ENERGY-STORAGE REQUIREMENTS DERIVED FROM LOW-VOLTAGE ELECTRICAL ARCHITECTURES AND POWER-SUPPLY USAGE. Armin Warm Bastian Hartmann, Björn Mohrmann

Transcription

1 ENERGY-STORAGE REQUIREMENTS DERIVED FROM LOW-VOLTAGE ELECTRICAL ARCHITECTURES AND POWER-SUPPLY USAGE Armin Warm Bastian Hartmann, Björn Mohrmann Advanced Power Supply & Energy Management AABC

2 INTRODUCTION Electrical power supply systems Enable electrical features Enabler for fuel economy functions Are highly critical for customer satisfaction and safety 1905: Light Starter Picture source: Auto Motor und Sport 1985: Light Starter ABS Power windows 2015: Light Starter ABS/ESP Power windows Engine ECU Customer ports EPS Driver assist Heated/cooled features Start/Stop operation 2020+: Light Starter ABS/ESP Power windows Engine ECU Customer ports EPS Driver assist Heated/cooled features Start/Stop operation e-booster Fully autonomous vehicle Active chassis systems 2 2/2/2017 Energy-storage requirements derived from low-voltage electrical architectures and pow er-supply usage

3 AGENDA Functions and requirements of electrical power supply systems Electrical power supply architectures Deriving requirements for energy storage solutions Conclusion & Outlook 3 02/02/2017

4 ELECTRICAL POWER SUPPLY Package Cost Electrical power demand Weight Electrical power supply system Scalability Emissions Fuel economy/co2 Robustness 4 02/02/2017

5 FUEL ECONOMY / CO2 Ford s commitment to reduce CO 2 and emissions Customer interest in fuel efficient vehicles Legislative pressure Fuel economy functions in the vehicle Engine stop/start Recuperation Torque assist Electric drive 5 02/02/2017

6 Average power demand AVERAGE ELECTRICAL POWER DEMAND Definition Electrical base load of the vehicle Constant loads for a specific operation or use case Mainly covered by the generator output Small car Midsize car Luxury car Cooling features Heating features Summer Winter 6 02/02/2017

7 Current (A) Transient power demand (kw) TRANSIENT ELECTRICAL POWER DEMAND Definition: Short pulse length High current gain Potential high frequency Mainly covered by the energy storage device Superset of constant loads and transient loads EPS ARC ARK ebooster ecat Time in s 7 2/2/2017

8 Average power ELECTRICAL POWER SUPPLY REQUIREMENTS POWER DEMAND Diverse product portfolio creates wide range of power demand B-D segment Commercial vehicles Premium brand Transient power 8 02/02/2017

9 SUMMARY: GENERIC FUNCTIONS OF A POWER SUPPLY SYSTEM Traditional Supply power to electrical loads Supply key-off loads Supply cold crank Start / Stop and hybridization Supply warm re-crank Recuperation for fuel economy Torque assist New electrical features Supply higher level of average and transient power Fulfill functional safety level (for safety critical functions) Autonomous driving Fulfill high functional safety level 9 02/02/2017

10 POWER SUPPLY ARCHITECTURES - OVERVIEW Single battery topologies Dual storage topologies Dual voltage topologies and many more variants! 10 2/2/2017

11 POTENTIAL LOW VOLTAGE BATTERY SYSTEMS Single Battery: Baseline for wide range of applications Further optimization potential Dual Battery: Noticeable fuel economy benefit For small and mid-size applications with moderate to high electrical power demand Diverse product portfolio requires balance of: electrical performance Cost Fuel economy Package 48V Battery Highest fuel economy potential Meets elec. performance demand of premium cars and commercial vehicles 11 02/02/2017

12 REQUIREMENT FOR POWER SUPPLY ENERGY STORAGE Example for impact on 48V mhev energy storage device imposed by power supply requirements: Discharge power current energy storage technology declines at low temperature To maintain critical functions the required -30 C discharge power is significantly higher 12 02/02/2017

13 FUNCTIONS TO BE COVERED BY AN ENERGY STORAGE Single battery topologies Dual storage topologies Dual voltage topologies Single 12V battery today Single advanced 12V battery Second battery: micro-hev Second battery: micro-hev + power supply 48V mhev 48V mhev + power supply Supply power to electric loads Supply key-off loads Supply cold crank ( ) Supply warm recrank Recuperation for fuel economy Supply high level of transient power = function required = function not required 13 02/02/2017

14 DERIVED BATTERY TARGET REQUIREMENTS Single battery topologies Dual storage topologies Dual voltage topologies Single 12V battery Second battery micro-hev Second battery: micro-hev + power supply 48V mhev 48V mhev + power supply Capacity 30Ah 100Ah ~ 10Ah > 10Ah ~ 10Ah > 10Ah Transient discharge power Dynamic charge acceptance Performance temperature range Cold crank temperature yes limited yes limited yes ~ 3kW ~ 3kW ~ 3kW ~ 12kW ~ 12kW -30 C 120 C (80 C) -10 C 50 C -30 C 120 C (80 C) -10 C 50 C -30 C 80 C -30 C N/A N/A N/A -30 C Component life Vehicle life Vehicle life Vehicle life Vehicle life Vehicle life 14 02/02/2017

15 CONCLUSION & SUMMARY Low voltage electrical systems are facing multiple vehicle level requirements Fuel economy Torque assist for enhanced driving performance Enhanced electrical features (Power supply) Increase of electrical features and functions will lead to enhanced power requirements for the power supply system Cascaded to the energy storage this means: Increased transient power Over the entire vehicle operation temperature range With high availability / robustness 48V as well as 12V With optimized package volume and weight At low cost 15 2/2/2017

16 Thanks for your attention! Questions? 16 02/02/2017 High Performance electrical Pow er Supply Systems - Requirements, Challenges and Design Concepts