DESIGNING AN ELECTRIFIED VEHICLE:

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1 DESIGNING AN ELECTRIFIED VEHICLE: How Vehicle Level Attributes Drive High Voltage Subsystem Design Dr. Daniel Kok Manager - Advanced Electrified Powertrain Systems Ford Motor Company International Conference on Future Mobility Innovation in Electric and Hybrid Vehicles 8-9 November 2015, Dubai, UAE

2 Ford Electrified Vehicles: The Power of Choice BEV Ford Focus Electric HEV Ford Fusion Hybrid Ford C-Max Hybrid PHEV Ford C-Max Energi Ford Fusion Energi There is no single electrification solution that satisfies all customer requirements The right solution depends on individual usage profiles and needs. 1

3 2015 US Sales Status (CYTD sales as of Aug 2015) Source : WardsAuto.com Reference Center Toyota Prius/Prius C Ford C-MAX/Fusion Toyota Camry Hyundai Sonata Lexus CT Honda Accord Toyota Avalon Kia Optima Lexus ES Lincoln MKZ Subaru XV Crosstrek Lexus RX Honda Civic Buick LaCrosse Toyota Highlander Infiniti Q50 Infiniti QX60 Honda CR-Z Lexus NX Nissan Pathfinder Honda Insight HEV YTD Sales 0 10,000 20,000 30, k sales Tesla Model S Nissan Leaf Ford C-MAX/Fusion Chevrolet Volt/Cadillac ELR BMW i3 Toyota Prius Fiat 500 Volkswagen Golf Chevrolet Spark BMW i8 Ford Focus Smart ForTwo Porsche Cayenne Porsche Panamera Porsche 918 Spyder Mitsubishi I Honda Accord Mercedes GLE Toyota RAV4 PHEV and BEV YTD Sales Ford has sold nearly 500,000 electrified vehicles worldwide since 2005 BEV PHEV 2

4 Customer Requirements are Described in Vehicle Attributes What vehicle level attributes are relevant for Electrified Vehicles? Cost of Ownership Fuel Economy / Efficiency Performance (Launch, Maximum Vehicle Speed) Noise, Vibration, Harshness Towing capability Cargo volume Electric Range (Plug-in HEV & BEV) Electric Charging Speed (Plug-in HEV & BEV) 3

5 Battery Installed Capacity vs. Curb Weight Battery Installed Capacity (kwh) Range Extender PHEVs Higher Cost PHEV 10 5 FHEV Curb Weight (kg) For PHEVs, the battery is sized to deliver EV range 4

6 Global Regulations Average Annual FE / CO 2 Improvement Required by Regulation ( ) US 4.7% CAN 4.7% EU 5.1% Brazil 3.4% China 5.5% Global CO 2 Regulations are becoming ever more stringent The average rate of improvement through 2020 is nearly 5% annually 5

7 Battery Installed Capacity (kwh) Impact of Global Regulations Range Extender PHEVs Future PHEV FHEV Curb Weight (kg) Global regulations and competitive landscape are driving increased battery capacity Increased battery capacity yields more EV range and reduced CO 2 emissions Luckily, battery energy and power density are continuously improving 6

8 Vehicle Package Package of a large High Voltage battery entails a trade-off with other attributes Cargo area, ride height, 5 person seating, etc. are all attributes impacted An acceptable trade-off on one application, such as cargo space in 5-door, may not be acceptable in 4-door application Future vehicle platform architectures aim to package the HV battery with minimal attribute tradeoffs Caradvice.com Kbb.com Wot.motortrend.com Mad4wheels.com Guideautoweb.com Motorauthority.com Automobilemag.com Automobilereporter.com 7 7

9 EV Range vs. Cargo Capacity Products in the Market Cargo Capacity xev (% of Conventional capacity) 100% 90% 80% 70% 60% 50% 40% 100% = No Impact on Cargo Capacity Better BEV PHEV Worse EV Range (miles) Battery capacity is often traded off against cargo capacity and fuel tank size in BEVs and PHEVs 8

10 Distance Between Fuel Fill-ups Long distance between fill ups gives great customer satisfaction PHEVs can help increase distance between fill-ups 9

11 PHEVs with Electric EV Range Need Less Fuel Fill-ups Customer Percentile 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 32 km EV Range 48 km EV Range 64 km EV Range 80 km EV Range ,000 1,200 1,400 1,600 1,800 2,000 2,200 2,400 2,600 2,800 3,000 3,200 Distance Between Fill-ups (km) The average distance between fuel fill-ups for our Ford C-Max PHEV customers is more than 1,100 km More EV range means less fill-ups Based on EUROFOT customer data Assumes 38 MPG and 14 gallon tank Assumes 1 charge per day 10

12 0-60 MPH Time vs. Combined Fuel Economy (US) EPA CombinedFuel Economy (mpg) MPH Time (sec) Mainstream Premium Includes PHEVs and HEVs In premium vehicles, electrification is increasingly used to deliver performance 11

13 High Voltage Battery Power Demand Battery Power Usage Performance More blended operation More BEV like operation Range Time Duration (sec) A common battery design between vehicles is preferred but challenging Different vehicles & different driving styles result in different battery requirements High power peaks with short duration to deliver vehicle performance Medium power with long duration to deliver EV range 12

14 FHEVs, PHEVs and BEVs Use Different Battery Cell Designs Vehicle Requirements drive battery cell design Power Cell Cathode Cells can be optimized for Power or Capacity (Range) Energy Cell Cathode Altenergystocks.com 13

15 Wide-Ranging Driving Conditions in Global Markets Dubai 14

16 Driving Conditions U.A.E. Driving Conditions High temperature with varying humidity Soak in heavy sun load Medium overnight temperatures Driving Patterns Dense traffic in rush hour Long idle time with AC on 15

17 Battery Power vs. Temperature Battery Power Limit Reduced capability of battery cells Cold Optimal operating temperature Warm Power limiting due to battery life considerations -30 C Battery Temperature 50 C Electric drive capability is impacted by extreme temperatures Battery temperature needs to be managed carefully A chiller is required to keep the battery cool in Dubai s climate 16

18 Battery Cooling System Options In-vehicle battery package Chilled air from passenger cabin is used Underbody battery package Liquid is cooled by a low-temp radiator and A/C chiller Liquid cooled battery Air-cooled battery 17

19 Battery Cooling System Design Vehicle Usage/Package location can drive substantial differences in thermal system requirements Blended operation PHEV s tend to have lower cooling requirements Performs more like HEV Range Extender PHEV s have higher cooling requirements due to higher Electric-Only usage Performs more like BEV but with smaller battery Cost / Complexity Air Cooling Cell Bottom Cooling Thermal Requirements Cell Face Cooling 18

20 HEV/PHEV Commonality With Ford Powersplit Architecture Component HEV PHEV High Voltage Battery Traction Motor Generator Inverter (s) Electric AC DC/DC Converter Regen Brakes Hardware Transmission Engine Charger & Wiring Electric Pumps / Cooling Circuits Ford s Powersplit architecture enables significant sharing between HEV and PHEV hardware achieving benefits of scale 19

21 Wrap Up Vehicle attributes along with operating environment drive battery requirements Battery is designed to be robust to operating conditions Designing a unique battery pack for every vehicle is not economically feasible Must find the right balance between attribute delivery and battery complexity OEMs must find commonality and scalability in battery subsystem design for use in all global markets Ford has High-Volume Electrified Powertrain products in select markets since 2005 and is actively developing its Electrified Products to operate in global markets 20

22 Q & A 21

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