battery-electrical & hybrid-electrical vehicles magneti marelli

May 2010

Battery-Electrical & Hybrid-Electrical Vehicles

MAGNETI MARELLI

BNDES Presentation

MAGNETI MARELLI PROPRIETARY & CONFIDENTIALRJ Brazil, May 2010

Magneti Marelli experience on HEV/BEV Componentes


MM interdivisional Team on Hybrid & Battery Electri c

Vehicle component development

� Three main products development with modular concept :

� Motor-generator to cover a range from 15 up to 90 Kw

� Power inverter with DC/DC up to 90 Kw

� Battery management Unit for Li-Ion Battery pack

� MM has launched an Interdivisional team that involves resources of Powertrain, Electronic Systems and Motorsport Divisions together with external suppliers


Prototype Builder

Partner B

Hybrid Road Map : PARTNERSHIP STRUCTURE

ElectricElectric

motorsmotors University support

HEV HEV BATTERIESBATTERIES

Partner 1

External engineeringExternal engineering

Partner A

PowerPowerElectronicsElectronics

Partner 2

Supplier Y

Supplier X

Engineering Support


ELECTRONICSYSTEMS EXHAUST

SYSTEMS

POWERTRAIN

SUSPENSION

SYSTEMS(Suspension Systems,

Cofap Shock Absorbers,SDC)

Company Overview

Magneti Marelli is an international group leader in developing and

manufacturing high-tech automotive systems and components.

With 46 Production Sites (56 production units), 9 R&D Centers and 27 Application Centers in 16 countries and a workforce of ~28,000, Magneti Marelli is a world class global automotive supplier .

AUTOMOTIVE

L IGHTING

MOTORSPORT

AFTERMARKETPARTS & SERVICES

Plastic


AMT

Power inverter

DC/DC &AC/DCConverter

Vehicle Management Unit

Motor

Generator

Internal Development & Production :

• Design • Development• Prototypes (2010)• Manufacturing (2012)

Technical partnership• Design of Battery pack and Battery

management units.• Development (in progress)• Prototypes (2010)• Manufacturing (2011)

Technical partnership• Design• Development• Prototypes (2010)• Manufacturing (2012)

MM Pwt strategy : Component portfolio target

Energy management system

- Element storage (cells/modules)- Battery management unit- Diagnostics- Battery pack assay


PRESTIGE : Full Hybrid Powertrain - diesel

Hybrid Transmission and Energy Management

� Target: provide a full components design & testing, covering main hybrid components� Inverter (HW/SW)� Permanent Magnet motor� Induction motor � Battery and BMS

� Full hybrid architecture� Two electric machines � Limited EV range � Power oriented battery pack

VMU Veicle

Managment Unit

ECU Engine control

Unit

BMU Battery

Managment UnitSistema di

accumulo

ICEGEN

MOT

Planetary

gearbox

Lock-up

MGCU

DC

AC

MGCU

DC

AC

PRogEtto Sistemi a Trazione Ibrida e Gestione Energia


Full Hybrid Powertrain - LCV diesel - PRESTIGE


PRESTIGE CROSS SECTION


PERF.E.T Transmission

Functional descriptionAn electric motor-generator is connected to the gea rbox output shaft, the motor can supply

torque to the wheels during gear-shift and fill the AMT torque gap when clutch is open.

The motor can be mechanically disconnected from the Powertrain over a defined vehicle speed: by this solution a small electric motor can grant a sufficient vehicle acceleration .

Engine Transmission gearboxwith AMT

ACDC

BATTERYPACK

InverterMotor-generator

( PERforming and Efficient Transmission)


PERF.E.T Simulation Model: Plant

13

V_bat

12

I_bat

11

Consumo

10

V

9

I

8

SOC_HV

7

SOC_SLI

6

veh_speed

5

veh_accel

4

gear act

3

Locked Clutch

2

T_wheel

1

speeds

[T,J]_in

Pendenza [%]

T freni [Nm]

V [m/s]

w_ruote [rad/s]

acc

T_wheel

Veicolo

[T,J]_in

w_out

[T,J]_Trsm

w_in [rad/s]

TrasmissionerigidaV. A.1

Trasmissione Rigida

[T,J]_in

Acceso

Tobj_ist [Nm]

Tobj_pre [Nm]

w_in [rad/s]

[T,J]_MCI

Consumo [g/s]

MCIcon RSV

P_AC P_DC

Inverter

[T,J]_in

tgt_N

w_out [rad/s]

[T,J]_GBX

act_N

w_in [rad/s]

Ver. A.1

Gearbox

(Tin,J)

Tric

EMG on

W in

(Tout,J)

Pe

W out

EMG

0

[T,J]_in

Tf

w_out

[T,J]_Clutch

Locked Flag

w_in

w2

Versionecon parastrappi

V. A.1

Clutch_Model

P_scamb

SOC

I_out

V_out

(P_max,Pmin)

Batteria SLI

P_scamb

SOC

I_out

V_out

Batteria HVTric

W in

(Pmax,Pmin)

(Tout,J)

Pe

BAS

9

EMG on

8

T_EMG

7

ICE on

6

Twheel_brake

5

Tobj_BAS

4

gear_ref3

T_clutch2

Tobj_MCI_ist1

Tobj_MCI_pre

w_gear_input

w_clutch

w_engine

Engine Clutch Gearbox

ElectricMotor Transmission Vehicle

TractionBattery

Inverter

Alternator 12 V Battery

Thermal Engine Torque[Nm]

0

50

100

150

200

250

0 1000 2000 3000 4000 5000 6000 7000

Engine Speed [rpm]

1 3,8182 2,1583 1,4753 1,0675 0,8756 0,744

RM 3,545RF 4,176


HEV & BEV component development: Electric motor/generator

� F1 derivation technology, high performances and small weight/size

� Codesign with partners for motor design and production process technology

KERS MOTOR for F1 applications HiSPD GearReductionMotor HiSPD Electric motor only

HiSPD technolgy

13-15.0006-9.000Motor speed (rpm)

-25%Ref.Weight

> 90%80-85%Efficiency

> 85%< 45%Slot filling

-30%Ref.Dimensions

HiSPDtechnology

Traditionaltechnology

Characteristic

13-15.0006-9.000Motor speed (rpm)

-25%Ref.Weight

> 90%80-85%Efficiency

> 85%< 45%Slot filling

-30%Ref.Dimensions

HiSPDtechnology

Traditionaltechnology

Characteristic


Motor-generator by HiSPD TECHNOLOGY

HiSPD Technology means:

� Less slot area and less volume.� Best thermal exchange => more

current density => less amount of copper

� Little headers size.

Comparison in slot filling: 80-85% versus 40-45% (standard motors)

Traditional technology

KERS technology

KERS technology for mass production


Preliminary comparison; HiSPD vs. traditional technology

HiSPD technology

Traditional motorComparison:Volume: - 25%Length : - 19%Weight : - 24%


E-Motor preliminary range definition for HEV and BEV


� Performance� Up to 90 kW for high speed motor� Possible integration of DC/DC converter

� Scalability� Different configurations for custom applications:

High power single motorDual motor Motor and Generator

� Power modules� Codesign with best in class power components supplier � In house power module assembly in existing Clean Room facilities� Liquid Cooling

• Engine cooling system 90°C• Dedicated cooling system 70°C

� Control electronic and firmware� Derivated by Engine control units� Re-use of existing technology

HEV & BEV component development: Power Inverter


Inverter – Modular Solution: Kers Motorsport reference

POWER Module

DC-BUS FILTER Module

Pre-Driver ModuleControl Board Module

Mechatronics Module

Current Sense Module


Control Unit for PROTO A

� Demo car� Driving Power Converter� DC/AC control and interface� External signal conditioning� Communication (CAN)


Battery Laboratory Test Bench

� Laboratory facilities for tests on cells and modules

� Development and identification of battery managemen t system

models

� Several sets of cells

under evaluations.


Battery Laboratory Test Bench Battery Charger

Unit Under Test

(U.U.T.)

Test BoardCustom

NIDAQ I/O

Board

PC supervisor +

Software (LabVIEW)

• 4 point Pack Temperature

• 1 point Climatic Cell Temperature

GPIB

USB

Relay Board

Custom

voltageClimatic

cell

current

Electronic Load

Acquired channels:

• 10 point Pack Voltage

• 1 point Pack Current

Battery ChargerUnit Under Test

(U.U.T.)

Test BoardCustom

NIDAQ I/O

Board

PC supervisor +

Software (LabVIEW)

• 4 point Pack Temperature

• 1 point Climatic Cell Temperature

GPIB

USB

Relay Board

Custom

voltageClimatic

cell

current

Electronic Load

Acquired channels:

• 10 point Pack Voltage

• 1 point Pack Current


Component System


DADOS PARA REFLEXÃO: Fonte seminário Automotive Business


Provisioning

Reporting

Billing

Help Desk

SERVICE/CONTENT SERVICE/CONTENT SERVICE/CONTENT SERVICE/CONTENT

PROVIDERPROVIDERPROVIDERPROVIDER

TLC Network

Infra Estrutura e cadeia de Serviços

TelCo Platform Service Providers

ICT Capabilities

Customer


♪

Entertainment

Service

Automotive

Infrastructure

Sensor/Body elec.Hybrid

Engine/Brake/Steering

ＬＬＬ

proving

Telematics

traffic control

Navigation

Traffic info.Estimate traffic

condition

Traffic Info.

Camera

Fleet management

Maintenance/Diagnosis Mobile

communicationInternet

Safety & Security Environment & Efficiency Comfort & Convenience

ECO-SYSTEM atual para Telemática e futuro uso nos HEV / BEV


Pursuing the Excellence

in Quality and Service

partnering with our Customers.

Thank you.

Obrigado

[email protected] 019 8111 1570

battery-electrical & hybrid-electrical vehicles magneti marelli

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