electrification of vehicle drive train – the diversity of engineering
TRANSCRIPT
1Frank Beste, DB
AVL ELECTRIC VEHICLE
ELECTRIFICATION OF VEHICLE DRIVE TRAIN –THE DIVERSITY OF ENGINEERING CHALLENGESA3PS – Conference, Vienna Dr. Frank BesteAVL List GmbH
2Frank Beste, DB
AVL ELECTRIC VEHICLEMotivation for Powertrain Electrification
Global Megatrends:Urbanization and mobilizationEnvironmental CareDemographic Challenge
Motivation for Powertrain Electrification:Replacement of energy generated by an ICE by regenerative electric energy supplied by the electric network Maximising the recovery of braking energy during vehicle decelerationReduction of power consumption of auxiliaries by strictly demandoriented operationShifting of engine operation points towards map areas of best BSFC or lowest specific pollutant emissionsCustomer oriented new vehicle package conceptsNew vehicle functions (automatic parking, turning on the spot, … )
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AVL ELECTRIC VEHICLEHybrid Types and Functionalities
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IC Engine
Transmission
Flexibility
high
small medium
≈ Cost,
Complexity& Risk
Control Strategy
Battery
Electric Motor
AVL ELECTRIC VEHICLEBase Elements of the Powertrain
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SI Powersplit Hybrid
Battery
IC Engine
Trans-mission
Electric Motor
Control Strategy
Flexibility
Fully Variable SI Engine+ Man. Transmission
Standard IC Engine+ Autom. Transm.
Battery
IC Engine
Trans-mission
Electric Motor
Control Strategy
Flexibility
Battery
Trans-mission
Electric Motor
Control Strategy
Flexibility
Electric Vehicle+ Range Extender
Battery
IC Engine
Trans-mission
Electric Motor
Control Strategy
Flexibility
AVL ELECTRIC VEHICLEBase Elements of the Powertrain
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Internal Combustion EngineElectric Motor Battery
E- Motors Battery
ICEE- Motors Battery
ICE
AVL ELECTRIC VEHICLEBase Elements of the Powertrain
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Typically non linear optimization task
Often there is no single optimum
Optimization methodology, development, production, operation boundaries and recycling bias the technical solutions
Changing cost structure of electric components will redirect the technical solutions
Legal requirements might influence the size of energy storage units
AVL ELECTRIC VEHICLEPowertrain Electrification Challenges
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AVL electric vehiclePlug-in vehicle demonstrator designedfor mega-city driving
AVL Range Extender System for at least 250km driving range
AVL ELECTRIC VEHICLEDemonstrator
No passenger compartment restrictions
Acceptable cost of energy storage system
Competitive driving performance
No performance restrictions with Range-Extender operation
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Drive Distance [km]0%
1%
2%
3%
4%
5%
6%
7%
8%
9%
2,50 27,50 52,50 77,50 102,50 127,50
45% of vehicles do not exceed 30 km and account for 20% of total driving
>70% of vehicles do not exceed 50 km (50% of annual mileage)
30 50 100 [km]
City Vehicle (EV)
All Purpose Vehicle
City Vehicle (EV) + RE
Reference: IVT, 2004
AVL ELECTRIC VEHICLEDistribution of Daily Driving Distances in Germany
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€ 0
€ 2.500
€ 5.000
€ 7.500
€ 10.000
€ 12.500
€ 15.000
€ 17.500
€ 20.000
€ 22.500
€ 25.000
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
500 € / kWh
250 € / kWh
Battery Costs - based on energy consumption of 20 kWh / 100km
Range [km]
12.200 € Saving
5.400 € Saving
AER pure EV
> 300
Total Range with RE
AER with RE
RE Cost
RE Cost
AER = All Electric Range
AVL ELECTRIC VEHICLEBattery Cost Comparison
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100 %S
tate
Of C
harg
e
Run time
Technical Minimum
Energy Reserve
AVL PURE RANGE EXTENDEREnergy Reserve - Recharging Strategy
If RE starts here: RE performance according to E-Drive
If RE starts here: performance according to max. configuration performance of E-Drive
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1. NVH, Comfort
2. Reliability
3. Package and Weight
4. Costs
5. Performance / Efficiency
AVL PURE RANGE EXTENDERSystem Targets
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AVL ELECTRIC VEHICLEConcept Study: Direct Drive
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AVL PURE RANGE EXTENDERCore Module with Rotary Engine
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Engine configuration: Single disk rotary engine
Displacement : 254 cc
Power: 18 kW @ 5000 rpm
Fuel consumption: 260 g/kWh
Generator concept: Permanent magnet synchronous machine
Thermal management: Single circuit liquid cooling
Controller: AVL rapid prototyping control unit
Software: Module embedded SW and CAN interface
Electric output: 15 kW @ 320 – 420 V (12 kW above 250 V)
Max. performance scaling potential: up to 36 kW electric output (= 240%)
1m averaged sound pressure: 65 dBA
System box dimension (L x H x W): 490 mm x 400 mm x 980 mm
Engine – generator unit weight: 29 kg
Module weight: 65 kg
AVL PURE RANGE EXTENDERKey Specifications Rotary Engine
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AVL PURE RANGE EXTENDERPerformance Scalability of Core Module
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AVL PURE RANGE EXTENDERSystem Integration
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AVL PURE RANGE EXTENDERAcoustic Optimization
65dB(A) 65dB(A)92dB(A)
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AVL PURE RANGE EXTENDERVehicle Integration
Range Extender integratedin vehicle back
Battery system in front of rear axleand in middle tunnel
75kW traction motor in vehicle front:- acceleration 0 – 60km/h: 6sec- top speed 130km/h
AVL Pure Range Extender
High VoltageLi-Ion Battery
Traction Motor
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AVL BATTERY DEVELOPMENTDevelopment Content
BATTERY DESIGN AND SIMULATION
BATTERY INTEGRATION
BATTERY TESTING AND VALIDATION
AVL ELECTRIC VEHICLEwith Range ExtenderAVL ELECTRIC VEHICLEwith Range Extender
Optimized, reliable and fully integrated battery systemdevelopment to maximize vehicle fuel economy potential:
Requirement development
Design and integration of battery system
Function and software development
Robustness and safety
Testing and validation
Battery benchmarkingBATTERY FUNCTION AND SOFTWARE
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Sim
ulat
ion
App
roac
h
Thermal performance analysis of battery modules• Current and temperature distribution
• Identification of hot spots
• Definition of cooling requirements
Thermal-electric cell characterization• Empirical Cell Model
• Thermal-Electric FE - Analysis
Vehicle simulation (AVL-CRUISE™)
• Determination of load pattern
• Optimization of hybrid-/ electric-control strategy
Battery thermal management simulation (FLOWMASTER)
• Improved thermal management strategy
• Improved battery cooling system
• Improved battery performance and lifetime
-20
-10
0
10
20
30
40
50
60
0 200 400 600 800 1000 1200
Time [s]
Pow
er [k
W]
-20
-10
0
10
20
30
Vel
ocity
[m/s
]
E-motor_mech_power <W> Velocity <m/s>
BatteryCircuit
AC-Circuit
• General material properties
• Cell performance specification
• Cell geometry
• Cell charge / dischargecharacteristics
• General material properties
• Cell performance specification
• Cell geometry
• Cell charge / dischargecharacteristics
Input
Simulation A key discipline within the requirement engineering process …
AVL REQUIREMENT ENGINEERING & SIMULATION From Cell-Level to Battery-Pack
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AVL ELECTRIC VEHICLE WITH RANGE EXTENDER
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AVL ELECTRIC VEHICLEContact
Dr. Frank BesteAVL List GmbH
Address: Hans-List-Pl. 1A-8020 Graz
Tel: +43-316-787 6556Fax: +43-316-787 8309web: www.avl.comEmail: [email protected]