Vehicle Impact due to E- Mobility 5. Bayerischer Innovationskongress 23.June 2016 Techbase

Transcription

1 Vehicle Impact due to E- Mobility 5. Bayerischer Innovationskongress 23.June 2016 Techbase Matthias Töns Division Powertrain BU Hybrid Electric Vehicle

2 Agenda 1 Business Driver for E-Mobility 2 2 Trends of E- Mobility 5 3 Bidirectional Charge and Traction System 9 4 Summary 18 M.Töns, Continental AG 2

3 Market Environment Business Drivers Enhance Technological Diversification OBD CO 2 Particles Legislation Diesel Electrification Technological Diversification CNG less CO 2 Flex Fuel OEM Consumer/Value M.Töns, Continental AG 3

4 Environmental Infrastructure Business Drivers Enhance Technological Diversification Urban planning Information and communications technology Energy and Environment Education and qualification Charging infrastructure Consumer / Value Source: Nationale Plattform Elektromobilität (NPE); Fortschrittsbericht 2014 Bilanz der Marktvorbereitung; p. 16 M.Töns, Continental AG 4

5 Agenda 1 Business Driver for E-Mobility 2 2 Trends of E- Mobility 5 3 Bidirectional Charge and Traction System 9 4 Summary 18 M.Töns, Continental AG 5

6 Trends in E-Mobility Remaining Problem: Infrastructure Diversity Range: 100km / 15kWh Charging: 6h / 3kW AC-1 System: 400V DC Link Market: Initial concepts Range: 150km / 24kWh Charging: 30min / 50kW DC 1h / 22kW AC-3 8h / 3kW AC-1 System: 400V DC Link Market: Local success Range: 300km / 50kWh Charging: 30min / 100kW DC 2h / 22kW AC-3 8h / 7kW AC-2 System: 800V DC Link Market: Reasonable cars Range: 500km / 75kWh Charging: 22min / 200kW DC 2h / 43kW AC-3 7h / 11kW inductive System: 800V DC Link Market: Established M.Töns, Continental AG 6

7 Charging Driver s View gain up to 25km range / h Home (AC) Inductive charging up to 11kW gain up to 50km range / h Work (AC) Inductive / conductive charging up to 22kW gain up to 100km range / h Shop (DC / AC) Conductive charging up to 100kW gain up to 300km range / h Our charging infrastructure is improving, but city and office tasks remain challenging Rest (DC / AC) Conductive charging up to 150kW M.Töns, Continental AG 7

8 Classical Electric Vehicle Architecture One Box per Function Makes it Costly M.Töns, Continental AG 8

9 Agenda 1 Business Driver for E-Mobility 2 2 Trends of E- Mobility 5 3 Bidirectional Charge and Traction System 9 4 Summary 18 M.Töns, Continental AG 9

10 Bidirectional Charge and Traction System Best Cost per Value for Future EVs M.Töns, Continental AG 10

11 Bidirectional Charge and Traction System Use Cases Energy flow Driving Charging Vehicle-to-Grid DC/DC increases efficiency Traction-power SOC-independent Traction: Motor mode Solution for infrastructure diversity Significantly cheaper infrastructure At home or in town: AC charging mode Compensates grid fluctuations Energy supply independence AC supply mode Regeneration: Generator mode On the motorway: DC charging mode DC supply mode M.Töns, Continental AG 11

12 Bidirectional Charge and Traction System Comparison with State-of-the-Art Vehicles Use cases AC Charging DC Charging Vehicle-to-Grid Vehicle types Slow-Chargers AC-Chargers 800V All-Chargers BCTS 1-phase (must 800V AC DC Vehicle hardware sufficient (charging station potentially to be adapted) Vehicle hardware not sufficient M.Töns, Continental AG 12

13 BCTS Drivetrain Increase the Vehicle Efficiency Scope: Cost effective electric powertrain with fast charging system Maximal flexibility of charging system (slow / fast, AC / DC) AC-Vehicle-to-Grid Technical Information (Engineering Targets) PSM Water Jacket Cooling Integrated Inverter Gear Ratio ~9.3 Parking Lock Max. E-Machine Speed 14000rpm Max. E-Machine Torque ~350Nm Max. E-Machine me. Power ~130kW Continuous Power ~80kW Benefits & Features Highly integrated Electric Drive System with Inverter, Electric Machine and Reducer Reduced efforts at customer for integration, sourcing, validation Star point opened for connection to mains phases E-Machine s inductance used as filter while AC charging Inverter reused as rectifier AC charging power possible up to installed average traction/regeneration power M.Töns, Continental AG 13

14 BCTS Inverter Control Software Enhanced to cover both: Driving and Charging Driving E-Machine E ~ E ~ E ~ Inverter DC-Link DC Booster Battery- Link Battery Position Encoder Charging E-Machine U ~ U ~ U ~ Input Filter Inverter DC-Link DC Booster Battery- Link Battery Mains supply Mains Voltage Information M.Töns, Continental AG 14

15 BCTS Inverter Testbench Measurements: 3-Phase 10kW Mains ~ Transformer Y X Y Z Line Impedance 200uH Demands A B C Inverter DC-Link Batt. (No Connection) Neutral Line Measurements DC-Link Measurements M.Töns, Continental AG 15

16 BCTS Inverter Testbench Measurements: 3-Phase 10kW Mains ~ Transformer Y X Y Z Line Impedance 200uH Demands A B C Inverter DC-Link Batt. (No Connection) Neutral Line Measurements DC-Link Measurements M.Töns, Continental AG 16

17 BCTS DC-Booster Increase the Vehicle Efficiency Scope: DC/DC Voltage conversion between battery-link and DC-link Technical Information 1-phase prototype 25kW average power SiC Mosfets & Diodes 400V / 800V buck-boost converter (H-Bridge) Benefits & Features DC Booster increases efficiency in driving cycle Increase of traction-power (SOC independent) Outlook Half-bridge design 3-phases 80kW average power (140kW peak) M.Töns, Continental AG 17

18 BCTS DC-Booster Testbench Measurements Test Case: Load change voltage remains constant Inductor Current Input Voltage Output Voltage Test Case: Switch off 500V 800V, 25kW Inductor Current Gate Signal Lower Transistor U DS Lower Transistor M.Töns, Continental AG 18

19 Agenda 1 Business Driver for E-Mobility 2 2 Trends of E- Mobility 5 3 Bidirectional Charge and Traction System 9 4 Summary 18 M.Töns, Continental AG 19

20 Bidirectional Charge and Traction System Summary We have developed a cost efficient solution for E-Mobility targeting all kinds of conductive charging. It solves the chicken-and-egg problem of investment for fast charging electronics by reusing existing electronics in the car. It makes the charging infrastructure as simple as possible. BCTS is compatible with all conductive charging systems. M.Töns, Continental AG 20

21 Thank you for your attention! M.Töns, Continental AG 21