Powertrain & Thermal Systems L'électrification et composants 48V des fonctions moteur et auxiliaires O. COPPIN N. DEVIENNE Électrification des fonctions et des auxiliaires Flins - 15 Décembre 2016 Flins 15 Décembre 2016 1
Agenda Drivers for hybridization Low voltage Hybrid systems and functions Alternative boosting : electric supercharger Function electrification Low voltage Road-Map Conclusion Flins 15 Décembre 2016 2
Driver for hybridization : CO 2 regulations Main issue of hybrid / electric: COST! China 2020(cars only):106 Diesel : the upper limit customers are willing to pay To develop in mass-market, hybrids need to be cheaper : Why 12V+12V and 48V make sense Flins 15 Décembre 2016 3
Powertrain Solutions for CO 2 3 main technical Areas 1 2 3 Internal Combustion Engine Downsizing Turbocharger/Supercharger Gasoline Direct Injection Gasoline Cooled EGR Variable Valve Activation Thermal management Electrification Stop-Start Mild Hybrid Full Hybrid Plug-in Hybrid Range Extender Battery Electric Vehicles Energy management Downspeeding & Automation Double Clutch Transmission Automatic Early lock-up Downspeeding Flins 15 Décembre 2016 4
Hybrid Architectures P3 P1 P2 P4 P4 P4 P0 P0 / P1 P2 P3 P4 E-motor linked to ICE E-motor decoupled from ICE, at same speed E-motor decoupled from ICE, at a speed multiple than ICE E-motor in driveline or in rear axle or in wheels 48V can address all hybrid architectures and enhance hybrid functions benefits Flins 15 Décembre 2016 5
Functions availability P0 Belt 12V P0 Belt «12V + 12V» P0 Belt «12V + 12V» + esc P0 Belt 48V (+ esc) 48V P2/P3/P4 Cold start o o o o / o / (P2) Change of Mind Stop & Start High Efficiency generator Durability (1mcy) Comfort Start Stalling help Coasting o / Regenerative braking o Torque Assist o o Torque Monitoring o o Downspeeding Engine Dowsizing ZEV o / Electrical Take off o / : Possible o : Limited : Impact on fuel savings Voltage increase will enhance hybrid functions P2, P3, P4 architectures increase hybrid energy management benefits Flins 15 Décembre 2016 6
Why 48V Hybrid is affordable Low voltage Small battery Cheap battery Belt Starter-Generator All-in-one : Just replaces the alternator with integrated inverter Standard powertrain architecture Limited power : air cooling possible if <8kW permanent 48V < 60V : No electric safety issues Limited insulation on wiring and connectors, easy passive safety Constant challenge : component right sizing Flins 15 Décembre 2016 7
Funded project Peugeot 308 48 Volt Electric AWD : Essencyele. Association of a 48V P0 belt machine and a 48V electric rear axle All Hybrid functions including electric driving Cost effective thanks to 48V P4 hybrid architecture efficiency Up to 22%* CO2 emission reduction on NEDC, up to 16%* WLTP AWD mobility function as added value for end customer. * Valeo estimate based on simulation, will vary per vehicle application Flins 15 Décembre 2016 8
Alternative Boosting : efficiency analysis Mechanical supercharger Electrical supercharger 17,4 100 > 82,6 100 > 100 High mechanical losses, only 82% of generated torque goes to the wheels No Mechanical losses. 100% of the generated torque is transferred to the wheels With e-supercharger there is no friction while boosting. Energy is free while recovered during braking Flins 15 Décembre 2016 9
Interest of alternative boosting : efficiency Hybrid system Electrical supercharger 25 kw 25kW 5 kw 25kW To get 25kW on the wheels, need ~25 kw from the e-motor. With 300Amps limit, 100V necessary To get 25kW on the wheels, need ~5 kw on the air thanks to combustion COP. With 300Amps limit, 48V is far enough With the electric supercharger there is fundamentally efficiency benefit linked to combustion COP For the same power at wheels, the hybrid voltage can be reduced from high voltage to 12V or 48V: the electric system, including batteries, is then far cheaper. Flins 15 Décembre 2016 10
Electric Supercharger = instantaneous response 26 BMEP (bar) 24 22 20 18 16 14 12 10 Electric supercharger after 0.5s Turbo after 2.0s Turbo after 1.0s Turbo after 0.5s Turbo engine Naturally aspirated engine 8 500 1500 2500 3500 4500 5500 6500 Engine speed (RPM) The higher the downsizing, the longer the turbo lag @ low RPM. The turbo is unable to compensate the lag. Response time is the key parameter Flins 15 Décembre 2016 11
Renault Fluence: SURAL-HY Supercharging system for hybrid gasoline engines with high downsizing Funded project Electric supercharger 3 kw, 12 Volts Integration of 1.2L Renault turbo engine with the Electric Supercharger 12V NiZn battery esc dedicated Design and integration of a larger Turbo to achieve 100kW / L Gearbox downspeeding (15%) Partial 'free' power boost, symmetry braking phases: energy recovery and energy use with 12V Engine downsizing and downspeeding thanks to esc integration Flins 15 Décembre 2016 12
Electric Supercharger 3 main applications More Power Better Fuel Efficiency Less pollutants Audi RS5 TDI 386HP Valeo NA Democar 8% FE Volvo edrive 450HP Ricardo HyBoost 20% FE Valeo-FEV : Euro6 w/o SCR 48V 12V Diesel Flins 15 Décembre 2016 13
Electrical board net : modular building 12V -> 48V 12V regen network Optional Piloted switch 12V clean network Reversible Machine Starter + Alternator 12V 12V + 12V Basic Set Starter 12V Battery 1 12V NON Sensitive Loads 12V Battery 2 12V Sensitive Loads 12V regen network Optional Piloted switch 12V clean network Reversible Machine Starter + Alternator 12V Starter 12V + 12V Extented Set 12V Battery 1 12V NON Sensitive Loads esc 12V Battery 2 12V Sensitive Loads 48V regen network DCDC 48-12 V 12V clean network Reversible Machine 48V 12V + 48V 48V Battery 48V NON Sensitive Loads esc 12V Battery Starter 12V Sensitive Loads Flins 15 Décembre 2016 14
Future steps Develop P2, P3 & P4 48V application to enhance efficiency 48V : a way to address low cost small electric vehicle? Power level compatible with 80 to 100 km/h max Autonomy up to 100km by battery sizing Keep cost and component modularity with 48V hybrids Flins 15 Décembre 2016 15
12+12V & 48V Road Map First 12V application : Stop & Start % CO2 Reduction 80 70 60 Systems CO2 gains / cost position 50 40 30 20 10 0 STT system cost Flins 15 Décembre 2016 16
12+12V & 48V Road Map 48V mild hybrid : more power and more energy available First and easier step : belt e-machine. % CO2 Reduction 80 70 60 Systems CO2 gains / cost position 50 40 30 20 10 0 system cost Flins 15 Décembre 2016 17
12+12V & 48V Road Map A better cost / CO 2 gain ratio than high voltage systems 48V : An increasing potential with boosted hybrid and power devices electrification A continuous extension : accessories electrification, P3/P4 hybrid architectures, new concepts. % CO2 Reduction 80 70 60 Systems CO2 gains / cost position 50 40 30 20 10 0 system cost Flins 15 Décembre 2016 18
48V board net opportunity : more power available 12V systems have a limit around 4 kw (~300 Amps max) BMW 750i Diesel 3.0L WLTC 40 C + comfort function ON Power (W) 12000 10000 8000 6000 Lights Board Fuel Pump ABS, CBC and DBC Actuators Small Power consumers Blower Fan defog (front and rear screen) Compressor Power 4000 Estimated limit of 12V systems 2000 0 0 200 400 600 800 1000 1200 1400 1600 1800 time (s) Flins 15 Décembre 2016 19
Analysis of vehicle measurements 4 500 Electric mean power Electric max power Mean/Max power per load Mechanical mean power Mechanical max power Vehicle measurements and analysis of load power during use (WLTC @ different conditions / static tests) Measures on WLTC (nominal conditions) Measures on WLTC (specific conditions) Static tests Accessories with 48V electrification potential Accessories for belt suppression 4 000 3 500 THS VDA test T amb. = 45 C 40% humidity 3 000 Powe er (W) 2 500 2 000 1 500 1 000 500 0 Estimated T amb. < 0 C T amb. < 15 C, cold sta art T amb. = 28 C, hot st tart T amb. = 28 C, ho ot start T amb. = -7 C, cold start Estimated Real mountain road Controllers * Windshield included Power Devices for comfort Property ** CBC & of DBC: Valeo Cornering Duplication Brake Prohibited Control & Dynamic Brake Control Small Power Machine & Devices Electrohydraulic Machines Flins 15 Décembre 2016 20
Comfort Auxiliaries 48V 12V 48V regen network DCDC 48-12 V 12V clean network Reversible Machine 48V 12V + 48V 48V Battery 48V NON Sensitive Loads esc 12V Battery Efficiency Weight Starter 12V Sensitive Loads 12V Non Sensitive Loads Switching Auxiliaries from 12V to 48V allows to gain Weight DC/DC Efficiency Additional gains Wire harness weight and costs Resistive losses in wires Other gains to be confirmed Efficiency in electrical machines thanks to finest wires and copper density increase Flins 15 Décembre 2016 21
48V 12V / Diversity On the same vehicle several Power train are co existing. Voltage of components shall be manage as a version Common mechanical interfaces For several years 48V components won t reach the same production volume Production cost difficult to converge with 12V A major stake is to communalize Industrial tooling between 12V and 48V 12 V 48 V Adapted to connectors design Power electronics - Adapted MOSFET - Driver 48V - Adapted Inductor - Adapted Capacitor PCB lay out New Connectors with CPA Carry over Carry over Winding adaptation (wire gage, nber turns, ) Carry over Dedicated to each HVAC application Dedicated to each HVAC application Flins 15 Décembre 2016 22
Conclusion 80 60 Hybridization: a necessity for CO 2 reduction Cost is always a driver : Affordable cars require simpler / cheaper solutions Modular Electric Architectures & topology as way to reduce integration cost Extended 12V & 48V mild hybrid systems address basis hybrid functions and allow superior fuel economy for best value equation Low voltage dual battery architectures are gateway to Extended regen capability Extended boost with electric supercharger Coasting and valuable driver functions Electrification can also address new board net functions 40 20 i-stars 0 Start er 12V Battery 1 12V NON Sensitive loads Piloted switch 12V Battery 2 (AGM/NiMH) 12V Sensitive loads Flins 15 Décembre 2016 23
Thank you for your attention Flins 15 Décembre 2016 24