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AVL Europe
PRODUCT DEVELOPMENT IN
MOTION 2016
Electrified Powertrains Testing
Product Development in Motion 2016 | Markus Maier, AVL Europe | 24. November 2016 | 2Public
ELECTRIFIED POWERTRAINS GOING MASS-MARKET
Selected major newsheadlines in 2nd Half-2016
Electrified Powertrains move from Light-Tower projects to Mass-MarketValidation of Electrified Powertrains must support accordingly
Product Development in Motion 2016 | Markus Maier, AVL Europe | 24. November 2016 | 3Public
ELECTRIFIED POWERTRAINS
Electrified
Engine
Components
Micro & Mild
Hybrid
Full
Hybrid
Full
Hybrid
Plug-In
Hybrid
Range
Extender
Battery
Electric
Fuel-Cell
Electric
FossilFuels
ElectricalEnergy
0% 0%
100%100%
To
rq
ue
To
rq
ue
MechanicalDrive
Mechanical Drive with electric Assist Electrical Drive withmechanical Assist
Electrical Drive
Hydrogen
Product Development in Motion 2016 | Markus Maier, AVL Europe | 24. November 2016 | 4Public
ELECTRIFIED POWERTRAINS VALIDATION
Rotor Stator
Subcomponents Components Subsystems Powertrain Vehicle
Drive Unit(Gearbox+E-Motor)E-Motor
Tra
ction
Pow
er
Ele
ctr
on
icB
atte
ry
Inverter DC/DC
(inductive) Charging
Increase of Interaction (and increase of Noise / EMC)
Cell Module PackBMS
Powertrain Controls / Electronics / Calibration + ICE (Gasoline, Diesel)
Electric Systems in the Vehicle (Chassis, Digital Horizon, Autonomous Driving)
HV Subsystem
Product Development in Motion 2016 | Markus Maier, AVL Europe | 24. November 2016 | 5Public
MASTERING ELECTRIFIED POWERTRAIN VALIDATION
Performance
Predictability and Correlation
Thermal Management
Safety
Reliability
Service and Component conditioning
1
2
3
4
5
6
Ch
ara
cte
rizati
on
Fu
ncti
on
ali
ty
Fail
Safe
En
du
ran
ce
NV
H
EM
C
Product Development in Motion 2016 | Markus Maier, AVL Europe | 24. November 2016 | 6Public
NEW EV LAB EXAMPLE
Product Development in Motion 2016 | Markus Maier, AVL Europe | 24. November 2016 | 7Public
The chosen sourcing strategy determines the amount of responsibility for Valdiation
Components: Buy-from Open Market vs. Make-Inhouse vs. Built-to-print
Powertrain: will always be under the respnsibility of the OEM as Integrator
xEV Vehicles are new Technology
Quality in Customer hands is key to maintain high reputation of the Vehicle Brand while on the other hand no historic data is available
Field Return analysis must be accomodated by the xEV testfield giving additional load in usage to the Lab
• With no historical data available, aging of components and Powertrain is key
Market introduction of new xEVs is time challenging
• The amount of test equipment and the under lying validation / cycle plan must support the vehicles project plan towards SOP
CONSIDERATIONS FOR EV LAB DESIGN
Product Development in Motion 2016 | Markus Maier, AVL Europe | 24. November 2016 | 8Public
WHAT AN EV LAB NEEDS TO SUPPORT
Characterisation
Endurance / Durability
Fail Safe + Diagnostics
Functional (nominal + aged)
NVH
EMC
Pre-Aging
Road-to-Lab
Fie
ld R
etu
rn A
naly
sis
New
Technolo
gy
Product Development in Motion 2016 | Markus Maier, AVL Europe | 24. November 2016 | 9Public
10:00h – 11:00h Workshop Testing Electrified Powertrains
10:00h – tonight Exhibition Open – all the experts are available
10:00h – tonight Ride it yourself – AVL Audi Hybrid available
WANT TO KNOW MORE?
Markus MaierBusiness Manager Electrification & RacingInstrumentation & Test Systems
Tel.: +49-711-45041-22Mob.: [email protected]