VECEPT. All Purpose Cost Efficient Plug-In Hybridized EV. Dr. Michael Nöst, IESTA; Dr. Theodor Sams, AVL. 9. April 2015, Science Brunch Wien

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1 VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Dr. Michael Nöst, IESTA; Dr. Theodor Sams, AVL 9. April 2015, Science Brunch Wien Slide 1 VECEPT Nov. 26, 2010 Marie-Curie ITN

2 E.-Mobility Flagship Project VECEPT VECEPT Vehicle with Cost Efficient Powertrain Targets: Development and testing of a PHEV demonstrator (volume model concept for the global market): All-purpose ability of the vehicle, Competitive performance, production cost and CO 2 reduction Equipped with a newly developed drivetrain system, cost-efficient charger, Next generation of battery technology, Optimized thermal management incl. HVAC strategy, Minimum AER of 30km and highest efficiency in all operation modes Investigation of BEV and PHEV in mixed fleets: Novel and sustainable mobility concept for mixed fleets Generic algorithmic toolset for strategic fleet management Installation and operation of charging systems with focus on PHEV Slide 2 VECEPT Nov. 26, 2010 Marie-Curie ITN

3 E.-Mobility Flagship Project VECEPT VECEPT Vehicle with Cost Efficient Powertrain Gesamt Volumen: ,- EUR, Förderung: ,- EUR Projektlaufzeit: Management: Konsortialleiter: AVL List GmbH, Projektmanagement: IESTA Konsortium: Slide 3 VECEPT Nov. 26, 2010 Marie-Curie ITN

4 Project Structure Slide 4 VECEPT Nov. 26, 2010 Marie-Curie ITN

5 Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 1 Vehicle Components & Integration AVL (Lead), IVD, ViF, Infineon Slide 5 VECEPT Nov. 26, 2010 Marie-Curie ITN

6 Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 2 Enhancement of Energy Efficiency MAGNA (Lead), ViF Slide 6 VECEPT Nov. 26, 2010 Marie-Curie ITN

7 Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 3 Applications & User Behaviour AIT (Lead), VIF(Task-Leader), UNIVIE (Task-Leader), Fluidtime, Samariterbund, ECO; VOR (LOI), T-Mobile Austria (LOI) Slide 7 VECEPT Nov. 26, 2010 Marie-Curie ITN

8 Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 4 Infrastructure VERBUND (Lead), ECO (3 MM) Slide 8 VECEPT Nov. 26, 2010 Marie-Curie ITN

9 Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 0.3 Evaluation & Quality Management VIF (Lead), ECO, IESTA, AVL, AIT, VER, FLU, SAM, INF Slide 9 VECEPT Nov. 26, 2010 Marie-Curie ITN

10 Conventional Hybrid Battery Electric Vehicle Flagship Project VECEPT Intended vehicle use profile vs. ICE technology Plug-In Hybrid Seriea / Parallel Range Extender Serial / Parallel Range Extender Pure Serial 2- / 3- / 4-cyl. Piston Engine 1- / 2- / 3-cyl. Piston Engine Rotary Piston Engine + - pure ICE Operation pure Battery Operation Share of Energy from Plug-In Source - % Slide 10 VECEPT Nov. 26, 2010 Marie-Curie ITN

11 BMEP 4 cyl [kpa] BMEP 4 cyl [kpa] BMEP 4 cyl [kpa] VECEPT Competitive investigation of Serial Hybrid Efficiency Mechanically coupled driving: ICE is directly coupled to 24 the wheels, both e-motors support in parallel configuration 22 Advantage: 20 no efficiency loss by energy conversion 18 Disadvantage: at low-load conditions ICE ICE-best point Serial mode (best line): ICE drives electric generator which delivers 6 electric power for the electric propulsion Advantage: 16 0 Disadvantage: energy conversion losses and at 6500 low-load N [1/min] Serial mode (best point): battery and generator deliver 20 6 energy for electric propulsion system, ICE and generator Slide 11 0 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 N [1/min] system; ICE is operated at best (BSFC) line continuous ICE operation with vehicle load conditions ICE ICE-best point Advantage: 8 Disadvantage: energy conversion losses plus battery deliver average 2 required energy by an alternating 16 operation 14 0(on/off) and are always operated in best N [1/min] efficiency point ICE operation best efficiency, low complex charge /discharge losses. Constant ICE operation (NVH) Source: AVL

12 EV + Range Extender VECEPT Degree of Electrification serial / parallel Hybrid Pure ICE Pure electric P2 or P3 Hybrid Full-purpose vehicle approach with full electric drivability (REEV / PHEV) P ICE or > P e-motor(cont) P ICE designed for cruising requirement P vehicle = P ICE + P e-motor better long-range fc in RE mode Power Split Hybrid Source: AVL 100% Degree of electrification Slide 12 VECEPT Nov. 26, 2010 Marie-Curie ITN

13 EV + Range Extender VECEPT Degree of Electrification Pure ICE Pure electric Electric Vehicle approach with ICE as reserve fuel can for HV-battery P ICE << P e-motor(cont) P ICE designed for average P vehicle P vehicle = P e-motor focus on pure electric driving Source: AVL 100% Degree of electrification Slide 13 VECEPT Nov. 26, 2010 Marie-Curie ITN

14 Approach Slide 14 VECEPT Nov. 26, 2010 Marie-Curie ITN

15 Brake Mean Effective BMEP 4 cyl Pressure [kpa] (BMEP) 8 Engine development for VECEPT Low Engine CO2 development Emissions for low CO2 Emissions BSFC < 240g/kWh g/kWh Demonstrator Engine BSFC Map N [1/min] Engine Speed - rpm Source: AVL Slide 15 VECEPT Nov. 26, 2010 Marie-Curie ITN

16 traction force at the wheel - N traction force at the wheel - N Engine development for VECEPT Low Engine CO2 development Emissions for low CO2 Emissions GDI-TC Gen.4 AT/DCT 6 BSFC < 240g/kWh energy consumed (WLTC) GDI-TC Gen.2 AT/DCT 6 BSFC < 240g/kWh refined engine technology Source: AVL Slide 16 VECEPT Nov. 26, 2010 Marie-Curie ITN

17 traction force at the wheel - N e-driving Engine development for VECEPT Low Engine CO2 development Emissions for low CO2 Emissions + Electricfication reduces ineffective ICE operation Recharging electrification ICE advances plus electrification reduce advantage of long overdrive ratios and small ratio steps reduce gear number Source: AVL Slide 17 VECEPT Nov. 26, 2010 Marie-Curie ITN Source: AVL

18 VECEPT All Purpose Cost Efficient Plug-In Hybridized EV PHILOSOPHY FOR THE FUTURE PHEV DRIVETRAIN full electric driving capability unrestricted drivetrain utility independent from the battery SOC Best in Class CO2 emissions in certification and charge sustaining holistic system approach - Best in Class PHEV add-on costs - compact dimensions - flexible design (torque capability, functional & package flexibility) Top Level Specification Description Vehicle Class C-segment Transmission AVL FH transmission ICE 1.2L, IL3, TGDI CO 2 emission (certified in NEDC) < 35gCO2/km (FC 2.1L/100 km) CO 2 emission (full hybrid mode in NEDC) < 79gCO2/km ( Best in Class ) Emission legislation EU 6c Fuel RON 95 Electric Range (AER in NEDC) > 30km Acceleration 0-100km/h (Hybrid) < 10s (ICE + E-Motor) Max. velocity (ICE only) > 170km/h Slide 18 VECEPT Nov. 26, 2010 Marie-Curie ITN

19 AVL Future Hybrid VECEPT Operation All Purpose Modes Cost and Efficient Function Plug-In Hybridized EV FUNCTIONAL REQUIREMENTS Pure battery electric driving forward and reverse using the integrated e-motor. Electric vehicle launch in conventional operation mode Torque-split ecvt (electric continuously variable transmission) modes to enable the ICE to be operated at minimum vehicle speed and provide a charging power of minimum 3.5kW to the vehicle s high voltage (HV) system ecvt 3 Transmission speeds for direct propulsion by the ICE with power shifts between each for best drivetrain efficiency at medium and elevated vehicle speed Electric boost & Recuperation to support the ICE and transmission shifting. Impulse start functionality for the ICE (for vehicle standstill / very low speed an additional conventional 12V starter needed) Slide 19 VECEPT Nov. 26, 2010 Marie-Curie ITN

20 VECEPT Drivetrain Quick View Source: AVL Slide 20 VECEPT Nov. 26, 2010 Marie-Curie ITN

21 AVL VECEPT Future Hybrid 7-mode All Purpose Transmission Cost Efficient Topology Plug-In Hybridized EV Lepelletier planetary gear set with the e-motor linked to an additional ring gear of the modified Ravigneaux gear set 7 transmission operation modes - 2 torque-split ecvt modes - 2 transmission speeds for electric driving - 3 transmission speeds for ICE operation Source: AVL compact design and low number of parts l = 350mm, m = 90kg (with EM) three shift elements plus C0 clutch with multiple functionalities of brakes and clutches Major interface specification: - ICE: 1.2L IL3 TGDI P max = - E-motor: induction machine P 10sec = 65kW, M 10sec = 140Nm Slide 21 VECEPT Nov. 26, 2010 Marie-Curie ITN

22 AVL VECEPT Future Hybrid CO2 All Purpose reduction Cost analysis Efficient Plug-In Hybridized EV Source: AVL PT: Powertrain: - AVL VECEPT 7-mode transmission with integrated EM - AVL ICE with Miller combustion cycle, cooled LP EGR, low friction design, beltless engine Rec/ED: Recuperation / Electric Drive Res: Vehicle drive resistance improvement (est.) Aux: Low power LV consumers * base vehicle with DCT transmission 103kW 119gCO2/km Base* DCT 103kW 119gCO 2 /km virt. Base MT, 30kmAER 125gCO 2 /km PT - 8gCO 2 /km VECEPT Hybrid Rec/ED - 25gCO 2 /km Res - 10gCO 2 /km Aux - 3gCO 2 /km CO 2 emission in NEDC: - charge sust.: 79gCO 2 /km - certification: 35gCO 2 /km NEDC Slide 22 VECEPT Nov. 26, 2010 Marie-Curie ITN

23 VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Dr. Michael Nöst, IESTA; Dr. Theodor Sams, AVL 9. April 2015, Science Brunch Wien Slide 23 VECEPT Nov. 26, 2010 Marie-Curie ITN

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