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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
Public
CII Autmotive R&D Trends 2017
3
March 09, 2017
Thalavai Venkatesan, © Continental AG
Powertrain Our Vision: Clean Power
Public
CII Autmotive R&D Trends 2017
4
Powertrain Main Drivers
March 09, 2017
Thalavai Venkatesan, © Continental AG
Public
CII Autmotive R&D Trends 2017
5
March 09, 2017
Thalavai Venkatesan, © Continental AG
Continental Powertrain OutlookGlobal PV/LV Engine Production (2015-2030)
Public
CII Autmotive R&D Trends 2017
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
Public
CII Autmotive R&D Trends 2017
7
March 09, 2017
Thalavai Venkatesan, © Continental AG
Continental Powertrain’s Vision & Main Drivers
Introduction to Electrification
Electrification Tailored to Fit
1
2
3
Agenda
Public
CII Autmotive R&D Trends 2017
8
March 09, 2017
Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017
9
March 09, 2017
Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017
10
March 09, 2017
Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017
11
March 09, 2017
Thalavai Venkatesan, © Continental AG
Continental Powertrain’s Vision & Main Drivers
Introduction to Electrification
Electrification Tailored to Fit
1
2
3
Agenda
Public
CII Autmotive R&D Trends 2017
12
March 09, 2017
Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017
13
March 09, 2017
Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017
14
March 09, 2017
Thalavai Venkatesan, © Continental AG
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)
Public
CII Autmotive R&D Trends 2017
15
March 09, 2017
Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017
P2 – Side Attached BSG Concept
16
March 09, 2017
Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017
17
March 09, 2017
Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017
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
Public
CII Autmotive R&D Trends 2017
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
19Thalavai Venkatesan, © Continental AG
Public
CII Autmotive R&D Trends 2017 March 09, 2017
20Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017 March 09, 2017
21Thalavai Venkatesan, © Continental AG
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
Public
CII Autmotive R&D Trends 2017
22
March 09, 2017
Thalavai Venkatesan, © Continental AG
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