VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Dr. Michael Nöst, IESTA; Dr. Theodor Sams, AVL 9. April 2015, Science Brunch Wien 9.4.2015 Slide 1 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 1
E.-Mobility Flagship Project VECEPT VECEPT Vehicle with Cost Efficient Powertrain Targets: Development and testing of a PHEV demonstrator (volume model concept for the global market): All-purpose ability of the vehicle, Competitive performance, production cost and CO 2 reduction Equipped with a newly developed drivetrain system, cost-efficient charger, Next generation of battery technology, Optimized thermal management incl. HVAC strategy, Minimum AER of 30km and highest efficiency in all operation modes Investigation of BEV and PHEV in mixed fleets: Novel and sustainable mobility concept for mixed fleets Generic algorithmic toolset for strategic fleet management Installation and operation of charging systems with focus on PHEV 9.4.2015 Slide 2 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 2
E.-Mobility Flagship Project VECEPT VECEPT Vehicle with Cost Efficient Powertrain Gesamt Volumen: 7.042.549,- EUR, Förderung: 2.803.800,- EUR Projektlaufzeit: 02.07.2012 01.12.2015 Management: Konsortialleiter: AVL List GmbH, Projektmanagement: IESTA Konsortium: 9.4.2015 Slide 3 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 3
Project Structure 9.4.2015 Slide 4 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 4
Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 1 Vehicle Components & Integration AVL (Lead), IVD, ViF, Infineon 9.4.2015 Slide 5 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 5
Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 2 Enhancement of Energy Efficiency MAGNA (Lead), ViF 9.4.2015 Slide 6 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 6
Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 3 Applications & User Behaviour AIT (Lead), VIF(Task-Leader), UNIVIE (Task-Leader), Fluidtime, Samariterbund, ECO; VOR (LOI), T-Mobile Austria (LOI) 9.4.2015 Slide 7 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 7
Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 4 Infrastructure VERBUND (Lead), ECO (3 MM) 9.4.2015 Slide 8 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 8
Flagship Project VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Work package 0.3 Evaluation & Quality Management VIF (Lead), ECO, IESTA, AVL, AIT, VER, FLU, SAM, INF 9.4.2015 Slide 9 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 9
Conventional Hybrid Battery Electric Vehicle Flagship Project VECEPT Intended vehicle use profile vs. ICE technology Plug-In Hybrid Seriea / Parallel Range Extender Serial / Parallel Range Extender Pure Serial 2- / 3- / 4-cyl. Piston Engine 1- / 2- / 3-cyl. Piston Engine Rotary Piston Engine + - pure ICE Operation pure Battery Operation 0 100 Share of Energy from Plug-In Source - % 9.4.2015 Slide 10 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 10
BMEP 4 cyl [kpa] BMEP 4 cyl [kpa] BMEP 4 cyl [kpa] 8 8 8 VECEPT Competitive investigation of Serial Hybrid Efficiency Mechanically coupled driving: ICE is directly coupled to 24 the wheels, both e-motors support in parallel configuration 22 Advantage: 20 no efficiency loss by energy conversion 18 Disadvantage: at low-load conditions ICE ICE-best point 16 10 6 15 20 25 260 30 35 40 45 50 55 60 65 70 75 80 330 14 10 Serial mode (best line): ICE drives electric generator 24 8 22 which delivers 6 electric power for the electric propulsion 20 4 18 2 Advantage: 16 0 Disadvantage: 14 500 1000energy 1500 2000 conversion 2500 0 3500 4000losses 4500 5000 and 5500 6000 at 6500 low-load N [1/min] 24 10 22 8 Serial mode (best point): battery and generator deliver 20 6 energy for electric propulsion system, ICE and generator 18 4 9.4.2015 Slide 11 0 VECEPT 500 1000 1500 2000 2500 0 3500 4000 4500 5000 5500 6000 6500 Nov. 26, 2010 Marie-Curie ITN-2011 N [1/min] 11 12 10 6 4 2 15 20 360 25 260 30 330 400 500 35 40 45 260 700 1000 50 240 55 60 65 system; ICE is operated at best (BSFC) line continuous ICE operation with vehicle load 4 2 12 10 6 conditions ICE ICE-best point 260 240 10 Advantage: 8 Disadvantage: energy conversion losses plus battery 6 4 2 4 2 15 20 360 360 25 30 330 330 400 500 400 500 35 40 45 260 700 1000 260 700 1000 50 240 55 60 65 250 250 250 70 deliver average 2 required energy by an alternating 16 operation 14 0(on/off) and are always operated in best 500 1000 1500 2000 2500 0 3500 4000 4500 5000 5500 6000 6500 12 N [1/min] efficiency point ICE operation best efficiency, low complex. 70 75 75 80 80 charge /discharge losses. Constant ICE operation (NVH) 330 330 Source: AVL
EV + Range Extender VECEPT Degree of Electrification serial / parallel Hybrid Pure ICE Pure electric P2 or P3 Hybrid Full-purpose vehicle approach with full electric drivability (REEV / PHEV) P ICE or > P e-motor(cont) P ICE designed for cruising requirement P vehicle = P ICE + P e-motor better long-range fc in RE mode Power Split Hybrid Source: AVL 100% Degree of electrification 9.4.2015 Slide 12 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 12
EV + Range Extender VECEPT Degree of Electrification Pure ICE Pure electric Electric Vehicle approach with ICE as reserve fuel can for HV-battery P ICE << P e-motor(cont) P ICE designed for average P vehicle P vehicle = P e-motor focus on pure electric driving Source: AVL 100% Degree of electrification 9.4.2015 Slide 13 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 13
Approach 9.4.2015 Slide 14 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 14
Brake Mean Effective BMEP 4 cyl Pressure [kpa] (BMEP) 8 Engine development for VECEPT Low Engine CO2 development Emissions for low CO2 Emissions 24 10 15 20 25 30 35 40 45 50 55 60 BSFC < 240g/kWh 65 70 75 80 22 20 18 16 14 6 260 330 200g/kWh Demonstrator 12 240 10 4 250 8 6 2 260 4 2 360 330 400 500 700 1000 Engine BSFC Map 0 500 1000 1500 2000 2500 0 3500 4000 4500 5000 5500 6000 6500 N [1/min] Engine Speed - rpm Source: AVL 9.4.2015 Slide 15 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 15
traction force at the wheel - N traction force at the wheel - N Engine development for VECEPT Low Engine CO2 development Emissions for low CO2 Emissions GDI-TC Gen.4 AT/DCT 6 BSFC < 240g/kWh energy consumed (WLTC) GDI-TC Gen.2 AT/DCT 6 BSFC < 240g/kWh refined engine technology Source: AVL 9.4.2015 Slide 16 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 16
traction force at the wheel - N e-driving Engine development for VECEPT Low Engine CO2 development Emissions for low CO2 Emissions + Electricfication reduces ineffective ICE operation Recharging electrification ICE advances plus electrification reduce advantage of long overdrive ratios and small ratio steps reduce gear number Source: AVL 9.4.2015 Slide 17 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 17 Source: AVL
VECEPT All Purpose Cost Efficient Plug-In Hybridized EV PHILOSOPHY FOR THE FUTURE PHEV DRIVETRAIN full electric driving capability unrestricted drivetrain utility independent from the battery SOC Best in Class CO2 emissions in certification and charge sustaining holistic system approach - Best in Class PHEV add-on costs - compact dimensions - flexible design (torque capability, functional & package flexibility) Top Level Specification Description Vehicle Class C-segment Transmission AVL FH transmission ICE 1.2L, IL3, TGDI CO 2 emission (certified in NEDC) < 35gCO2/km (FC 2.1L/100 km) CO 2 emission (full hybrid mode in NEDC) < 79gCO2/km ( Best in Class ) Emission legislation EU 6c Fuel RON 95 Electric Range (AER in NEDC) > 30km Acceleration 0-100km/h (Hybrid) < 10s (ICE + E-Motor) Max. velocity (ICE only) > 170km/h 9.4.2015 Slide 18 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 18
AVL Future Hybrid VECEPT Operation All Purpose Modes Cost and Efficient Function Plug-In Hybridized EV FUNCTIONAL REQUIREMENTS Pure battery electric driving forward and reverse using the integrated e-motor. Electric vehicle launch in conventional operation mode Torque-split ecvt (electric continuously variable transmission) modes to enable the ICE to be operated at minimum vehicle speed and provide a charging power of minimum 3.5kW to the vehicle s high voltage (HV) system ecvt 3 Transmission speeds for direct propulsion by the ICE with power shifts between each for best drivetrain efficiency at medium and elevated vehicle speed Electric boost & Recuperation to support the ICE and transmission shifting. Impulse start functionality for the ICE (for vehicle standstill / very low speed an additional conventional 12V starter needed) + 9.4.2015 Slide 19 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 19
VECEPT Drivetrain Quick View Source: AVL 9.4.2015 Slide 20 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 20
AVL VECEPT Future Hybrid 7-mode All Purpose Transmission Cost Efficient Topology Plug-In Hybridized EV Lepelletier planetary gear set with the e-motor linked to an additional ring gear of the modified Ravigneaux gear set 7 transmission operation modes - 2 torque-split ecvt modes - 2 transmission speeds for electric driving - 3 transmission speeds for ICE operation Source: AVL compact design and low number of parts l = 350mm, m = 90kg (with EM) three shift elements plus C0 clutch with multiple functionalities of brakes and clutches Major interface specification: - ICE: 1.2L IL3 TGDI P max = 66kW@3500min-1 - E-motor: induction machine P 10sec = 65kW, M 10sec = 140Nm 9.4.2015 Slide 21 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 21
AVL VECEPT Future Hybrid CO2 All Purpose reduction Cost analysis Efficient Plug-In Hybridized EV Source: AVL PT: Powertrain: - AVL VECEPT 7-mode transmission with integrated EM - AVL ICE with Miller combustion cycle, cooled LP EGR, low friction design, beltless engine Rec/ED: Recuperation / Electric Drive Res: Vehicle drive resistance improvement (est.) Aux: Low power LV consumers * base vehicle with DCT transmission 103kW 119gCO2/km Base* DCT 103kW 119gCO 2 /km virt. Base MT, 30kmAER 125gCO 2 /km PT - 8gCO 2 /km VECEPT Hybrid Rec/ED - 25gCO 2 /km Res - 10gCO 2 /km Aux - 3gCO 2 /km CO 2 emission in NEDC: - charge sust.: 79gCO 2 /km - certification: 35gCO 2 /km NEDC 9.4.2015 Slide 22 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 22
VECEPT All Purpose Cost Efficient Plug-In Hybridized EV Dr. Michael Nöst, IESTA; Dr. Theodor Sams, AVL 9. April 2015, Science Brunch Wien 9.4.2015 Slide 23 VECEPT Nov. 26, 2010 Marie-Curie ITN-2011 23