Hybrids & Electromobility New prerequisites and customer values Robert Eriksson Volvo Cars Group 2018-02-26 2018-03-05
OuTline Volvo cars vision History and studies CO2 comparison and reductions Requriement landscape Electrification concepts and components Values for the customer 2
Vision commitments No one should be seriously injured or killed in a new Volvo by 2020 Till 2025 we shall have put 1 Mio. electrified Volvos on the road. We shall give back one week of quality time per year to our customers 3
On the horizon Autonomy Multiple brands multiple segments Electrification Connectivity System of systems Crowd sourced data Machine learning Sharing Third party access Personalization Product evolution after original sale Decreasing time to market Increasing OEM control over OEM concerns Unknowns 4
SOME Major activities on the journey of efficiency Concept vehicle Internal studies Test fleet Mass production Knowledge build ReCharge ECC HEV 98 Range Ext EV 3CC Electric car1976 C30 electric Pure EV V70 PHEV HEV 98 V60 PHEV Plug-In Hybrid Mild Hybrid Stop/start ISG Micro Hybrid ISG / 48V 1989 Power supply 48V/12V Total efficiency & Light weight 1980 SVEA SEMINAR THE FUTURE OF COMBUSTION ENGINES 48V/12V PZEV (Early intro) 3CC LWD Paulus 1979 LCP 1983 1970 2018-02-26 42V/12V Λ -Sensor (1st OEM) Emission control S60L PHEV XC90 PHEV ISG/42V Soft Hybrid ISG/48V Mild S/V90/XC/V60 PHEV Stop/start ESM Stop/start ESM S40 Power splitford ESCAPE HEV Paulus 1979 Full Hybrid 1990 2000 DrivE M-KERS 2010 2015 5
Electrification - Why not then - why now? 1970 s Concerns about fuel price and limited availability of fuel. (Proved to be incorrect!) No market request for efficiency but awareness of emissions Lack of mature technology Knowledge gaps Now Increased public awareness about global warming and energy resource limitations Market awareness of possible improved attributes Major steps in technology development (batteries, power electronics, machine control) Regulations on fuel economy and emissions Technology EXPERIENCE FROM 40 YEARS WITH VOLVO CARS EFFICIENCY AND ELECTRIFICATION ROBERT ERIKSSON VOLVO CAR CORPORATION 2013-04-23 Timing 6
Hybrid Concept definition / CO2 reduction Brake regen Power vs % brake energy 100.0% Ack. Energy (%) 90.0% 80.0% 70.0% 60.0% 50.0% 40.0% 30.0% Mild HEV P0/P1 US Comb WLTP NEDC Mild HEV P2-P4 20.0% 10.0% Estimation of CO2 potential with Stop/start as ref: Maximum 12V regen (P0) ~3g Mild HEV Gen1 (48V) ~12kW: ~7g Mild HEV Gen2 (48V) 15-20kW: ~15g Full HEV (High Voltage) 35-50kW: ~20g Source: Daimler 0.0% 0 10 20 30 40 50 Regen Power event (kw)
EnErgy comparison 8
Energy split HybriD Propulsion ENERGY SPLIT FOR PARALLEL HYBRID DRIVELINES (WLTC ) 100% 6% 20% 90% 80% Optimum 70% ICE Finding best possiböle SEK/g CO2 63% ICE 59% 60% 50% Maintain or Improve the other attributes 40% CO2 reduction ICE TR Aux 30% 9% TR 9% 2% Aux 2% 20% Kinetic 14% Kinetic 12% 10% Roll res 5% Aero 7% Roll res 5% Aero 7% 0% ICE-Diesel Aerodynamics 2018-02-26 Rolling resist. SVEA SEMINAR THE FUTURE OF COMBUSTION ENGINES ICE-Mild Hybrid Kinetic+recup energy Auxilaries/El 52% TR 10% Aux Kinetic Roll res Aero 2% 6% 5% Cost 7% ICE-Full Hybrid Transmission Electric drive/ic-engine 9
China Admin Rules & future predictions on NEV Average fuel consumption targets CAFC. 2020 5 l/100km (~120 g CO2/km) 2025 4 l/100km (~96g CO2/km) 2030 3,2 l/100km (~77g CO2/km) Average is a function of weight. Multipliers for NEV & low fuel consumption NEV Credit system Start 2019 with 10% on production per entity 2020 12% on production per entity Multipliers for BEV 2-6 cars (max 350km, less 16,1 kwh/100km for 2 ton car) Multipliers for PHEV 2 if 50km e-range + max 70% of FC limits. Multipliers from 2020 might not be as generous as today. NEV target for 2030 up to~40% of new car production. Admin rules. Trade between entities are allowed within the company, Banking up to 3 years for CAFC, NEV credits can be sold/bought on the market Penalties. Entities not fulfilling the demands after trading etc. will be ordered to adjust their production or even be closed. Other future, VCC predictions EV consumption limits for PEV from 2019. Ex. a ton car can have maximum electricity consumption of 19,3 kwh/100km. Advance level max 16,6 kwh/100km In phase 5 CAFC from 2021 high probability for conversion of electricity to l/100km. Ex Nissan Leaf (15 kwh/100km) would then have 1,3-2,2 l/100km depending on method. In Phase 5 from 2021 expected introduction for China Cycle. End of national incentives 2020-12-31 Admin rules trading between entities, sales and banking WLTC China Cycle 2018-02-23 10
Efficiency optimising focus now and then Shares of propulsion energy sinks Today/ICE: Total efficiency improvement potential is dominated by powertrain efficiency. Auxiliary loads are significant but not dominating. Tomorrow/BEV: Total efficiency improvement potential will be dominated by road load (and aux loads, not shown)! BEV efficiency competitiveness means competing with road load (and range) Images courtesy of Göran Almkvist, Facts of Energy Consumption 2018 11
Electrification strategy 12
Volvo cars engines, transmissions, electrification Eg: T8 Position Current and near term building blocks VEP4 4-cyl Petrol, 2.0L (&1,5) F22 8-speed Planetary Automatic VED4 4-cyl Diesel, 2.0L GEP3 3-cyl Petrol, 1.5L M66 6-speed Manual 7DCT 7-speed Dual Clutch Automatic M76 6-speed Manual Electrification High Voltage Battery Li-Ion Power Electronics ERAD C-ISG Electric Rear Axle Drive Crankshaft mounted Integrated Starter Generator New FWD PHEV power pack KERS 48V Kinetic Energy Recovery System 13
Batteries for different applications 14
Plug In - technology 15
Twin Engine AWD PHEV on SPA Internal Combustion Engine Crankshaft mounted Integrated Starter Generator (C-ISG) Power Electronics High Voltage Li-Ion Battery Power Electronics Electric A/C compressor Electric Rear Axle Drive (ERAD) PHEV = Plug-in Hybrid Electric Vehicle Mild HEV = Hybrid Electric vehicle (10 20 kw, 48V) ERAD = Electric Rear Axle Drive C-ISG = Crankshaft mounted Integrated Starter Generator Automatic Transmission " 65 kw El Machine " 10,3 kwh Battery " 43-53 km El Range
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Mild Hybrids ON 48V 18
Why do we need 48V Mild HEV " Todays 12V system is approaching it s maximum capability. # Migration of 12V loads over to 48V to make space for a future 12V expansion " 48V Mild HEV is an enabler for introduction of new enhanced functionality # Introduction of high power features beyond the capability of today 12V architecture. (example E-boost, emission control, advanced chassis systems, climate comfort..) " 48V Mild HEV is enabler to improve fuel economy and support fleet average CO2 " Europe CO2 from 2020 and beyond. (95g/km2020 -> 75 g/km2025) " China CAFC from 2019 and beyond (China CAFC, 5 L/100 km req.) # Cost effective fleet CO2 reduction with 48V mild hybrid technology # WLTP will change the cost sensitivity of CO2 actions 19
48V in comparison to other HYBRID technologies Same requirements and solutions as for 12V Mild hybrid Changed requirements and component solutions Personal safety limit Full hybrid >120V/30kW PHEV 400V/50kW BEV 400V/>150kW Cost. Mild Hybrid Micro hybrid 48V/10-20kW S/S in speed S/S in speed S/S in speed 12V/3kW Stop/start Limited recuperation Up to 80% Recuperation Coasting Limited E-drive 60v 100% recuperation Coasting Limited E- drive 100% recuperation Coasting E- drive System Voltage 20
P0 Mild HEV - belt integrated starter (BISG) 2 Mild HEV P0 48V FEAD KERS System voltage: 48V EM: " ~10 kw " Installed on FEAD belt ( B-ISG ). " EM always rotates with engine. " EM replaces std alternator and starter. 10 kw 48V E- Machine B-ISG Bidirectional belt tensioner system Facts & benefits: " CO 2 improvement (WLTP); ~7 gco 2 " Refined engine cranking (better NVH). " Added power; # ~10kW mech boost # ~8 hp mech boost for petrol engine max power. # ~10 hp mech boost for Diesel engine max power. $ Improved take-off (see next page). " Potential to reduce engine-out emissions " The 48V power supply can enable further vehicle functions.. EM = Electric Machine B-ISG= Belt driven Integrated Starter Generator FEAD = Front Engine Accessory Drive 21
P0 Mild HEV Attribute enhancements Reference P0 HEV Initial acceleration and distance travelled can be considerably improved also with a relatively low power P0 Mild HEV
P2 solution GAD Gearbox auxillary drive 23
Volvo system topology FOR P2 solution - GAD Functional Overview View Mechanical System View DMF and K0 Clutch 48V EM EWP Combustion engine Clutch AC AT E-machine and PE 4812V DCDC 12V 48V 48V Battery Li-Ion 48V Battery Chain drive Optional AC drive 24
P2 gad Boost Torque, with 2 different EM sizing alternatives
Method to compare attributes for hybrid concepts Mild concepts are compared according to its resulting characteristics for a choosen vehicle Attribute examples Concept evaluation chart CO2 reduction Attribute 8 Ideal Plug-In Hybrid vehicle Parasitics System Weight Base P/T Vehicle Weight Energy storage size Range CO2 Fuel Consumption Bildd Vehicle Acceleration edrive concept /size Aero Total Power Launch improvements Dynamic support at different speeds E-drive w engine off E-Range AWD feasibility Attribute 6 Attribute 7 Attribute 1 ICE vehicle Attribute 2 Concept evaluation Package HEV Architecture Layer Attribute 5 Attribute 3 Vehicle Application/Platform Layer Attributes Costs Attribute 4 26
Propulsion attributes comparison for P0 and P2 SOLUTIONS Attribute Conventional 12V S/S 48V P0 BISG CO2 reduction 2 5 7 El. Drive capability 1 1 3 Emission control 1 4 5 Power boost 1 4 6 Dynamic boost/fill-in 1 4 6 48V P2 - GAD Engine start NVH AWD Feasability Attribute Evaluation 12v S/S P0- BISG P2 - GAD CO2 reduction 7 6 5 4 3 2 1 0 El Drive cap Dynamic boost (fill in) AWD feasibility 1 1 1 Engine start NVH 1 5 7 The Attribute values shall be seen as sample evaluation and not final Volvo Car Data Emission red Power boost 27
Energy system - VISION Energy numbers are examples to illustrate positive effect of externa charging (example for total EV range of total 150 km/day) Internal consumption PV Micro production 60 kwh during daytime 30 kwh during daytime Household with loads Night kwh EV kwh EV with home charging 10 kwh from during storage night Power & Energy management Excessive power 30 kwh 10-20kWh for charge at work 10 kwh consumed at night 10 kwh charge during daytime Power grid Remote use of home produced energy PV Energy use at external site 10-20kWh for other use Energy Storage Note: Storage size is limited, often much smaller than an EV battery External EV charging will act as a storage during daytime The stored energy is used for transport later the same day.
Conclusions and summary " Volvo commits strongly to electrification, with 1 Million electrified vehicles on the road 2025 Mild, PHEV or BEV " PHEV technology will be the bridge into battery electric vehicles. " 48V technology will be important to support fuel efficient entry level segments. Further expansion of the 48V board net can be foreseen once the infrastructure is in place and a mature commodity base exist on the market. " The P2 GAD configuration offers higher total attributes and can be viewed as Mild-HEV + " Plug In vehicles (BEV s and PHEV s) will play a role as rolling energy storage for renewal energy production. 29