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OPTEMUS Project: Leveraging low energy

consumption and energy harvesting

Dr. Alois Steiner

November 2016 OPTEMUS 2

Content

• OPTEMUS Concept, Work Packages & Partners

• OPTEMUS Technologies

• Compact refrigeration unit

• Smart battery housing

• Smart cover panels, heated and cooled seat

• Energy harvesting

• Intelligent control concept

• Impact on Driving Range


Concept

Reference vehicle:

▪ Fiat 500 E-Vehicle

Definition of „extreme conditions“ using 2 use cases:

▪ Use case 1: Hot ambient (35 °C, 40 % r.H.)

▪ Use case 2: Cold ambient (-10 °C, 95 % r.H.)

Impact of OPTEMUS:

▪ Use case 1: 60 % reduced energy consumption for passenger comfort and

33 % reduced energy for component cooling incl. the battery (with ensured

life enhancement) and gained energy from harvesting architectures

▪ Use case 2: 78 % reduced energy consumption for passenger comfort and

33 % reduced energy for component heating (and/or cooling) incl. the battery

(with ensured life enhancement) and gained energy from harvesting

architectures


Work Packages


OPTEMUS Technologies and Partners

DENSO,

CRF,

IFPEN Control

Thermal Management ECU

DENSO,

CRF,

Virtual Vehicle

Continental,

Fraunhofer,

University of

Aachen

Battery Thermal Management

Mondragon

Smart Cover Panels

Fraunhofer,

University of

Aachen,

CRF,

DENSO

Magneti Marelli,

Scuola Superiore Sant‘Anna,

Fraunhofer,

University of Salerno

Virtual Prototype, Cost- Benefit-Analysis

ESI,

Bax & Willems

Compact Refrigeration Unit (CRU)

Heated and Cooled Seat

Energy Harvesting


OPTEMUS Technologies



• Coolant/coolant heat pump

using a natural refrigerant

• Control of heat flows in the

vehicle

• Connecting heat sinks and heat

sources, e.g. using the battery

as heat source



Battery as thermal storage:

• Example: 200 kg battery, ΔT=20 K

→ approx. 1 kWh thermal energy

• Preconditioning of battery

→ Presentation of Andrés Caldevilla (DENSO)

• Strategies to enhance battery life duration



Smart battery housing:

• Implementation of novel polymer composites and

phase change materials (PCM)

→ Increased heat storage capacities

→ Cost efficient manufacturing capabilites



• Creation of a micro-climate around the passenger(s)

→ Presentation of Felix Weidmann (Fraunhofer)

• Smart cover panels:

→ Reduction of heat up in summer and radiation heating in winter

• Heated and cooled seat using Peltier-Elements



• Suspension shock absorber

→ Electromechanical rotary hydraulic damper

Electric motor charges

12 V battery



• Photovoltaic modules

→ Maximum Power Point Tracking Algorithm

maximizes harvested energy

→ Charges 12 V battery

→ Validation on test car



Intelligent control concept:

• Usage of cloud data (calender entries, planned routes, weather etc.)

• Eco-Driving and Eco-Routing

• Preconditioning of battery and cabin

• Predictive thermal management



• Real time Eco-coaching: Android app „GECO“ for OPTEMUS



• Eco-Routing: identification of the ideal route in terms of …

• Energy consumption

• Travel time

• Travel distance



• Eco-Routing: identification of the ideal route in terms of …

• Energy consumption

• Travel time

• Travel distance

• Experimental campaign in Turin

• 5% savings ECO vs SHORT

• 13% savings ECO vs FAST

3 repetitions

for each route



• Preconditioning of battery and cabin

→ Presentation of Andrés Caldevilla (DENSO)


Impact on Driving Range

• Baseline measurements on Fiat500e on rolling bench in

climatic chamber

• Comfort evaluation via „PACO“ manikin



Validation of OPTEMUS technologies:

Demonstrator vehicle

• Compact refrigeration unit

• Predictive preconditioning &

thermal management

• Smart Cover Panels

• Heated and Cooled Seat

• Eco-Driving, Eco-Routing

Testbench measurements

• TMECU

• Battery thermal

management

• Suspension shock

absorber

• Photo voltaic panels



Validation of OPTEMUS technologies:

→ calculation of overall benefit through Virtual Prototyping


Estimated Impact on Driving Range

• 14 % (20 km) higher driving range at „normal“ ambient conditions (solely reduction

of traction energy through Eco-Driving, Eco-Routing – without Energy Harvesting)

• 38 % (44 km) higher driving range for Use Case 1 (hot ambient conditions)

• 70 % (63 km) higher driving range for Use Case 2 (cold ambient conditions)

Thank you for your attention!

The OPTEMUS consortium

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