vehicle electrification focus and challenges · elkraftdagen 2016 - cth, electric propulsions...

Vehicle electrificationfocus and challenges

Karl Klang

Electric Propulsion Systems, Volvo Cars

Elkraftdagen 2016 - CTH

Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang

Issue date: 2016-03-22, Security Class: Public

Overview

• Introduction

• Vehicle electrification challenges of today

• Volvo cars electrification – history and present

• Q&A



Why Hybrids & Electrification? Up to today

Political and market forces limiting CO2 emissions and usage of fossil fuels

Electricity as a main track for cars and light trucks- Efficiency- Infrastructure and conversion flexibility

Global Warming

• climate change

Energy Security

• fuel availability

• delivery conditions

Electrification – image step 1

Generation 1

• Decent performance

• Slight improvement in fuel efficiency

• No revolutionaryattributes

• Huge productplacement effort!



Electrification – Image step X

Tesla

High performance electric vehicle

Message:

Electric performance can be competible with ”normal” cars!





Worldwide legislations on CO2 emmisions

130 g/km 2012

95 g/km 2020

CO2-development over time – new cars EU

Source: icct (the international

council on clean

transportation)

Automotive electrification today



• Electrification strategies adopted by many car

manufacturers and many models are already available

• Expected legislated emissions decreases steadily

• Incentive programs for electrification are ramping out

Automotive electrification today



• Electrification strategies adopted by many car

manufacturers and many models are already available

• Expected legislated emissions decreases steadily

• Incentive programs for electrification are ramping out

The “chasm”

Focus and challenges today – the MarketExtremely competitive market, relatively untested for these applications, where the standard questions are to be answered:

• What do customers want?

• How much is it worth?

• At the expense of what is it still desirable?

• How do we brand whatever level we chose to offer?

• What does customers not yet know that they want?

• How and at what time will the infrastructure adapt?



Focus and challenges today – industry vs automotive

Automotive applications requires:

• Capability to handle harsh and varying environmental conditions

• Documented fulfilment of “appropriate” standards for liability and/or legal reasons

Suppliers typically comply with industry “best practice” standards + Automotive industry standardization is lagging Brand/model unique solutions, low volumes, long lead times and expensive development



Focus and challenges today – Functional safety vs robustness

• ISO 26262 introduced as an automotive “best practice” standard

• High (documented) confidence levels are required for applications where very little quality data is available

• Failing to fulfil the required confidence levels might mean that you have to go to a safe state where the electric propulsion ability is typically either not available at all or greatly reduced.

• Consequence of lost function increases as the utilization of electric propulsion increases

• Some market enforce very strict penalties for setting faults too often while still requiring action on all present faults

• No customer is happy with a car that has highly noticeable faults (at any point)

• Limited operation strategies where some functionality is maintained even though the system is not fully operational are required!



Focus and challenges today – Platform preparations

• Adapt the platform to enable optimized electrification from the start instead of adapting the electrification to fit the platform available

• Extremely high investments

• Uncertainties/risk due to the market situation

• Crucial in order to reduce cost and staying competitive





25 Years ago…. Flywheel mounted

Starter alternator

Test bench 1990



VCC electrification programmes and studies

1992 ECC - Environment Concept Car at Paris Autoshow

Concept:

Series Plug-in Hybrid

Gas Turbine

High Speed Generator



HEV 98 – Demonstration Vehicles

Integration of Hybrid systems into target vehicles.

Battery: NiMH 20 kWh

Drive system: 90 kW AC induction motor

+ 2step transm

APU: 3cyl 1,4L ICE, 30 kW generator

Onboard Charger

EL AC compressor

DCDC converterDC/AC

Converter

Field Wound

Synchronous

Generator + regulatorDrive unit

1,4 L 3 cyl

Gasoline engine



Desiree

1998 - 2000

Concept: Power Split Hybrid

Showed at Geneva

Auto Show 1999

Performance 0-100 13,5s

Electric Range 1-2 km

Top speed 150 km/h

Base Vehicle: S40/V40

Added weight: 183 Kg



Desiree Technology

· Engine 1.4 litres, 56 kW

· Electric motor 55 kW

· Generator 25 kW

· Battery 2.5 kWh, 300V, 55kW NiMh

Demonstration objective:

Study vehicle attributes and

system implications of

power split technology in

VCC platforms

Dual Inverter Transaxle

unit

3cyl ICE with electronic throttle Water cooled NiMH battery

DCDC converter AC compressor



ISG Vehicle

1998 - 2001

Concept: Mild Hybrid ISG (Integrated Starter Generator)

42V/12V Dual Voltage System

>10 Vehicles built 760/S/V40/S80/Ford (1st built 1988)

Demonstrated for 150 Journalists Seville Spain 2001

Performance: Improved – Enables downsizing

Top speed: No change 42 V Battery

Fuel tank

Integrated Starter

Generator

Base Vehicle: S80 Added weight: 60 Kg

Air

conditioning



ISG Technology

ISG Machine ISG Converter incl DCDC conv.

ISG Battery Pack ISG Automatic transmission Hybrid AC Compressor

· ISG Electric machine12 kW

· DC/AC- and DCDC-converter 140A

· Battery NiMh 36cells, 0,7 kWh 15kW

· Both manual and automatic application

Induction and PM Synchronous

technology

· Electric Air Condition during

engine stop, mechanically driven

while engine is running



Research project to build knowledge

Focus on safety/battery packing

Test fleet

- 0-100km/h on 10.5s

- 4 seats + luggage

- safe as all Volvos

- 120 - 150km range

- max 130km/h

Volvo C30 BEV



DC DC converter200A @ 12V

Electrical AC-compressor 8kW

PDU (Power Distribution Unit)

Inverter

Rear battery12kWh

Tunnel battery12kWh

On board charger16A @ 230V

El. motor 82/40 kW

230V AC harness

Charge Inlet

C30 Electric-Powertrain



V60 PHEV D6

World-first Diesel PHEv with 48g CO2/km and 50km pure electric range



On the EU market 2012

Lithium Ion battery 12 kWh energy

Chargeable from power network - on board charger

Electric motor 50 kW (70 hp)

Combined with an efficient premium diesel 150 kW (205 hp)

Start/Stop system included

Regenerative braking system

Electrical air condition

Electric / hydraulic power steering

V60 Plug-in Hybrid Electric Vehicle – Tech facts

Why Hybrids & Electrification? today

Legislation and environmental impact, but also:

• Performance option

• New/improved driving attributes

• Relatively low complexity to add features

• Cost savings?

• Electric drive feeling!





The Plug In Hybrid Electric Vehicle - Challenges

COST

Package space

Cooling

Efficiency

Durability

SAFETY

LiFE SPAN

Integration

performance

competence

Charging time/km

XC90 PHEV - Challenges for the ”second” project

• Extremely high attribute requirements

• Platform based dimensioning of all main components

• Added flexibility and more efficient developement of vehicle near functionality – strategic SW components developed inhouse

• No pre-existing (already stabilized) platform to build on

• New and hard EMC requirements

• World wide introduction

• Compared to V60 PHEV and required to be better or equal in all categories



XC90 PHEV – EPS parts



XC90 T8 PHEV – Tech facts



Production start in 2015

No compromise: high performance & low CO2

High performance 400 HP and 650 Nm

Low emissions that complies with Euro 6 and TZEV standards.

Low CO2 64 g/100km and fuel consumption 2,7 l/100 km.

Up to 50 km electric range

Battery capacity: 9,3 kWh

Electric AWD

“Designed around you” … three cars in one … you decide



Q&A

We want you as a power engineer!

vehicle electrification focus and challenges · elkraftdagen 2016 - cth, electric propulsions...

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