China International Automotive Congress Vehicle concepts, tailor made for e-propulsion. Shenyang, 13. September 2009

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1 China International Automotive Congress 2009 Vehicle concepts, tailor made for e-propulsion Shenyang, 13. September 2009 Prof. Dr.-Ing. habil. J.-W. Biermann Dipl.-Ing. Bastian Hartmann Institut für Kraftfahrzeuge RWTH Aachen University # bh0072.pptx Folie Nr. 1

2 Content Introduction New vehicle requirements based on electric powertrains Vehicle examples with electric powertrain Alternative vehicle concepts at the ika Summary # bh0072.pptx Folie Nr. 2

3 Content Introduction New vehicle requirements based on electric powertrains Vehicle examples with electric powertrain Alternative vehicle concepts at the ika Summary # bh0072.pptx Folie Nr. 3

4 Ölpreis [$/bbl] Introduction Motivation Exhaust and noise emissions Taxes CO 2 German national development plan for electrical mobility Rising mobility Legislation # bh0072.pptx Folie Nr. 4

5 Introduction State of the Art Body Combustion engine + gear box Exhaust system Fuel tank Hydraulic brake system Auxiliaries # bh0072.pptx Folie Nr. 5

6 Introduction The Old Strategy... Old vehicle concept - Old powertrain + New powertrain = New vehicle concept? # bh0072.pptx Folie Nr. 6

7 Introduction Mini E: Curb weight: 1465 kg Seats: 2 Motor power: 150 kw Battery capacity: 35 kwh Battery weight: 260 kg Trunk volume: 60 l Mini Otto motor: Curb weight: 1205 kg Seats: 4 Motor power: 128kW Trunk volume: 160 l Source: BMW AG # bh0072.pptx Folie Nr. 7

8 Content Introduction New vehicle requirements based on electric powertrains Vehicle examples with electric powertrain Alternative vehicle concepts at the ika Summary # bh0072.pptx Folie Nr. 8

9 New Vehicle Requirements Customer Expectations (crucial aspects) Costs High purchase price But: Range Lower operating costs (for example with off-peak electrical power ) Low maintenance costs Tax benefit Smaller range due to insufficient energy density of modern battery systems Recharging Longer charging duration due to lower power density of charging cable But: Low-power charging stations very common Infrastructure for high-power charging can be built up fast No need to go to gas-stations anymore NVH-Performance Unfamiliar noise behaviour of the electric powertrain (comparable to electric tram) But: Use of vehicle mostly in close-up range (i.e. city cars) Systematic recharging at the end of travel distance Useage of a Range-Extender Unit But: Lower noise level Opportunity to establish this as a characteristic sound on the market # bh0072.pptx Folie Nr. 9

10 New Vehicle Requirements R&D topics (Overview) Powertrain Powertrain concept (central, close to wheels, wheel hub) Selection of electric motor type Electric energy-storage Body High energy density Modular layout Durability Lightweight construction Aerodynamics Package concepts for battery and powertrain Crash performance of the new components Electric system Electrification of the auxiliaries Energy management Functional architecture Chassis Low-resistance tire Recuperative brake system Full vehicle Sound Engineering Thermomanagement (Heating/Cooling) # bh0072.pptx Folie Nr. 10

11 Content Introduction New vehicle requirements based on electric powertrains Vehicle examples with electric powertrain Alternative vehicle concepts at the ika Summary # bh0072.pptx Folie Nr. 11

12 Existing Vehicle Examples Difference Conversion/Purpose Design Conversion Design Modification of the ICE serial vehicle for the electric drive Existing vehicle architecture and components are not adapted Purpose Design Vehicle development with focus on the electric drive Redesign and modification of all relevant vehicle modules Advantage: Low development effort Existing processes and structures are kept the same Disadvantage: The potential of the electric vehicle cannot be fully tapped Advantage: New drive train concepts can be realized appropriately Business area for new companies Disadvantage: High development effort Not many common parts with ICE vehicles # bh0072.pptx Folie Nr. 12

13 Existing Vehicle Examples Examples Conversion Design Smart Electric Drive Tesla Roadster Platform of the Lotus Elise Battery pack consists of standard notebook cells Platform is the serial Smart First generation uses ZEBRA batteries Second generation is driven by Li-ion batteries Mini E Platform is the serial Mini Powertrain components from AC-Propulsion Compromise for fleet tests # bh0072.pptx Folie Nr. 13

14 Existing Vehicle Examples Examples Purpose Design Blue Zero Light-weight construction Body design Sandwich architecture Modularity Interior design Twike New vehicle concept Optional use as a bike Reduced air resistance Aptera New vehicle concept Light-weight construction Reduced air resistance EV1 Light-weight construction Reduced air resistance Battery package Heuliez Friendly Seating concept Wheel-hub drive # bh0072.pptx Folie Nr. 14

15 Content Introduction New vehicle requirements based on electric powertrains Vehicle examples with electric powertrain Alternative vehicle concepts at the ika Summary # bh0072.pptx Folie Nr. 15

16 Alternative Vehicle Concepts at the ika History # bh0072.pptx Folie Nr. 16

17 Content Introduction New vehicle requirements based on alternative powertrain technologies Vehicle examples with electric powertrain Alternative Vehicle Concepts at the ika Example 1: Ford Model T 2015 Example 2: RWTH Electric Vehicle "StreetScooter" Summary # bh0072.pptx Folie Nr. 17

18 Ford Model T 2015 The Competitive Challenge 1908 That was Tin Lizzy 2008 Specifications Ford Qualitative Easy Robust Light Attractive Low price Innovative production techniques Usable for all customer segments in different surroundings Diversity and upgradability Easy to repair Long model life span A car for every one Quantitative Target costs $ Min. 2 passengers Range: min. 200 km # bh0072.pptx Folie Nr. 18

19 Ford Model T 2015 Concept phase Length Width Height Wheel base Track Passengers Power Fuel consumption Electric consumption Top speed Weight Drive position Front axle Rear axle Tires Brakes (front / rear) 3220 mm 1810 mm 1590 mm 2110 mm 1624 mm 3 (in a row) Design # bh0072.pptx Folie Nr. 19

20 power [kw] Ford Model T 2015 Powertrain Concept Length Width Height Wheel base Track Passengers Power Fuel consumption Electric consumption Top speed Weight Drive position Front axle Rear axle Tires Brakes (front / rear) 3220 mm 1810 mm 1590 mm 2110 mm 1624 mm 3 (in a row) kw l/100 km 11 kwh/100 km 120 km/h 800 kg (+ battery) Powertrain module ICE Hybrid Plug-In EV Constraints: v max = 120 km/h m Veh = 800 kg kg c d A = m 2 = 0.72 m 2 Range: 200 km NEDC power demand at wheel average (propulsion) power demand at wheel time [s] Peak power: 28 kw Average power: 3,12 kw Energy consumption: 94 Wh/km # bh0072.pptx Folie Nr. 20

21 Ford Model T 2015 Vehicle Architecture Length Width Height Wheel base Track 3220 mm 1810 mm 1590 mm 2110 mm 1624 mm Central driver seat Vehicle Architecture Profile intensive body Passengers 3 (in a row) Power kw Fuel consumption l/100 km Electric consumption Top speed Weight 11 kwh/100 km 120 km/h 800 kg (+ Battery) Tank Modular drive unit Drive position Rear engine Front axle McPherson Rear Axle Semitrailing arm Tires Brakes (front / rear) 175/65 R14 Disc / drum Battery # bh0072.pptx Folie Nr. 21

22 Content Introduction New vehicle requirements based on alternative powertrain technologies Vehicle examples with electric powertrain Alternative Vehicle Concepts at the ika Example 1: Ford Model T 2015 Example 2: RWTH Electric Vehicle "StreetScooter" Summary # bh0072.pptx Folie Nr. 22

23 Airbag Airbag RWTH Electric Vehicle "StreetScooter" Goals Project Goals Goals StreetScooter Adaption of a vehicle concept to the pros and cons of an electric drive Development of a demonstrator vehicle and factory capable of series production (assistance until start of production if necessary) Creation of a scalable vehicle architecture Cutting of production costs (in particular of the components of the electric drive) Development of series-production electronic components Implementation of a new marketing concept Standardization of gateways and module boundaries; creation of a quasi-norm Fast implementation of research results Utilisation of synergies with other electric vehicles Construction kit for electric cars Vehicle derivatives Powertrain modules Battery modules Comfort modules Requirements Basic price remarkably lower than competition Adaptability to customer specifications and upgradability Scalability of power and range Security and reliabilty at the level of today s compact category High redundance of common parts # bh0072.pptx Folie Nr. 23

24 RWTH Electric Vehicle "StreetScooter" Development Process Compact Cabrio Friends Work Coupé Pickup Package 2D Package 3D Design Draft Design Surface Model Modular Body Concept # bh0072.pptx Folie Nr. 24

25 RWTH Electric Vehicle "StreetScooter" Vehicle model Compact Vehicle Data Compact Length 2900 mm Width 1650 mm Height 1500 mm Wheel base 2000 mm Passengers 2 Power 30 kw Electric consumption 13 kwh/100 km Main battery 10,6 kwh (30 kw) Additional battery (1 / 2) 6 kwh (<30 kw) Top speed 120 km/h Acceleration 6 s (0 50 km/h) Reach (modular) km Curb weight 1000 kg (incl. battery) Drive position Rear motor Front axle McPherson w/o subframe Rear axle Semi-Trailing-Arm Axle Tires 175/65 R15 Brakes (front / rear) Disc / drum Powertrain consisting of two electric motors close to the wheels in one common housing No differential necessary; just two gear boxes between motor and wheel Battery pack consisting of parallel battery modules Power scaling by adding parallel modules # bh0072.pptx Folie Nr. 25

26 Content Introduction New vehicle requirements based on electric powertrains Vehicle examples with electric powertrain Alternative vehicle concepts at the ika Summary # bh0072.pptx Folie Nr. 26

27 Summary The development of alternative vehicle powertrain systems is marked by social, ecological and economical restraints. Above all the electric powertrain is in the focus of interest Vehicles with alternative powertrains are subject to new requirements, which affect nearly all category groups of the vehicle Current Research & Development projects demonstrate possible approaches and show the potential of the Purpose-Design approach compared to the old-fashioned Conversion-Design Topics like costs, electric range, recharging and NVH-performance are determining for the customer acceptance for the new vehicle concept. In the end the customer defines the market success # bh0072.pptx Folie Nr. 27

28 Thank you very much for your attention! # bh0072.pptx Folie Nr. 28

29 Contact Prof. Dr.-Ing. habil. J.-W. Biermann Institut für Kraftfahrzeuge RWTH Aachen University Steinbachstr Aachen Germany Phone Telefax biermann@ika.rwth-aachen.de Internet # bh0072.pptx Folie Nr. 29

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