Integration of Multi propulsion power train. Green Car initiative 10.3 CASTOR. Infineon, CRF, Volkswagen SINTEF, Ficosa, UoS, Magnomatics

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1 CASTOR CAr multi propulsion integrated power train Integration of Multi propulsion power train Green Car initiative 10.3 Infineon, CRF, Volkswagen SINTEF, Ficosa, UoS, Magnomatics Page 1

2 The four leg principle for sprinter and runner 600Kg 0.7 KW Vmean = 30 km/h Vmax = 72 km/h 1kg Heu/40min Distributed propulsion Distributed power Page 2

3 The Efficiency of future EV mobility is driven by multi propulsion and the integration of the power train The activities for the integration are to functionalize, to integrate, and to miniaturize. 2 mag gear mag gear e-motor e-motor AC supercap batteries supercap batteries AC AC batteries supercap batteries supercap AC e-motor e-motor mag gear mag gear FIAT s 4WD distributed powertrain urban vehicle with solar panel for the vehicle supply Page 3

4 Project objective: Integration of Multi propulsion power train for the next generation of electrical vehicles! Advancements in efficiency and safety will be achieved by implementing a multi propulsion power train based on the integration of the energy storage with the propulsion unit based on the related synergies.! The future requirements of the multi propulsion EV- power train are determined by there integration level, the interoperability of the propulsion units, there functionality and robustness.! The future concept is not based only on the integration of the component functionalities but also considering an holistic approach for the thermo management.! The research will focus on the EV-power train consisting of the drive inverter, accumulator and engine. Page 4

5 Key topics addressed in Castor! Integration of accumulator (Battery, Super cap) and Inverter enabling next generation of high dynamic electrical power train! Integration of thermo management for the Inverter and Accumulator enabling high efficient decentralized thermo systems! Accumulator performance based on the combination of cells with physically different properties in terms of power dense cells and energy dense cells (e.g. Li-Ion and Super cap) will enable new functionalities and higher efficiency. Page 5

6 Car Dynamics and Power train Efficiency based on distributed propulsion and distributed energy supply Conventional Vehicle First + generation EV Next generation EV Central engine, gear, transaxle Central drive - Unsysmmetrical Central Mass, (Elchtest) - Transmission losses (Gear,...) - Weight of transmission system - Distributed propulsion (4WD) on high cost - Dynamics handicapted by masses - Partial load driving with low efficiency (ICE) single engine or distributed engine central power supply - Central high Mass is safety concern - Transmission losses - high EMV Pulses due to Central power - el. system encapsulation and shielding distributed propulsion distributed power supply + High dynamics due low mass + Shortest connection to power + Elimination of central mass Page 6

7 Power ratings for different power train applications *1 Evt. < 60V instead<65v Illustrated Examples for integrated power train applications 4 x 13 KW 2 x 7,5KW =15KW light Car, Vehicle Quadricycle personal propulsion Page 7

8 Benefits of the distributed multi propulsion power train: SAFETY " Reduced braking and stopping distance: EHB: 20%, EMB:25-30% + 0.5s ~ 25% off all accidents caused by skidding -> ESP > 30% road traffic deaths caused by (A) car-to-car front-end and (B) rear-end collisions 0.5s gain in reaction time is believed to reduce A by 30% and B by 50% " No pedal vibration during ABS mode (inexperienced drivers commonly mistakenly reduce brake pressure and thereby terminate ABS control mode) " Optimized brake-pad wear, fade-control COMFORT " Less pedal force, tunable pedal feel, more comfort (soft-stop) " enabler for comfort/ safety features such as Adaptive Cruise Control ACC ENVIRONMENT " Elimination of brake-fluid (4-5 ltr. / vehicle) being the most poisonate fluid in the vehicle OTHER " Compatibility with ABS, TCS, ACC, ESP, Collision Avoidance; EPB integration " Packaging flexibility, reduced risk of injury " Lower Relative price of EMB over EHB Page 8

9 Project Castor Step 1: Integration of Power Supply and Power Conversion: Integration of Accumulator and Drive-inverter on shortest way to the motor Computer on wheels CPU Step1.1: Development and Integration of the functionality Step1.2: Miniaturization and increase of the power density Page 9

10 Project Castor Step 2: Integration of Battery and Supercap: Integration of two physically different cell matrixes Into one accumulator Battery Supercap Accumulator Charging e.g. Li-Ion e.g. Supercap Driving, Rekuperation, high power Charging Step1: Development and Integration of the functionality Step2: Miniaturisation and increase of the power density Page 10

11 Step 3: Integration of the control structures, smart dynamic monitoring and power electronics Accumulator Management EV Power pack Battery Driver Isolation 500V Power electronic < 120V ->MOSFET Supercap Proessing and Control uc 16/32bit + Driver Isolation 500V Power electronic < 120V ->MOSFET Inverter Driver Isolation 2KV Power electronic > 160V -> IGBT U,I,T - Sensor Buck converter n Channels Buck converter n Channels Bridge 8 KW Tradeoff between number of cells/channels/size/costs/efficiency and weight Page 11

12 EVs - A Way of Life - A New Lifestyle Enjoy Life! Emissions -> Electrical vehicle vs. combustion vehicle: CO: -99%, HC: -97%, NOx: -92%, CO 2 : -50% Page 12