energie

mechan. Energie

hydraul. Energie

chemische Energie

thermische Energie

nukleare Energie

elektrische Energie

Strahlungs-energie

magnet. Energie

mechanisch -

mechanisch

hydraulische -

mechanisch

chemische -

mechanisch

nukleare -

mechanisch

thermische -

mechanisch

elektrische -

mechanisch

magnetische -

mechanisch

Strahlung -

mechanisch

mechanisch -

hydraulisch

hydraulische -

hydraulische

chemische -

hydraulische

nukleare -

hydraulische

thermische -

hydraulische

elektrische -

hydraulische

magnetische -

hydraulische

Strahlung -

hydraulische

mechanisch -

chemische

hydraulische -

chemische

chemische -

chemische

nukleare -

chemische

thermische -

chemische

elektrische -

chemische

magnetische -

chemische

Strahlung -

chemische

mechanisch -

nukleare

hydraulische -

nukleare

chemische -

nukleare

nukleare -

nukleare

thermische -

nukleare

elektrische -

nukleare

magnetische -

nukleare

Strahlung -

nukleare

mechanisch -

thermische

hydraulische -

thermische

chemische -

thermische

nukleare -

thermische

thermische -

thermische

elektrische -

thermische

magnetische -

thermische

Strahlung -

thermische

mechanisch -

elektrische

hydraulische -

elektrische

chemische -

elektrische

nukleare -

elektrische

thermische -

elektrische

elektrische -

elektrische

magnetische -

elektrische

Strahlung -

elektrische

mechanisch -

magnetische

hydraulische -

magnetische

chemische -

magnetische

nukleare -

magnetische

thermische -

magnetische

elektrische -

magnetische

magnetische -

magnetische

Strahlung -

magnetische

mechanisch -

Strahlung

hydraulische -

Strahlung

chemische -

Strahlung

nukleare -

Strahlung

thermische -

Strahlung

elektrische -

Strahlung

magnetische -

Strahlung

Strahlung -

Strahlung

pneumat. Energie

pneumat. Energie

pneumatisch -

mechanisch pneumatisch

-hydraulische

pneumatisch -

chemische pneumatisch

-nukleare

pneumatisch -

thermische pneumatisch

-elektrische

pneumatisch -

magnetische pneumatisch

-Strahlung

mechanisch -

pneumatisch

hydraulische -

pneumatisch

chemische -

pneumatisch

nukleare -

pneumatisch

thermische -

pneumatisch

elektrische -

pneumatisch

magnetische -

pneumatisch

Strahlung -

pneumatisch

pneumatisch -

pneumatisch

mechan. Quelle

hydraul. Quelle

chemische Quelle

thermische Quelle

nukleare Quelle

elektrische Quelle

Strahlungs-quelle

magnet. Quelle

pneumat. Quelle

mechan. Energie

hydraul. Energie

chemische Energie

thermische Energie

nukleare Energie

elektrische Energie

Strahlungs-energie

magnet. Energie

mechan. Energie

hydraul. Energie

chemische Energie

thermische Energie

nukleare Energie

elektrische Energie

Strahlungs-energie

magnet. Energie

mechanisch -

mechanisch

hydraulische -

mechanisch

chemische -

mechanisch

nukleare -

mechanisch

thermische -

mechanisch

elektrische -

mechanisch

magnetische -

mechanisch

Strahlung -

mechanisch

mechanisch -

hydraulisch

hydraulische -

hydraulische

chemische -

hydraulische

nukleare -

hydraulische

thermische -

hydraulische

elektrische -

hydraulische

magnetische -

hydraulische

Strahlung -

hydraulische

mechanisch -

chemische

hydraulische -

chemische

chemische -

chemische

nukleare -

chemische

thermische -

chemische

elektrische -

chemische

magnetische -

chemische

Strahlung -

chemische

mechanisch -

nukleare

hydraulische -

nukleare

chemische -

nukleare

nukleare -

nukleare

thermische -

nukleare

elektrische -

nukleare

magnetische -

nukleare

Strahlung -

nukleare

mechanisch -

thermische

hydraulische -

thermische

chemische -

thermische

nukleare -

thermische

thermische -

thermische

elektrische -

thermische

magnetische -

thermische

Strahlung -

thermische

mechanisch -

elektrische

hydraulische -

elektrische

chemische -

elektrische

nukleare -

elektrische

thermische -

elektrische

elektrische -

elektrische

magnetische -

elektrische

Strahlung -

elektrische

mechanisch -

magnetische

hydraulische -

magnetische

chemische -

magnetische

nukleare -

magnetische

thermische -

magnetische

elektrische -

magnetische

magnetische -

magnetische

Strahlung -

magnetische

mechanisch -

Strahlung

hydraulische -

Strahlung

chemische -

Strahlung

nukleare -

Strahlung

thermische -

Strahlung

elektrische -

Strahlung

magnetische -

Strahlung

Strahlung -

Strahlung

pneumat. Energie

pneumat. Energie

pneumatisch -

mechanisch pneumatisch

-hydraulische

pneumatisch -

chemische pneumatisch

-nukleare

pneumatisch -

thermische pneumatisch

-elektrische

pneumatisch -

magnetische pneumatisch

-Strahlung

mechanisch -

pneumatisch

hydraulische -

pneumatisch

chemische -

pneumatisch

nukleare -

pneumatisch

thermische -

pneumatisch

elektrische -

pneumatisch

magnetische -

pneumatisch

Strahlung -

pneumatisch

pneumatisch -

pneumatisch

mechan. Quelle

hydraul. Quelle

chemische Quelle

thermische Quelle

nukleare Quelle

elektrische Quelle

Strahlungs-quelle

magnet. Quelle

pneumat. Quelle

Systematic synthesis of drive conceptsTechnology library

Mechanical

Mechanical

Electrical Electrical

Electrical Source

Electrical Source

Electrical -

Mechanical Electrical

-Mechanical

Electrical

Chemical -

Mechanical Chemical

Mechanical

Electrical -

Electrical Electrical

-Electrical

Chemical Energy

Electrical Energy

Chemical Energy

Electrical Energy

Mechanical. Energy Mechanical. Energy

Electrical Energy

Electrical Energy

Electrical

Chemical

Source Source… …

Source

… … …

Source

…

Source

……

… Source…

Source

Source

Source

…

Source

…

…

…… …Source

…

…

… …

…

… … … … …

…

Systematic synthesis of drive conceptsMorphological process of synthesis

Mechanical energy

Source

Mechanical energy

Energy

Drive energy chain

Electric motor

Li-ion battery

Electricity Mechanical energy

Available energy source

Infrastructure Vehicle

Battery charger

Systematic synthesis of drive conceptsSystematic shifting of system boundary

Infrastructure expense

Externally driven drive concepts

Mobile-supplied drive concepts

Storage-supplied drive concepts

ExamplesInfrastructure expense

Systematic synthesis for drive conceptsTypes of drive concepts

Investigation of traditional and alternative drivesDefinition of two application cases

Requirements and constraints

Short-distance vehicle

Long-distance vehicle

Maximum speed vmax 130 km/h 200 km/h

Acceleration t0-100km/h 15 s 10 s

Range sNEDC 150 km 500 km

Charging time tcharge,100% 540 min 5 min

Auxiliary equipment load PNV,NEDC

200 W 200 W

Vehicle segment Small car Mid-range

Max. drive volume Vmax 300 litres 600 litres

Annual distance driven 12,000 km 20,000 km

Ranking

Short-distance vehicle

Long-distance vehicle

1. Natural gas drive€10.73/100 km

Natural gas drive€11.55/100 km

2. Petrol drive€11.36/100 km

Diesel drive€11.89/100 km

3. Diesel drive€11.61/100 km

Petrol drive€13.02/100 km

4. Battery-powered drive€16.71/100 km

Fuel cell drive€37.65/100 km

5. Fuel cell drive€25.55/100 km -

Investigation of traditional and alternative drivesResulting total costs

Petrol engine

Natural gas engine

Electric motor Fuel cell Li-ion

battery

Costs +30% +/- 0% -60% -80% -65%

Efficiency +5% +7% +2% +4% +1%

Mass -5% -10% -30% -25% -40%

Volume -7% -20% -15% -40% -55%

Diesel Petrol Natural gas Hydrogen Electricity

Costs +80% +60% +50% +/- 0% +20%

…

Sources: McKinsey – A portfolio of power-trains for Europe; SupplierBusiness - The Advanced Automotive Energy Storage Report;Roland Berger – Powertrain 2020; Wallentowitz – Strategien in der Automobilindustrie; Expertengespräche (Strategies in the Automobile Industry; Expert Meetings)

Investigation of traditional and alternative drivesPredictions for 2020

Ranking

Short-distance vehicle

Long-distance vehicle

1. Battery drive €10.42/100 km

Natural gas drive€11.14/100 km

2. Natural gas drive€10.83/100 km

Petrol drive€16.54/100 km

3. Petrol drive€14.32/100 km

Diesel drive€16.74/100 km

4. Fuel cell drive€14.98/100 km

Battery drive€20.49/100 km

5. Diesel drive€15.56/100 km

Fuel cell drive€23.62/100 km

(4.)

(1.)

(2.)

(5.)

(3.)

(2.)

(3.)

new

(4.)

Investigation of traditional and alternative drivesResulting total costs in 2020

Compressed-air drive

Hydraulic drive

Capacitor drive

Flywheel drive

Features of vehicle Value and unit

Vehicle weight without drive mveh.,excl.drive 300 kg

Drag coefficient cd 0.18

End face A 1.5 m²

Maximum drive volume Vdrive,max 200 litres

Maximum speed vmax 100 km/h

Acceleration time t0-60 km/h 10 s

Unconventional drives in city carsDrive concepts and constraints

Compressed-air drive

Hydraulic drive

Flywheel drive

Capacitor drive Battery drive

Unconventional drives in city carsEnergy consumption vs. range in ECE

Ene

rgy

cons

umpt

ion

in k

Wh/

100

km

Range in km

Linear motor drive

Induction drive

Overhead wire drive

Linear motor ≈ 8

Million €D-kmOverhead wire ≈ 2

Induction system ≈ 6 Million €D-km

Million €D-km

Mobile-supplied and externally driven drive conceptsDrive concepts and route-related costs

D-km = double kilometres (there and back)

Route type Total length Share of length

Share of distance driven

Municipal roads 460,000 km 66.6% 28.0%

District roads 91,700 km 13.3% 8.0%

Country roads 86,600 km 12.5% 17.0%

B-roads 39,900 km 5.7% 15.5%

Motorways 12,800 km 1.9% 31.5%Sources: German Federal Ministry of Transport, Building and Urban Development; German Federal Statistical Office; German Federal Environment Agency; ISV (University of Stuttgart)

Statistics

Car population 42,302,000

Annual average distance driven per car in km 14,160

Mobile-supplied and externally driven drive conceptsCar statistics and traffic network in Germany

0

2

4

6

8

10

0 10 20 30 40 50 60 70 80 90

Driv

e-re

late

d pu

rcha

se c

osts

in th

ousa

nd €

Driving costs in €/100 km

Linear motor drive

Petrol drive

Diesel drive

Natural gas drive

Overhead wire drive

Induction drive

Mobile-supplied and externally driven drive conceptsPurchase costs vs. driving costs (forecast for 2020)

Driv

e co

sts

in th

ousa

nd €

Driving costs in €/100 km

Thank you!

“If I had asked people what they wanted, they would have said faster horses.”

― Henry Ford