Austrian Association for
Alternative Propulsion Systems (A3PS)
Task 17System Optimization and Vehicle Integration
Final Presentation
4-6, November, 2015
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Table of contents
Introduction
Task 17
Initial Position
Definition
Member Countries
Scope & Impacts
Working Methods
Final Report
Results
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Global megatrends strongly influence
the future of our mobility
Urbanization Demographic changeClimate change
Sustainable
power source
Spend less
energy
From A to B
hassle free
Use
intermodality
Safely
mobility of
elderly people
“Zero emission”
by EV
“Intelligent mobility”through, telematics & Smart Grids
“Zero accidents”
by stability control and
predictive ADAS systems
Will lead to new kind of mobility concepts
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Global megatrends strongly influence
the future of our mobility
Focus on efficient transport and zero impact on the environment
Advanced driver assistance systems & autonomous driving will be
required
Environment, Smog, CO2
CongestionParking
Demographic
change“Demographic mind
change” &Digital lifestyle of the
younger generation
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The future of our mobility requires xEVs
Connectivity
Automated
Driving
Alternative Fuels
Light-
weighting
Shared Mobility
Fuel Cell
Shift to Asia
Digital
Experience
ICE
Advancements
New Retail
xEVs (BEVs, HEVs, PHEVs, FCEVs,…)
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Task 17 - Initial position
Market introduction & hurdles of xEVs
Sales numbers are far behind expectations
The difficulties are often focused on:
• battery performance
• charging time
• costs and
• missing charging infrastructure
Other aspects are less considered
Integration & configuration of components
reduction of vehicle costs enlargement of customer acceptance
Image courtesy of Renault and Wiener Linien
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Task 17 - Definition & Members
Idea: to start a technically oriented Task, focusing on the topics which
haven’t been considered so far (2010)
Task 17: System Optimization and Vehicle Integration for
Enhanced Overall Vehicle Performance
Analyzes technology options for the optimization of EV components
and drive train configurations which will enhance the vehicle energy
efficiency performance
Member countries:
Austria, Germany,
Switzerland, United States.
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Task 17 - Scope & Impacts
Task 17:
OEMs-review of different strategies/technologies for xEVs
Analysis of existing component technologies (potential)
Overview/analysis of different simulation tools (design
considerations)
Improvements in energy efficiency, operational safety, durability
Integration and control of software solutions
Reductions in weight, volume, cost
Drive train configurations
Image courtesy of Renault
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Task 17 - Working Methods
Working methods basically included:
Questionnaires & Personal interviews
Foresight analyses of future options and opportunities
Simulation of different component configurations
International networking and Information exchange
Dissemination of results of participating countries
Technology assessment report
Workshops
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Task 17 – Workshops (2010-2015)
Output: Several topics for System Optimization
3 Operating Agents
84 Speakers& 131
Participants9 Workshops @
7 Locations
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Task 17 - Workshops - Speakers
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Task 17 - Workshops - Topics
Performance Assessment
E-Motors and Batteries
Simulation Tools
Thermal/ Battery Management
Lightweight Concepts and Materials
E/E-Architecture and Power Electronic
Drive Train Technologies
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Task 17 - Results - Final Report
Cover: www.creativequantumjumps.com
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Task 17 - Final Report
Introduction and Development of xEVs
OEM and Industry Review
Markets
Strategies
Current technologies
Comparison of different
vehicle specifications
(cost, durability, energy,
power density, etc.)
International Deployment & Demonstration Projects
Incentives
International demonstration projects
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Task 17 - Final Report
Advanced Vehicle Performance Assessment
Vehicle technologies (HEV, PHEV, BEV)
HEV - results
Fuel economy results
Engine On-Off capability
Engine utilization
Regen
Improvement by thermal management
EV - operation comparison
Configuration & operational differences
Battery utilization & recharge efficiencies
Electric powertrain efficiency comparisons
Auxiliary loads (HEV, PHEV, BEV)
Standby auxiliary losses
Hot & cold temperatures
Future trends Image courtesy of ANL
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Task 17 - Final Report
System Optimization and Vehicle Integration
E-motors
PM - motors
Induction - motors
SR - motors
Battery management systems
Definition & description
Determination algorithms (SoC and SoH)
Integration of BMS into an EV
Examples of integrated BMS into an EV
Technology Trends
BatPaC: A Li-ion battery performance &
and cost model for EVs
Selection of BMS suppliers & manufacturers
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Task 17 - Final Report
System Optimization and Vehicle Integration
Thermal management
Heating technologies
Automotive thermal comfort by Valeo
Nanofluids for cooling by ANL
EKo-Lack: simulation & measurement
of an energy efficient infrared radiation
heating of a BEV
Simulation tools –
overview of International Research Groups
Definition & description
CRUISE - Vehicle System Simulation (by AVL)
Autonomie (by ANL)
Dymola/Modelica (by AIT)
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Task 17 - Final Report
System Optimization and Vehicle Integration
Lightweight
Vehicle mass impact on efficiency & fuel economy (by ANL)
Functional & innovative lightweight
Simulation
Materials
Bionic
Functional Integration
Power Electronics & Drive Train Technologies
Reasons for an increasing amount of software & electronics
Electrified drive trains leads to increasing complexity
Benefits through optimized power electronics & drive train technologies
Image courtesy of GF and
Fraunhofer
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Task 17 - Results (2010-2015)
Task 17 output:
lightening the car, improving the ECU,
optimizing of thermal management solutions as well as
improvement of the battery management system
enhances the overall performance of an xEV.
Worldwide nearly 900,000 BEVs & PHEVs
Estimation: 1 Mio. till the end of 2015
Predictions: EV market will reach 8% of total car sales by 2020 2.5 Mio. BEVs
3.1 Mio. PHEVs
6.5 Mio. HEVs
(Source: Bosch, 2015)
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Task 17 - Results (2010-2015)
Batteries
A lot of progress in the field of electrochemical storage devices and FCEVs
During the last decade costs have been falling rapidly and are expected
to continue doing so for the next (10) years (Source: CEA)
The battery’s durability is already expected to be sufficient for automotive
use, giving ten years calendar life and 150,000 mi. (Source: CEA)
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Task 17 - Results (2010-2015)
Thermal & Battery Management
Standby losses were highly varied
among the vehicles: Volt & Sonata
losses were similarly three times
higher than those of the Prius
Generally increased speeds and
accelerations/ aggressive driving
translate to higher energy
consumption (except for the
conventional one)
Highly efficient vehicles can offer very
high fuel efficiency, but these benefits
rapidly deteriorate in hot and cold
conditions
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Task 17 - Results (2010-2015)
Thermal and Battery Management
Running the heater off battery
energy in electric-only mode of
either a PHEV or BEV can double
the consumption rate (reducing the
range to one-half)
Cold start energy consumption is
larger than the hot start energy
consumption (BEV)
Largest energy consumption
increase for an EV occurs at -7°C
(20°F) and for a conventional one
at 35°C (95°F)
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Task 17 - Results (2010-2015)
Simulation Tools
xEVs increasing complexity of vehicles
building hardware is expensive
Greater emphasis has to be placed on
modeling and simulation (reduce costs &
improve time to market)
Need for expertise to perform the required
sophisticated simulations and calculations
Predicted future driving information like
route based energy management (deterministic
& stochastic information) will play a key role
The work on Task 17 pointed out, that the
demand for companies, focusing on simulation
tools for EVs, is still increasing
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Task 17 - Results (2010-2015)
Lightweight (Leaf (2011), Fusion Hybrid (2012), Fusion ICE V6 (2012))
Dynamometer study by ANL
General rule of thumb: for every 10% reduction in
vehicle weight the fuel consumption of vehicles is
reduced by 5-7%
The light weighting benefits on fuel/energy
consumption depends on the driving type
City type driving & aggressive type driving light
weighting any vehicle type will reduce the
energy/fuel consumption
Highway type driving light weighting vehicles
doesn’t significantly reduce the energy/fuel
consumption
Image courtesy of ANL
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Task 17 - Results (2010-2015)
Output: lighter vehicles require less
power on average to complete a
driven cycle the load demand on
the powertrain is lower lower
powertrain efficiency
Energy savings on the highway
cycle are relatively low
Better tire technology, aerodynamics,…
would significantly reduce the energy
consumption
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Task 17 - Results (2010-2015)
The largest
proportional energy
change occurred in the
city/ aggressive-type
driving
(vehicle mass has a direct
impact on the inertia
energy required to move
the vehicle forward)
In the absolute energy or fuel savings graphs, lightweight conventional
vehicles provide the largest fuel savings per mass saved, because the
conventional vehicles have the lowest vehicle efficiency
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Task 17 - Results (2010-2015)
Lightweight
Chassis dynamometer testing of fuel- or
electrical energy consumption showed that
in city-type driving, a 10% mass reduction
can result in a 3 to 4% energy consumption
reduction for the conventional ICE engine,
HEVs, and BEVs
Bionic concepts: reduces development time,
minimizes development costs, identifies new
light weight solutions, finds efficient
concepts in product development
New materials: sandwich materials
(combination of different materials to
improve the total abilities)
Image courtesy of Airex, 4a Manufacturing and AWI
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Task 17 - Results (2010-2015)
Lightweight
Functional integration:
will play a major role in future vehicles
(reduce the amount of total parts)
Functional integration: reduces weight,
helps to improve the driving abilities
and leads to a fundamental technology
turnaround
Don’t forget about LCA!Image courtesy of Fraunhofer & DLR
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Task 17 - Results (2010-2015)
Power Electronics & Drive Train Technologies
Automotive industry: traditionally mechanical but
the amount of software & electronics is increasing
rapidly challenge
Customer demands for ADAS, connectivity, trend
towards autonomous driving systems are
becoming increasingly complex
xEVs present unique challenges
Today: conventional vehicle:
20-35% content of IT; E/-E-Architecture
In xEVs, this share will increase to up to 70%
(70 main controllers/ more 13,000 electronic
devices)
Image courtesy of BMW
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Task 17 - Results (2010-2015)
Power Electronics & Drive Train Technologies
Future: every second Euro/Dollar will be spend on the production for
electronics (Source: CEA)
Currently, the share of electronic components to the manufacturing cost is
around 30%, by 2017 it will grow to 35% and will still increase to 50% in
2030 (Source: Bosch)
Image courtesy of Renault
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Task 17 - Results (2010-2015)
Power Electronics & Drive Train
Technologies
Fields of importance:
modular drive train topologies
to increase the chances for a
market breakthrough of xEVs by
providing a better opportunity for
high production volumes
layered, flexible & scalable
architecture to enable different
system aspects (e.g. uniform
communication, scalable/flexible
modules)
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Task 17 - Results (2010-2015)
Change within the Automotive Value Chain
E-mobility massive changes along the
automotive sector’s entire value chain
Impact of all areas
Traditionally: the ICE was almost the
component with the highest value within
the value chain
Future: xEVs components (ICE, clutch,
exhaust system, etc. won’t be needed
any more new and additional
components
(power electronics, e-motor, software,…)
will be necessary
Power electronic unit & e-motor will be on the top of the hierarchy
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Task 17 - Results (2010-2015)
Further hybridization/ electrification is inevitable in order to reach the global
consumption requirements: EU: 95 gCO2/km (4.1 l/100 km petrol || 3.6 l/100 km diesel)
ICE: further fuel savings are still possible (diesel: 10% / petrol up to 20%).
SUVs & heavy vehicles won’t reach the 95 gCO2/km limits though (Source: Borsch)
xEVs don’t mean the “end of the ICE” but xEVs will sooner or later dominate
Austrian Association for
Alternative Propulsion Systems (A3PS)
Thank you for your attention!
Questions?