The electrification of the vehicle driveline

The HAN perspectiveThe HAN perspectiveHAN Automotive op weg in

duurzaamheidBram Veenhuizen

May 28, 2009

JP Balkenende (Autorai, 1 april ’09)

“Ik vind het doel wat u heeft, 1 miljoen auto’s in 2020 ontzettend goed. En je hebt zo’n stipaan de horizon nodig. Ik ben er volstrekt van overtuigd dat we die kant op moeten.” overtuigd dat we die kant op moeten.”

In Zeist opent Elipo, een nieuwe dealer in elektrische voertuigen, op woensdag 27 mei officieel zijn deuren. Herman Wijffels verzorgt de openingsspeech.

ContentsHybrid, electric and fuel cell drive trains:� trends and developments

– International automotive

– National automotive

– National energy companies– National energy companies

� Consequences for Han University of applied science

� Where are we now? Hymotive project. See also parallel session and student exposition

� Future plans

� Conclusions

HAN R&D activities on sustainable mobility (visit afternoon sessions)

� Alternative fuels– Ethanol– LPG– …

Light weight vehicle design� Light weight vehicle design� Sustainable manufacturing, efficient use of

resources (C2C)� Hybrid, electric and fuel cell vehicles, electric

power components in the vehicle driveline

Trends and developments� Macro developments

– Oil resources are deminishing, demand increases– Unstable oil price, political unstability in oil/gas supplying

countries– Emissions have increasing influence on public health and

global warming

Consequences:� Consequences:– CO2 legislation/ Euro 6– Strict regulations for inner city emissions– Tax incentives for cleaner vehicles– Trend for smaller vehicles

� Trends– Niche players emerging for E-mobility– Test pilots by OEM’s– Major investments in battery and e-drive components

Mercedes / Daimlers’ view

Toyota’s view

The ICE – EM continuum

Honda Clarity Fuel cell vehicle

� Proton exchange membrane stack� 100 kW� 3.9 kg H2 @350 bar� 400 km range� 400 km range

Daimler – Mercedescollaborates with Evonik, Tesla Motors en RWE

� Blue Zero� E-cell: 200 km (Li-ion)� E-cell plus: 600 km with

1.0 l ICE from Smart 1.0 l ICE from Smart Fortwo

� F-cell: 400 km with fuel cell

GM-Opel prototype

� Opel Ampera (Chevy Volt)

� Series hybrid with 1.4 l gasoline engine

� 60 km e-range� Over 500 km with

range extender

BMWCollaborates with E.on

� Pure electric vehicle� 150 mi range� 260 kg lithium-ion

battery pack, 35 kWhbattery pack, 35 kWh� 95 mph� 500+ on the road

Tesla Model S

� 300 mi range� Battery swap option� 190 kph top� 65 kWh� 65 kWh� 45 min. charge

option (480 V outlet)

Mitsubishiwith Peugeot/Citroën

� i-MiEV� 47 kW� RWD� 16 kWh� 16 kWh� 130 km� 130 kph

The Plug-In Hybrid, Toyota

Source:Toyota

Toyota Plug in Prius

Gemco

� Series hybrid w/o batteries� Separate motors at each rear wheel

Superbus motors by E2M

� Direct Drive� Two identical

motors, back motors, back to back ontest rig

Drive Train Innovations

� Hybrid power shift module

E-traction

� Wheel hub motors

Duracar

� Battery electric vehicle

Hytruck: fuel cell range extender

NedstackFuel Cell SystemH2 tank: 400 km

Batteries, also charged from the grid

Electronics

E-traction in-wheel motors

Source: ATC

HAN automotive strategy towards electrified powertrain engineering� Create strategic alliances with (regional) stakeholders:

HTAS, ATC, TNO, TU/e, PDE, Exendis, SMC, Nedstack, E-traction, E2M, ECE, Duracar, Evisol, KEMA, TU/e, TUD, HRo, authorities, Epyon, Friend, Essent, DTI, Alphatron, Centurion, ECN, AGV,…

� Participate in technology projects (example later)Participate in technology projects (example later)� Create own HIL testing environment (example later)� Research: modeling, power electronics, control,

electric machines, drive train, batteries, fuel cells. � Collaborate with electric engineering dept. on vehicle

to grid R&D.� Incorporate R&D in BaMa education: projects, lecture

examples, practical exercises, etc.

Sustainable Mobility Innovations; a Learning Experience - SMILE

� On top of regular educationemphasis on aspects like:

– C2C, w2w analysis, Recyclability, Emissions regulations, etc.

– Sustainable Mobility projects– Sustainable Mobility projects– Starting with first grade 25

students in 09-’09

PHBO power electronics for hybrids/EV’s

onderwerp

Inleiding management systemen

Inleiding Hybride Systemen

Inleiding wisselstroom theorie

Inleiding filtertheorie met decibels etc.

Inleiding theorie 3 fasen systemen

Vermogenstransistoren (Bipolair, MOS, IGBT)

DC-DC conversie (choppers etc)

Practicum opdracht 1 Wisselstroom systemen en filters met Multisim

DC-motoren met H-brug en PWM sturing theorie + berekeningen

Practicum opdracht 2 Choppers etc.

AC-motoren/generatoren (Hoofdzaak synchroon, kort asynchroom)

Practicum opdracht 3 DC-motoren

Frequentie omvormers, Inverters

Practicum opdracht 4 AC-motoren

Accu’s en Supercaps

Brandstofcellen

CAN en Flexray

Energie management

Casus of Simulatie

Some ResultsHymotive project (parallel session 1)

� Hymotive: “hydrogen implementation projects for automotive SME’s”.

� Fuel cell power pack for fork lift truck

� Controller hard- and � Controller hard- and software for power pack

� Hydrogen hardware in the loop test facility

� …

�������������

���� ��

���� �� ���� �����

Fork lift power train layout proposal

��� �� ������ �

� �����

������������� ���� �����

� ��������

�� ���

��

Component sizing by simulation

kg H2

0.08442

PI controlFC + SC parallel

P_EM

U_SC

P_in_FC

P_in_SCFuel Cell

P_in P_FC

Energy [J]

1.198 e+007

Energy Consumption

P_fuel

kg H 2

Energy

Electrical power link

P_in P_out

Duty Cycle 1

P

I

U

E

Battery

Supercapacitor

P_SCU_SC

Scope 1

Detailed loss modeling• Resistive losses in the

supercapacitor modules• Compressor losses• Hydrogen pump losses• Water circulation pump

losses• Cooling fan losses

Battery load profile

For more info: visit parallel session 1

Outlook

� Electric Power Train laboratory

ePT-LAB Scope

V-Cycle Product Development

System definition

Data acquisition, Modeling and

HIL testing,

System testing

Modeling and Simulation,prototyping

Targeting &Detailed design

HIL testing,Controller

testing

Consortium

Programmateam HAN AdviesbureauSubsidies

HAN ePT-LAB

Chargers, Converters,Inverters, Chargers

Projects

Fuel Cell systems, Batteries and

Energy Management

Motors, Transmissionsand

Mechanical Systems

Projects Projects

Conclusions

� Electrification will play a major role in drive train research, development, design, testing, production, sales

� Automotive engineers (mbo, hbo, wo) should become knowledgeable about drive trains become knowledgeable about drive trains with electric components and systems

� HAN incorporates the electrified drive train in its curriculum (Smile, PHBO electronics, etc.)

� HAN carries out applied R&D in this field

Thanks for your attention