Conferenza del Dipartimento DIITET

26 e 27 maggio 2014

Carlo Beatrice (c.beatrice@im.cnr.it)

DIITET nel settore dei veicoli a basso impatto ambientale

CONSIGLIO NAZIONALE DELLE RICERCHE

Pisa, November 17th, 2015

Convegno del Dipartimento di Ingegneria,

ICT e Tecnologie per l’Energia e i Trasporti

The next-generation powertrains for 2050 mobility

1

Smart & Environmental friendly vehicles

Powertrain Technologies (hybrids, sensors, control, devices, etc.) Alternative fuels

Storage SystemsThermo-fluidynamic & vibroacoustic

Vehicle & Environment(incl. LCA)

ICT/ITS Infrastructures, Smart Grids, …..,

Materials

2

3

Scenarios / The indicative evolution of passenger road transport energy source and propulsion technology, towards 2050

[Source: ERTRAC - European Road Transport Research Advisory Council]

2050

4

IEA projections of future road transport energy sources to 2050

5

Scenario of powertrains for 2030

6

Hybrid vehicles classification: Level of hybridization

[Source: ERTRAC]

Conferenza DIITET

Pisa, November 17th 20157

Series Parallel

Parallel-series Hybrid Split configuration

IC engine and electric drive connected to separate axles

Electric vehicle with super-capacitors and batteries

Hybrid vehicles classification: Architecture typologiesToyota Prius

Opel Ampera

Peugeot 3008

8

H2020 calls 2016-2017

Smart, green and integrated transport 2016 - 2017

1. GV-02-2016: Technologies for low emission light duty powertrains;

2. GV-03-2016: System and cost optimised hybridisation of road vehicles;

3. GV-06-2017: Physical integration of hybrid and electric vehicle batteries at pack level aiming at increased energy density and efficiency;

4. GV-07-2017: Multi-level modelling and testing of electric vehicles and their components;

Conferenza DIITET

Pisa, November 17th 2015

9

The Hybrid Powertrain

Looking at the ICE technology roadmap

Conferenza DIITET

Pisa, November 17th 2015

10

The ideal Diesel cycle

Max thermodynamic efficiency of the Diesel cycle

Conferenza DIITET

Pisa, November 17th 2015

With a compression ratio of 18 the efficicency of the ideal cycle is 62%

11

The energy balane in the internal combustion engine

Diesel Heavy-Duty case (e.g. Truck engine)

Conferenza DIITET

Pisa, November 17th 2015

12

Automotive (ICE) Technology Roadmap

Conferenza DIITET

Pisa, November 17th 2015

13

Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_1: Diesel and Liquid fuel spray studies

Different approaches: X Ray / tomography Laser / LED

• 3D spatial and temporal analysis of liquid sprays from injection systems for ICE

Reference: L. Allocca, A. Montanaro

14

Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_2: Fuel spray & combustion studies in optical engines

Optical diesel engine Optical GDI engine

Reference: E. Mancaruso, S. Merola

15

Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_3: Fuel spray & combustion studies in optical engines

Reference: P. Sementa

Direct Injection CNG spray Direct Injection CNG combustion

Gasoline-PFI

Injector

DI-GAS

Injector

16

Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_2: Advanced research engines for downsizing studies

Advanced engine test laboratory @ IM-CNR

Reference: C. Beatrice

17

Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_3: Fully dynamic & transient engine test benches

Reference: C. Guido, S. Iannaccone, M.V. Prati

6-cylinder HD NG engine on 315 kW transient test bench

Chassis dynamometer for vehicle testing

18

Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_4: Design and development of advanced components

Reference: A. Di Gaeta, V. Giglio

Electromagnetic actuation of engine valves

Rivestimenti superidrofobici per ridurre l’attrito da strisciamento

19

Sample CA with ARNICA 46(°) st. dev.

Tal Quale 16.7 2.3

Coated 123.8 11.8

20

T= 150s T= 350s

T= 700 s T= 1500s

T= 700s

D1) 1500x2

D3) 2000full

D2) 2000x5

D4) 2500x8

A)

B)

Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_4: 3D CFD of spray and engine combustion

Reference: M. Costa, V. Fraioli, M. Migliaccio

21

Mitigazione degli effetti degli agenti fisici sugli operatori e sull’ambiente (NHV)

Analisi sperimentale e gestione delle caratteristiche del campo acustico mediante tecniche intensimetriche ed verifiche in camera anecoica

Sistema di analisi automatica delle analisi intensimetriche su componentistica

Noise emission qualification and control

High Performance Computing (HPC) per la simulazione vibroacustica

Simulazione integrata BEM - FEM

Interventi nel cofano motore.

Interventi di tipo passivo per la riduzione dirumore e vibrazioni

Reference: E. Carletti IMAMOTER, D. Siano IM

22

The Hybrid PowertrainLooking at the E-Motor technology roadmap

Conferenza DIITET

Pisa, November 17th 2015

23

Automotive Hybrid and Electric vehicles Roadmap

Conferenza DIITET

Pisa, November 17th 2015

24

100 kW DynamicTest Bench

Analisi sperimentale delle prestazioni di sistemi di accumulo in condizioni di funzionamento stazionarie e dinamiche

Valutazione delle strategie di gestione dell’energia on board per sistemi di propulsione elettrici su cicli di guida standard, al variare dei parametri della strada e del veicolo

High Specific Energy Storage Devices

Lead Acid

Studio Sperimentale di Sistemi di Propulsione Elettrici per Veicoli Elettrici ed Ibridi

DC

DCVsc VDC

SC +

SC -

DC +

DC -

Control System Supervisor

LiFePO4 ZEBRA Li[NiCoMn]O2

Super-Capacitor Li-Ion Capacitors

High Specific PowerStorage Devices

Strategie di gestione dell’energia elettrica in sistemi di accumulo di tipo ibrido (batterie+supercondensatori)

Test bench di laboratorio per azionamenti elettrici da 3 a 100 kW, comprensivi di moduli software e volani per la simulazione delle forze di inerzia.

10 kW Eddy Current Brake

30 kW Eddy Current Brake

Energy Storage Modules Test Bench

I V

CYCLE

TESTER

P

+-Data

Battery

TEMP.

SENSOR.

TEMPERATURE

Reference: O.Veneri, C. Capasso

25

Architetture per sistemi di propulsione ibridi di tipo Termico-Elettrico

Attività di Ibridizzazione del sistema di propulsione della

Nave Oceanografica del CNR G. Dalla Porta

G

6-CYLINDER

THERMAL ENGINE

Tra

ns

mis

sio

n G

ea

r

HYDRAULIC

SYSTEMS

SISTEMA DI

ACCUMULO

WINCH

M AC

DC

DC

AC

MOTORUOTE

ELETTRICHE

+

FRESA

HYBRIDIZATION

Strategie di gestione dei flussi energetici finalizzate all’incremento dell’efficienza complessiva ed alla riduzione delle emissioni

Architetture Ibride di Propulsione per Veicoli Cingolati

Ibridizzazione del sistema di propulsione mediante

Operazioni di Retrofit su configurazioni preesistenti

Analisi architetture di potenza per la generazione elettrica e la propulsione ibrida in applicazioni navali

Modellazione e simulazione di Architetture Ibride diPropulsione per Pescherecci, su cicli di pesca prestabiliti,con approccio systems engineering e modelli 3D - Catia v6

Reference: O.Veneri (IM), P. Paoluzzi (IMAMOTER)

26

AC/DC Bidirectional

Converter

DC/DC Unidirectional

Converter

DC Bus

Electric Connections

to Battery Packs

I/O Control Signals

Main Switch

Room for Future

Extensions

Voltage and

Current Sensors

DC/DC Bidirectional

Converters

Architetture di potenza per l’integrazione di veicoli elettrici e fonti rinnovabili in contesti di tipo smart grid

Analisi sperimentale e gestione dei flussi energetici su sistemi di ricarica rapida con pacchi batteria di diversa tecnologia

Dimostratore di laboratorio di micro-grid in corrente continua per operazioni di ricarica rapida per veicoli PEV

Sitema di Accumulo Buffer basato su tecnologia LiFePO4

Valutazione sperimentale di strategie di gestione per l’integrazione ottitmale in architetture di potenza in corrente continua di sistemi di generazione di energia ellettrica da fonti rinnovabili e sistemi di accumulo

0 0.2 0.4 0.650

55

60

65

70

Time [h]

EV

Ch

arg

ing

Vo

ltag

e [

V]

0 0.2 0.4 0.60

0.75

1.5

2.25

3

EV

Ch

arg

ing

Po

wer

[kW

]

0 0.1 0.2 0.3 0.4 0.5 0.60

20

40

60

80

Time [h]

EV

So

C [

%]

Architetture di tipo micro-grid in DC e AC per la ricarica rapida di veicoli elettrici ed ibridi plug-in

Architetture di potenza per l’integrazione di fonti rinnovabili in contesti di tipo smart grid

High efficiencyHetero-Junction HIT Modules

Sito di

installazione

SUD

Sito installazione impianto fotovoltaico.

DC

DC

MPPT

DC

DC

MPPT

DC

DC

MPPT

DC

AC

PV1

PV2

PVnBattery

Pack

DC

DC

MPPT

DC

DC

MPPT

DC

DC

MPPT

DC

AC

PV1

PV2

PVnBattery

Pack

A B

Smart PV Panels with distributed MPPT controller

2

Vehicle Battery Pack

DC

DC

DC

DC

Po

we

r F

lux

Po

we

r F

lux

AC

DC

Energy Storage Buffer

2

Reference: O.Veneri, C. Capasso

Conferenza DIITET

Pisa, November 17th 2015

CONCLUSIONS I

27

• Even if pure electrical and Fuel Cell powertrains are the long term solution for sustainable surface transport, 2050 estimations indicate a predominance of thermal and hybrid engines;

• From the ICE side, while pollutant emission will be controlled mainly from exhaust-after-treatments in order to fulfill the future worldwide regulations, improvement of fuel efficiency (and CO2 reduction) will be the main target of the ICE R&D activities;

• Such targets can be achieved through several areas of investigation like, engine downsizing, waste heat recovery, friction loss reduction, advanced engine control, new renewable clean fuels etc., based on both fundamental and applied studies;

• Both of them can be found in the CNR institutions, while a increase of the synergy between fundamental and applied research has to be pursued;

• The cooperation between IM and ITAE in the study and testing of new renewable fuels (MIPAAF Project “TERVEG”) is an example. Other examples can be found in the possible cooperation on the use of new materials for friction and heat losses reduction (e.g. engine component coating or new lubrication/cooling fluids employing nanoparticles)

Conferenza DIITET

Pisa, November 17th 2015

CONCLUSIONS II

28

• From the E-motor side, there are available technologies on the market for hybrid vehicle diffusion, and a lot of them are under development;

• Anyway, the limiting points to the large diffusion of the hybrid vehicles are the increase of the capacity of the batteries and their recharging process through advanced Battery Management Systems (BMS) (the fast recharging systems represent the core of this item);

• Another crucial point that requires additional relevant research effort lies on the on-board energy management system (intelligent energy fluxes control and breaking energy recovery), from which depends the mileage range of the vehicle.

• As for ICE, the synergy between fundamental and applied researches are the key point for the development of robust and long-range hybrid vehicles. The cooperation between IM and IMAMOTER in the study of the hybridization of a snow groomers is an example.

• Several CNR Institutes could be involved in IM activities relatively to the design and development of specific components of the electric powertrain that could be tested and validated in demonstrator vehicles at IM laboratories.

Conferenza DIITET

Pisa, November 17th 2015

Thanks for the attention

29

Tavolo di lavoro AP Veicoli a basso impatto ambientale:Carlo Beatrice IMMichele Gambino IMGiorgio Dispensa ITAEElena Ciappi INSEANSandro Ianniello INSEANAlessio Ferrari ISTIGianpaolo Vitale ISSIAPietro Marani IMAMOTERPasqua d’Ambra ICARCésar de Julián Fernández IMEM