a3ps conference eco mobility 2012 e-mobility flagship –...
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A3PS Conference Eco Mobility 2012E-Mobility Flagship – VECEPT
Beste FrankAVL List GmbH11.12.2012
2Dr. Frank Beste, AVL List GmbH, 11.12.12
and Variants
of non-conventional powertrain by 2020
Source: Boston Consulting Group, AVL
CHALLENGE: Diversification of Vehicle and Powertrain Concepts
3Dr. Frank Beste, AVL List GmbH, 11.12.12
CHALLENGE: Increasing Powertrain Complexity
Control Strategy
Battery
Electric Motor
TransmissionIC Engine
System: Vehicle /Powertrain
System: Driver System: Environment
4Dr. Frank Beste, AVL List GmbH, 11.12.12
“Best in Class” HEV regarding FC
Competitive constant velocity FC
“Best in Class” add-on costs for PHEV drivetrain
AVL ELECTRIC VEHICLE3 reasons to build an AVL PHEV demonstrator….
7Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPT
KickOff VECEPT Förderprojekt am 18.10.2012, Klima und EnergiefondVECEPT - Vehicle with Eost-Efficient Power Train
Ziel:VECEPT fokussiert sich auf die Entwicklung und Erprobung eines alltagstauglichen, kostengünstigen PHEV als Volumenmodell für den Weltmarkt (geplanter Markteintritt 2017), das eine international wettbewerbsfähige Kombination aus Leistungsfähigkeit (Reichweite, Komfort, Sicherheit) und Kostengünstigkeit darstellt. Einerseits wird ein Demo-Fahrzeug mit einem neu entwickelten Antriebsmodul und neuen Komponenten aufgebaut, das eine rein elektrische Reichweite von mehr als 30 km und höchste Effizienz in allen Betriebsmodi aufweisen soll, und dabei sämtliche erwartete Emissionsstandards sowie Produktionskriterien hinsichtlich Fertigung und Qualität erfüllt. Gesamt Volumen: 7.042.549,- EUR, Förderung: 2.803.800,- EUR Projektlaufzeit: 02.07.2012 – 01.07.2015 Konsortialleiter: AVL List GmbH Konsortialpartner: AIT GmbH, ecoplus GmbH, Fluidtime Data Service GmbH,
IESTA, Infineon AG, IVD GmbH, Magna Steyr Battery Systems GmbH & Co OG, Verbund AG, VIF mbH, Samariterbund Wien GmbH, Uni Wien
8Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPT
KickOff VECEPT Förderprojekt am 18.10.2012, Klima und EnergiefondVECEPT - Vehicle with Eost-Efficient Power Train
Arbeitspakete AP1 Entwicklung von Fahrzeugkomponenten & Integration ins Gesamtfahrzeug entwickelter und getesteter Demonstrator (AVL List GmbH)
AP2 Steigerung der Energieeffizienz und der Sicherheit des Gesamtfahrzeuges Integrierte Steuerung für das Thermo- und Energie-Management + (Gewichts-, Energie-) optimierte Batterie (Magna Steyr Battery Systems GmbH & Co OG)
AP3 Anwendungen, Nutzerverhalten: Strategisches Planungs-Software-Framework für das Management gemischter Flotten (AIT GmbH)
AP4 Infrastruktur: Installation und Betrieb von Ladestellen + Verhaltensmuster von Nutzern (Verbund AG)
AP0.3 Evaluierung & Qualitätsmanagement: Umfassende Evaluierung der AP1-4 unter realen Bedingungen (VIF mbH)
9Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPTVehicle Specification & Vehicle Targets
Top Level Specification Unit DescriptionVehicle Class [-] C-segment (e.g. VW Golf MQB, Prius 3)Transmission [-] 4-gear transmissionICE [-] 1.0L, IL3, TGDICO2 emission (certified in NEDC) [g/km] < 50 (FC ≈ 2.1L/100 km)CO2 emission (full hybrid mode in NEDC) [g/km] < 79 (“Best in Class”)Emission legislation [-] EU06_1Fuel [-] RON 95Electric Range (AER in NEDC) [km] > 20Acceleration 0-100km/h (Hybrid) [s] < 11 (ICE + E-Motor)Max. velocity (ICE only) [km/h] > 170 (capable for 180)
Fuel Consumption – Losses: Best in Class Fuel Consumption• Energy Demand: the amount of energy to drive the vehicle through the reference cycle shall be
minimized; the energy harvesting out of cycle operation shall be maximized (recuperation) Reduce vehicle weight & friction Reduce auxiliary / board net power demand
• Losses: the losses inside the components & powertrain shall be minimized Improve the operational efficiency of all component in the relevant operation areas
• Efficiency: the efficiency of all components (propulsion as well as supporting / auxiliaries) shall be optimized to minimize the amount of primary energy increase the working / conversion efficiency of every component in the relevant operation areas
10Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPTSensitivity analysis
70
75
80
85
90
95
-50 0 50 100sust
aini
ng m
ode
CO
2 em
issi
on (h
ot) [
g/km
]
change to proposal [%]
ITWF0ITW + F0BSFC*
Aux. PowerEnergy Demand*****
Prius3
±1class
±1class
BSFCmin = 245 g/kWh
3cyl (1.2L)
800WWLTC v5 * note: effects influence sustaining mode only
** referred to driven distance
*** note: temperature influence may change depending on distance
Displacement*
Proposal
Prius3
11Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPTPowertrain Configuration: Plug In Hybrid - Proposal
• ENG: Combustion Engine• IL2; 0.8L; TGDI (or TMPI)• Atkinson combustion cycle• cooled EGR• 12V Starter* (high performance)
• D: Damping Element• Isolation of torque fluctuations from
Gearbox input Shaft
• sCL: Separation Clutch• friction clutch (OPEN) – not for launch• capable for impulse start
• 4 spd TNT: Transmission• Integrated electric drive (45kW)• shifting w/o torque interruption• integrated final drive & differential• DC/AC: power electronics – chassis
mounted*
* for demonstrator build up
• HV BAT: Plug In Hybrid Battery• Charging Unit (2x* 3.3kW)• HCU: Hybrid Control Unit
• Hybrid Functions• Vehicle & Driver Interface
• Cooling System (ENG, EM, PE, GBX, BAT)• DC/DC – LV Board Net Supply (1.5 .. 2kW)• Driver Comfort (conventional AC System)
12Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPTVehicle Functional Targets & Requirements
Functional Targets – Functions for Demo Vehicle Presentation
• Plug In Mode – Pure Electric Mode• The demonstrator support a plug in operation mode – to use primary the energy charged from the
grid; performance in pure electric mode is limited to normal driving in city & extra urban areas (in highway operation v>125km/h, the engine mode is activated)
• Full vehicle performance is available only in hybrid mode
• Forced Sustaining Mode (i.e. Range Mode)• if the grid energy is completely used or the demanded performance is to high, the vehicle change
into the sustaining mode; this mode could be selected by the driver manually (demonstration)
13Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPTPowertrain & Vehicle Functionality – Overview
Remark: The engine could provide drive torque only above a specific velocity limit (no mech. launch element) The engine could be activated at standstill to re-charge the HV Battery – if Park is applied by Driver Vehicle max. acceleration is available in Hybrid mode only (e.g. in EV mode: 0-60km/h in ≈7s) Vehicle max. velocity is not available in Pure Electric mode (limited to ≈130 km/h)
Driv
e
Bra
ke I
Bra
ke II
Bra
ke II
I
Sto
p / S
tand
still
Cre
ep
Driv
e
Acc
eler
atio
n I
Vehi
cle
Velo
city
Acc
eler
atio
n II
Sto
p / S
tand
still
Pure Engine conventional
Pure ElectricBattery Powered
Pure ElectricBattery Powered
Engine Charging
Engine Charging
HybridEl. supported Drive / Drive & Charge
14Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPTICE – operation in sustaining mode
** NEDC optimized simple open loop strategy
* BSFC < 240 g/kWh
15Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPTCompetitor comparison at constant velocity
16Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPTDriving Strategy
SOC
Velocity
Time / Range
certified0 25 HEVmode
25certified0 25 HEVmode
25HEV mode
Ene
rgy
cont
entb
atte
ry AER
86 g/km0 g/km
Standard vehicle
79 g/km0 g/km
Optimzed vehicle
48 g/km
Certified CO2
41 g/km
Electric Driving Electric DrivingICE only Drive and Charge
17Dr. Frank Beste, AVL List GmbH, 11.12.12
E-Mobility Flagship – VECEPTPowertrain Cost Assessment
Reduction Potential
18Dr. Frank Beste, AVL List GmbH, 11.12.12
AVL DRIVETRAIN ELECTRIFICATION
Contact: Dr. Frank BesteSenior Program Manager Electric Vehicle and Range Extender
Phone: +43 664 8509 209E-mail: [email protected]