Hybrid4All: A low voltage, low cost, mass-market hybrid solution Daniel BENCHETRITE, System and Integration Dept. Manager Valeo Powertrain Systems IQPC Automotive Power Supply System 48V Frankfurt 13th November 2013 October 2013 October 2013 I 1
Agenda 1 2 3 4 5 Market Analysis Main issues of Hybrid / Electric vehicles Simulation approach Valeo Components Conclusions October 2013 I 2
Agenda 1 2 3 4 5 Market Analysis Main issues of Hybrid / Electric vehicles Simulation approach Valeo Components Conclusions October 2013 I 3
Regulation is the main driver of Powertrain evolution Consensus on regulation target 2020 5 l/100 km (117g) 4,5l/100km (106g) for P Cars China 2020(cars only):106 2025 54.5 mpg 93g CO 2 /km eq NEDC for P Cars 3.9 l/100 km 2020 95g CO g CO 2 /km 4.0 l/100 km US Speeding up, China have set up the rules All catching up on Europe October 2013 I 4
2020 European CAFE prospective 150 140 130 120 Breakthroughs are a necessity 142g 130g -17g ICE Drastic improvement on ICEs needed, at least 5 points in efficiency Hybrids are mandatory to reach at least 38% efficiency Even with limited numbers, EVs (with 100% FE) bring significative benefit 110 100-14 g Hybrids - 4 g EVs 95g 90 80 2010 2015 2020 To reach 95g, ICE and transmissions efficiency is not enough. Hybrids and EVs will be necessary October 2013 I 5
There are a lot of Hybrids From simple Start-Stop to ZEV mode Micro Hybrid Mild Hybrid Full Hybrid Plug In Hybrid Range Battery EV Extender Fuel Cell EV Nissan Leaf GM Volt Toyota Prius3 Smart Honda Insight + Electric drive + Electric take off Buick LaCrosse + Engine Torque assistance + Kinetic Energy recovery Stop & Start October 2013 I 6
There are a lot of Hybrids By definition, an Hybrid has 2 DNAs ; combustion and electric engines Electric motor on Combustion Engine (Buick LaCrosse) Electric motor in transmission (Toyota PRIUS) Electric motor on rear axle (PSA 3008 HY4) October 2013 I 7
Electrification Forecast: Worldwide Vehicles <6T, Oil barrel $120 2020, Li-Ion Battery 300 /kwh 2020 Internal Combustion Engine Source: 2013 Valeo Powertrain Forecast Growth of Stop- Start FULL as niche, then growth MILD takeoff Emergence of PHEV Stop-Start 98.2 % ICE MILD FULL PHEVEREV BEV 1.8 % Trends BEV/FCEV : only 1.6% in 2023, still a limited market (lower segments), urban usage or image product EREV : not confirmed FULL / PHEV : faster growth than in last forecast, growing weight of PHEV from 2018 2019 MILD : market take off delay, rather in 2018 Stop-Start : getting mainstream with regular growth from now still 23% CONV, mainly in BRICS October 2013 I 8
Electrification Forecast: Europe Vehicles <6T, Oil barrel $120 2020, Li-Ion Battery 300 /kwh 2020 Trends Internal Combustion Engine Fast growth of Stop-Start Stop-Start Emergence of Electric Growth of MILD / FULL Rising importance of PHEV Source: 2013 Valeo Powertrain Forecast MILD FULL No real EREV/BEV take off PHEV EREV BEV/FCEV : lower forecast than in the past (A / B / C + LCV), EREV remaining a niche FULL / PHEV : growing significance, with higher weight of PHEV in sales MILD : somewhat postponed take off expected in 2018 Stop-Start : becoming standard within the next 6 years, almost 0% conventional engines in 2023 Significant Hybrid growth expected before 2020 to reach 95 g (expected 103g 2020, 88 g 2023) October 2013 I 9 BEV 97.0 % ICE 3.0 %
Agenda 1 2 3 4 5 Market Analysis Main issues of Hybrid / Electric vehicles Simulation approach Valeo Components Conclusions October 2013 I 10
Main issue of Hybrid/ Electric : COST! 10000 Cost of powertrain ( ) WW Market Share 2012 9000 8000 68% 7000 6000 29% 5000 4000 3000 2000 1000 0 % 1% 2% 0 % 0 % 0 GASOLINE STOPSTART DIESEL STOPSTART GASOLINE HYBRID48V GASOLINE MILD HYBRID GASOLINE FULL HYBRID GASOLINE PHEV BEV Diesel today just represent the upper limit customers are ready to pay for Hybrids won t develop in mass market without a clear cost breakthrough October 2013 I 11
Main issue of Hybrid/ Electric : COST! 10000 9000 8000 Cost of powertrain ( ) Systems 300-600V 7000 6000 5000 4000 Systems 12V Systems 48 V Systems 100-200 V 3000 2000 1000 0 GASOLINE STOPSTART DIESEL STOPSTART GASOLINE HYBRID48V GASOLINE MILD HYBRID GASOLINE FULL HYBRID Main reason of high cost is battery voltage. The higher the voltage, the higher the cost GASOLINE PHEV BEV October 2013 I 12
Agenda 1 2 3 4 5 Market Analysis Main issues of Hybrid / Electric vehicles Simulation approach Valeo Components Conclusions October 2013 I 13
140 120 100 80 60 40 20 0 0 200 400 600 800 1000 1200 TIME (s) Optimized hybrid : simulation approach Architecture study (e-machine location) VEHICLE SPEED (km/h) Gearbox EM EM Starter/Alternator ICE DC/DC LV Battery EDLC Electric motor & battery (Technology, Power, Voltage, Capacity) Mission profile (NEDC, WLTC, Artemis Urban) HV Bus HEV simulation platform Supervisor model Vehicle & driver model Traction model Energy Management Voltage and current curves Operating modes Energy storage Fuel consumption CO2 saving Cost / gco2 Vehicle platform (Engine displacement, segment) Efficient use of Optimized energy system October 2013 I 14
Architecture study BSG Electric Motor directly on the crankshaft of the engine Gearbox ICE EM DC/DC LV Battery EDLC HV Bus Single Electric Machine Easy integration in case of belt driven system Low global efficiency due to engine losses Engine losses compensation by EM CMG Electric Motor between engine and gearbox with an additional clutch Gearbox EM EM Starter/Alternator ICE DC/DC LV Battery EDLC HV Bus No engine losses to compensate Original clutch to be controlled & additional clutch required Integration issue on transversal engine Potential additional starter / alternator Torque control during engine start Electric Motor behind the gearbox through a disconnect clutch GMG Gearbox EM EM Starter/Alternator ICE DC/DC LV Battery EDLC HV Bus No engine nor gearbox losses to compensate Torque continuity during gear change Original clutch to be controlled & additional clutch required Additional starter / alternator Speed range issue for electric motor efficiency First conclusion: Easiest / cheapest system is with belt-driven machine October 2013 I 15
Operation modes Extended Stop / Start (even with manual gearbox), coasting Electric mode: running and take off (even with belt driven system) Generation mode & regenerative braking Torque assist / Overboost Operation mode Torque split management Driver request Overboost request Electric machine Thermal engine Torque request Conventional Electric Torque assist Generation Overboost October 2013 I 16
Battery capacity sizing Electric energy stored in EDLC during regenerative braking [kj] 1200 1000 800 600 NEDC results NEDC - MH1 400 6kW CP 8kW MR 200 ~50 kj 14kW MR 14kW PM 14kW PM pancake 0 0 50 100 150 200 250 300 350 400 1200 1000 800 600 NEDC - MH2 BSG MH1 CMG MH2 400 8kW MR 14kW MR 14kW PM 200 14kW PM pancake 20kW PM ~75 kj 20kW PM pancake 0 0 50 100 150 200 250 300 350 400 1200 1000 800 600 NEDC - MH3 8kW MR: ZEV2 400 14kW PM pancake: ZEV2 14kW MR: ZEV2 200 14kW PM: ZEV2 20kW PM pancake: ZEV2 ~75-105 kj 20kW PM: ZEV2 0 0 50 100 150 200 250 300 350 400 EDLC max. storable energy [kj] GMG MH3 Electric energy stored in EDLC during regenerative braking [kj] 1600 1400 1200 1000 800 600 400 200 Artemis Urban - MH1 6kW CP 8kW MR 40-70 kj 14kW MR 14kW PM 14kW PM "pancake" 0 0 50 100 150 200 250 300 350 400 1600 1400 1200 1000 800 600 400 200 1600 1400 1200 1000 800 600 400 200 Artemis urban results 40-75 kj Simulation results on B segment vehicle EM power limitation Artemis Urban - MH2 EM power limitation Artemis Urban - MH3 EDLC max. storable energy [kj] BSG MH1 CMG MH2 8kW MR 14kW MR 14kW PM 14kW PM "pancake" 20kW PM 20kW PM "pancake" 0 0 50 100 150 200 250 300 350 400 EM power limitation GMG MH3 8kW MR 14kW MR 14kW PM 75-105 kj 14kW PM "pancake" 20kW PM 20kW PM "pancake" 0 0 50 100 150 200 250 300 350 400 Second conclusion: Best value usable energy capacity < 100 kj October 2013 I 17
Battery capacity sizing 100 kj is the optimal usable level of energy However, to size the storage pack, need to apply SOC and safety factors Using ultracapacitors, the only limit in SOC is voltage drop. To keep voltage at nominal level, we have then considered a maximum 50% depletion in use: We then considered the size of UCAPs pack at ~200kJ Using Li-Ion batteries, it is necessary to limit the SOC swing in order to have a good lifetime (ex : 30%). Also, the peak currents (12kW under 48V gives 250Amps) might seriously damage the battery. Hence, in accordance with battery makers, we have applied an additional safety factor of 2 to 3. We then considered the size of the Li-Ion pack at ~600-900 kj (~180-270Wh) therefore, a Li-ion cell around 6Ah Third conclusion: Small storage capacity is enough (< 900 kj) October 2013 I 18
Electric Motor sizing Simulation results on NEDC cycle B segment vehicle CO2 emi issions benefit (%) BSG MH1 CMG MH2 GMG MH3 CP : Claw Pole MR : Mixed Rotor PM : Permanent Magnet PM P : Permanent Magnet Pancake OEM on cost wo integration overcost ( ) MH1 4kW CP MH1 BSG 6kW CP MH1 BSG 8kW MR MH1 BSG 14kW MR MH2 CMG 8kW MR MH2 CMG 14kW PM MH2 CMG 14kW MR MH2 CMG 14kW PM PMP P MH2 CMG 20kW PMP P MH3 GMG 8kW MR MR MH3 GMG 14kW MR MH3 GMG 14kW PM MH3 GMG 20kW PM Fourth conclusion: best cost to value with a 6-8 kw BSG motor October 2013 I 19
Agenda 1 2 3 4 5 Market Analysis Main issues of Hybrid / Electric vehicles Simulation approach Valeo Components Conclusions October 2013 I 20
Valeo i-bsg Product Definition E-machine description 166,5mm Claw poles number : 8pp Interpolar magnets type : Low Dy rate Stator type : U pins Stator length : 42mm Phases number : 2 x 3 169 mm** Stator thermal sensor Cooling : Forced air convection Ø 155* Electronics : Integrated inverter Protection level : IP25 Weight : 9,5kg * Bracket diameter ** Without pulley October 2013 I 21
Valeo i-bsg Product Definition E-machine Mappings October 2013 I 22
Valeo DC/DC Converter Definition Prototype Specifications Item Electronic Input Voltage Range Output Voltage Range Value Reversible buck (pre-charge and/or boost feature) Uninsulated chopper with embedded EMC filters in LV side Buck: 24 48 54V Boost: 36 48 52V Buck/Boost: 8 14 16V Derating between 8 and 10V Max Rated Power 2,5kW @ 14,5V Efficiency Weight Cooling Full Temperature Range Protection class Energy Storage 96% @ 500W 93,5% @ 2500W < 3,1kg Air cooled with minimal air velocity 2m/s -30 to +75 C Derating between 75 and 105 C IP67, IPX9X Full compliance with Li-Ion battery (bidirectional power flow when Vin > Vout) Bi-directional power flow Can supply the energy storage unit with power High safety class (ASIL C), high power (2,5kW) October 2013 I 23
Valeo DC/DC Converter Definition Prototype Packaging Dimensions Length: 218mm Witdh: 152mm Height: 78mm Volume: 2,6l Estimated weight: 3kg H Control Board Power Board Scalable Design 4 Cells L W October 2013 I 24
Vehicle implementation Engine & Powertrain Control Unit Energy Storage DC/DC Converter BSG e-machine Inverter Demonstrator : BSG implementation on 1,6l Turbo GDI M/T : i-bsg integration scheduled October 2013 I 25
Fuel economy results Simulation results on NEDC cycle B segment vehicle Regen and boost Up to 5% Electric modes Up to 3-4% Extended stop start Up to 5.5% 13-15% Fuel economy can be achieved October 2013 I 26
Vehicle assessment Stop Start extended function Faster starting with BSG machine than starter / starter generator Very low vibration level and silent cranking Capability of Reflex start & coasting up to 70kph Excellent Engine stop assistance : -70% stop time & oscillation Torque assist Transparent to the driver, Turbolag compensation at low revs Electric mode in running & take Off conditions Transparent switch from thermal to electric mode even in take off Up to 30kph electric drive possible in steady state conditions, up to 20% driving time in city conditions Overall excellent driveability October 2013 I 27
Cost estimate Total system cost estimate (Machine, Inverter, Battery, DCDC and ancilliaries) in Production volume sensitivity with projection up to 1 Mu/yr. 1400 Current Mild Hybrids 1200 1000 800 600 400 200 0 40 ku/yr 150 ku/yr 1 Mu/yr The value equation turns very positive with mass production volumes, in the 40 /g CO 2 range October 2013 I 28
Agenda 1 2 3 4 5 Market Analysis Main issues of Hybrid / Electric vehicles Simulation approach Valeo Components Conclusions October 2013 I 29
Conclusion A 48V mild hybrid system can deliver 13-15% fuel economy A 48V system allows, through rightsizing of the storage element, to cut cost of current mild hybrids by half This is why we believe mild hybrids could go to mass-market and reach a 10-12% WW market shares in 2020. Thank you October 2013 I 30
October 2013 I 31