Economic Concepts and Solutions for Hybrid … · © ZF Friedrichshafen AG, 2008 Bernd Vahlensieck, Frank-Detlef Speck, Ralf Kubalczyk, Presented by Dr. Rolf Gall ... TI-H – 8 Economic

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Bernd Vahlensieck, Frank-Detlef Speck, Ralf Kubalczyk, Presented by Dr. Rolf GallZF Friedrichshafen AG, ZF Getriebe GmbH

Economic Concepts and Solutionsfor Hybrid Drivelines

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Economic Concepts and Solutions for Hybrid Drivelines

Agenda

� Introduction

� CO2 Legislation and Market for Hybrid Drives

� Possible approaches

for CO2 reduction

� Summary

� Parallel Hybrid concepts and solutions

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Agenda



for CO2 reduction

� Summary


� Introduction

JSAE Paper: 20085071

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2007 at a glance

480.000

Commercial Vehicles

Off road machineryPassenger cars

80.000

694 Mio. €

584 Mio. €

57.372

12.649 Mio. €

1.300.000

Transmission production (as an example)

R&D expenses

Capital expenditure

Employees

Sales

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CO2 reduction potential of Driveline and Chassis Technology

Transmission

6 %

Optimization

Chassis / Driveline

up to 5 %

Hybrid technology

up to 25 %

Electro-

mechanical

steering

up to 3 %

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Agenda

� Introduction


for CO2 reduction

� Summary




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CO2 penalty proposed by the European Union*

6HP and light weightconstruction -100 kg CO2-costs 2012: 619 € (+ 16 €)

8HP Full Hybrid(consumption – 25 %)CO2-revenue 2012: 346 €(- 949 €)

8HP (consumption – 6 %)CO2-costs 2012: 396 € (- 207 €)

EU

pro

po

sa

l=

VD

A 6

0%8HP and start-stop (consumption – 11 %)

CO2-costs 2012: 213 € (- 390 €)8HP, start-stop and electric steering (consumption – 15 %)CO2-costs 2012: 82 € (- 521 €)

1400 1500 180017001600

130

140

150

160

170

180

190

200

CO

2e

mis

sio

n [

g/k

m]

Vehicle mass [kg]

6HP and 4-wheelCO2-costs in 2012: 852 € (+ 249 €)

Base vehicle 6HP (6-speed AT)Otto engine (3 l), model year 2007

CO2-costs 2012: 603 €

*) Proposal of the European Commission, Nov. 11, 2007. 2012: 20 €/gCO2; 2015: 95 €/gCO2

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Forecasts of Hybrid Passenger cars and light commercial vehicles

2005 2010 2015 2020

0 %

5 %

10 %

15 %

20 %

Mercer: 1,1 Mio. in 2011

J.D.Power:3,7 Mio. in 2013

Morgan Stanley:7-10 Mio. in 2015

GlobalInsight: 0,6 Mio. in 2009

Glo

ba

l m

ark

et

sh

are

of

Hyb

rid

ve

hic

les

Freedonia: 4,3 Mio. in 2015

(2004: 7,5 Mio.)

Global Insight: 1,5 Mio. in 2011

Advanced Automotive Batteries: 2,0 Mio. in 2015

Freedonia: 8,5 Mio. in 2020 (2004: 11,5 Mio.)

Freedonia: 1,8 Mio. in2010 (2004: 2,7 Mio.)

Forecast in 2007

Forecast in 2006

Forecast in 2004

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Agenda

� Introduction


� Summary



for CO2 reduction


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Possible approaches for CO2 reduction

CO2

CO2

Alte

rna

tive

Fu

els

today tomorrow far future

Electric Vehicles

Ele

ctr

ic P

ow

er

fro

m t

he

pu

blic

gri

d

Fo

ssil

Fu

els

Optimization of conventional

Drives (Transmission, Combustion Engines)

Alternative Drives (e.g.

Hybrid Drives)

Fuel Cell Vehicles

Hydro

gen

Hydrogen Engine

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Solution field for Hybrid drives

Module Hybrid systemHybrid

transmissionComponentComplexity

Axle

SerialPower-split

ParallelBase Hybrid architecture

AT (DCT)

Plug-InFullMildMicroLevel of

Hybridization

(e)CVT

Commercial Vehicles, …

MT

Upper

AMT

Medium

AT (Planet)

(Base) transmission

SmallVehicle class

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Complexity of Hybridtechnology vs. Scope of delivery

Hybrid components

Hybrid modules

Hybrid transmissions

Hybrid systems

+ Battery+ functions

+ Regenerative brake+ functions

+ Transmission+ functions

+ Clutches+ Torsion dampers+ functions

Electric motor + Power electronics+ functions

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Base architectures for Hybrid drives

SerialPower-SplitParallel

Generator

Generator/Motor

Generator

Battery

Battery

Battery

Motor

+ -+ -

+ -

Motor

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Solution field for Hybrid drives Current focus of ZF

Module Hybrid systemHybrid

transmissionComponentComplexity

Axle

Serial(Bus)

Power-Split

ParallelBase Hybrid architecture

AT (DCT)

Plug-InFullMildMicroLevel of

Hybridization

(e)CVT

Commercial Vehicles, …

MT

Upper

AMT

Medium

AT (Planet)

(Base) transmission

SmallVehicle class

Not in the focus

Partially in the focus

In the focus

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Agenda

� Introduction



for CO2 reduction

� Summary



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Parallel Hybrid concepts I Mild Hybrid / Full Hybrid

Mild Hybrid

� Crankshaft Starter Generator CSG

� Electric Motor directly connected to ICE

� No Clutch

Full Hybrid

� Clutch between Electric Motor and ICE

� Optimal use of electric motor possible

� Additional clutch, integration into the transmission preferred

PSM

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Modular kit for passenger car Hybrid transmissions

Micro Hybrid

Mild Hybrid Mild+ Hybrid

8 HP

8-speed base transmission (Hybrid ready AT)

Full Hybrid

IAE

IAE IAE

IAE: Integrated Launch Device

HIS: Hydraulic Impulse Storage

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8HP70 and HIS®

Hydraulic Impulse Storage

Hydraulic Control

HIS®

� Spring operated

� Mechanically locked

� Capacity app. 100 cm³

� Pressure level 3 ... 7 bar

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Full Hybrid transmission for passenger cars

� Base transmission 8HP (AT)

� Torque converter functions replaced by electric motor

� Actuation of Clutch 0 with existing hydraulics

� Permanently exited synchronous machine

� Inner rotor design

�Power range 10 to 30 kW

� Package installation space neutral

Integrated launch device(existing shift element)

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Hybrid Component and Module Hybrid Transmission and System

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Full Hybrid Transmission Solution for Commercial Vehicles

� Base transmission AStronic lite

� Electro-hydraulic automation

� SAE 2 engine flange

� Dry launch clutch

� Permanently exited synchronous machine

� Inner rotor design

� Power: app. 60 kW

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Parallel Hybrid concepts IIAxle Hybrid / Electric Axle

Axle Hybrid

�Electric Motor at wheel or differential

� Feasible as module for Serial or Parallel (full) Hybrid or pure electric drive

�AWD function as additional benefit

� Flexibility concerning package

�No starter or generator function

Electric Wheel Drive for Buses

�Electric Motors close to the wheels

� Flexible use in Serial Hybrid and other electric propulsion systems

�Beneficial in city bus applications

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Axle hybrid module for passenger cars

� Electric Motor

� Axle drive

� Power electronics

axle parallel / east-west coaxial / north-southcoaxial / east-west

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Battery/Hybrid

Aerial line

Diesel-electric

Fuel cell

Electric axle for city Buses

� Flexibility in package space

� Possibility of low-floor concept

� Flexibility in alternative propulsions

� Additional driven axle(s)

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Agenda

� Introduction



for CO2 reduction


� Summary


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Summary

Economic Hybrid Solutions

Cars

CV’s

Buses

Mild

Full

Micro

Components

Systems

Transmissions

Modules

Partnership

Focus on economic

concepts

Highcommitment

Return on invest ?Legislation ?

Goals: CO2 reduction, Increase of Driving Efficiency

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Thank you for your kind attentionContact: [email protected]

Documents

Economic Concepts and Solutions for Hybrid … · © ZF Friedrichshafen AG, 2008 Bernd Vahlensieck, Frank-Detlef Speck, Ralf Kubalczyk, Presented by Dr. Rolf Gall ... TI-H – 8 Economic