A3PS-conference Alternative Propulsion Systems and Energy Carriers Parallel session 1, electric mobility: Alternative propulsion Systems with Main Focus on Electric Vehicles 1. Increasing problems for mobility 2. View of the customer 3. Car technology and concepts 4. Situation of the suppliers 5. Eamples of MAGNA STEYR activities in EVs and Hybrids 6. Magna View on the market 7. Summary Marius Meinert Magna Steyr Fahrzeugtechnik GmbH & Co KG Graz 1
1. Increasing problems for mobility Increasing energy demand eploding prices Shortage of resources Becoming energy independent Environmental protection (climate change CO 2, dust emissions) Legal limits, restrictions in cities Battery development status, especially LiIon Traffic Restrictions: Speed limits Bigger pedestrian areas Zone-Models, e.g. City-Toll (London, Stockholm, Berlin) Complete locking of areas for emitting vehicles Strict traffic guidance Increased pressure to use public transport limited resources increasing traffic Development of CO 2 emissions 160 130 of fossile fuels peak oil Fuel consumption will increase roughly 55% until 2030 in the transport sector in g CO 2 / km 2006 2012 2020 2025 Legislation continuously tightening up ehaust gas and noise emissions limits (CO 2 -Emissions, Dust, etc.) 95 70 Investigation on alternative fuels for cars is motivated by lots of influences, such as social changes and climate changes. Changes can lead to electrification of the powertrain. 2
2. View of the customer User does not want to have any restrictions caused by infrastructure, e.g. lack of charging stations User must trust in battery package in terms of driving range and driving performance of EV Costs of EV should be similar to current vehicles with conventional technologies Users will not accept functional problems while driving and charging the EV personal interest and behavior Source: Frost & Sullivan Customers are very sensitive and do not accept disadvantages compared to conventional vehicles in terms of technology and personal interests. 3
3. Car technology and concepts alternative propulsion systems mean change of vehicle systems Compleity of vehicle change of vehicle systems enables to change of vehicle architecture FC battery goal is to re-minimize the vehicle propulsion systems Variants: a) Pure electric b) EV with range etender E- motor LPG/NG/ H 2 -Tank Traction chain gasoline tank ICE conventional, monovalent conv./altern. bivalent conventionell hybrid conv./altern. bivalent, hybrid alternativ, monovalent Fuel Cell (FC) EV. Change of vehicle systems Change of vehicle architecture Only basic changes will reduce compleity of modern cars in terms of weight and costs. There will be comple interim solutions. 4
4. Situation of suppliers Situation of supplier: more or less no strategic departments like an OEM Needs of supplier: needs direction, where society moves no direct contact to the user/customer needs feedback, how customers react on changes in technology needs specifications from the customer (OEM) and directions from institutions/public authorities less possibilities to effort technology-changes and to take over the risk of failing support, eg. by funding or co-financing stable political basis for technology direction over long time (same as OEM) Suppliers can provide with own smart solutions, can industrialize concepts or make them mature for serial production and the use in costumer hands, if there is an agreement about the basic direction. 5
5. Roadmap Hybrid and EV Alternative Propulsions Systems are significant part of MAGNA Advanced Development. MAGNA groups are working in a project house on components systems for Alternative Propulsion Systems. Lots of activities are funded projects. MAGNA STEYR as complete car developer, also presented some concept cars, e.g. HySuv or MILA-concept cars. Vehicle Programs HiCEPS HySUV MILA EV Range Etender MILA EV Thanks to lots of discussions with OEMs and national and international groups or public authorities MAGNA STEYR has long-term roadmap for Hybrids and Electrical Vehicles. 6
5. Roadmap H2 Storage Systems 2010 2015 C-H2-storage L-H2-storage simple design duration of storaging costs weight/package driving range costs driving range package/weight boil-off C-H2 storage at 3570 MPa & ambient temp. up to 70 MPa, CFK optimized for manufacturing and costs up to 70 MPa, CFK, automotive industrialized L-H2-storage at -253 C metal, optimized for manufacturing, costs, weight and package with lightweight materials, package optimized 2015 combination? solid/liquid StorHy l ca i og ns o ti p o combination CcH2? profile 2010 ol n ch bus and truck e t 2008 2005 le b a st ch te og l no y rm o f t ke r a ro t in tio c du n 2002: start of H2 activities at MS with BMW H7 Recognizing the importance of energy storages MAGNA STEYR started to develop storage systems for hydrogen. First automotive serial hydrogen storage system worldwide has been made by MAGNA STEYR (BMW hydrogen 7). 2009-10-16 Marius Meinert Disclosure or duplication without consent is prohibited 7
5. Li Ion Batteries As system supplier MAGNA STEYR offers complete energy storage systems. Modular design and packaging Scaleable power and energy capacity Air and liquid cooling available Fleible battery management Integrated contactor bo Universal safety concept Protection class up to IP6k9 2 L D H: 266 195 298 mm prismatic cells different cell sizes: (30/40/60 Ah) Module weight: 13/16/24 kg Number of cells / module: 12 integrated electronics for Monitoring and balancing 5 4 1 3 module 1 Prismatic Li-ion cells 2 Cooling tubes 3 Mounting parts (depending on application) 4 Cooling plates Serial battery system for truck application 5 Cell Connector Board with Cell Supervision Circuit 6 Battery Management Unit (BMU); not visible 7 Battery Disconnect Unit (BDU); not visible Most important system for EVs is the battery system. Therefore main focus of MAGNA STEYR is on developing and integrating battery systems for all kinds of automotive application. 2009-10-16 Marius Meinert Disclosure or duplication without consent is prohibited 8
5. Hybrid: HySUV Demonstrator vehicle show MAGNA STEYR knowledge of hybrid vehicle development, vehicle integration and controller SW development. Development of a complete full hybrid in cooperation with key partners to achieve enhanced driving dynamics and fuel savings. Series and parallel hybrid with unique electric 4 WD capability Unique ICE/E-Motor/Transmission integration with clutches to fleible power front or rear ale MAGNA STEYR built Lithium-Ion battery capable of powering two 50 kw electric motors Operating strategy including start/stop, load shifting for recharging battery, regenerative braking and electric driving Electric air-conditioning compressor, electric steering and other electric auiliaries Unique AWD module integrated between ICE and AMT, designed for easy implementation in other powertrains Combining fuel savings up to 24 % with enhanced driving dynamics & electric driving MAGNA STEYR HySUV TM Technology concept vehicle Full hybrid battery module Vehicle Integration Electric 4WD module With decades of eperiences in developing complete cars, MAGNA STEYR and partners from research and industry built a complete hybrid concept car. 9
5. Plug-In Hybrid with range etender Mila EV = electric dominant PHEV (Plug-In Hybrid Electric Vehicle) Inverter Range Etender Common Rolling Chassis for EV/Hybrid/CNG/ICE Generator E-Motor EV-Transmission Li-Ionen-BatteryModul (Energy type) MAGNA s strong interest in pushing electrification of cars according to costumer demands into the market has born the MILA EV a car concept which gives several options for using Alternative Propulsion Systems. 2009-10-16 Marius Meinert Disclosure or duplication without consent is prohibited 10
6. Magna view on the market 2012-2014 will be an important phase for further development of EVs Technical key-factors: Significant reduction of battery-prices Reasonable price compared to ICE Optimization in charging time and infrastructure Economic and political key factors: OEMs follow the road of green cars with main focus on EVs In minimum one OEM will be the key actors of EVs and competitors will follow soon Support by public authorities Strong demand of commercial and communal fleets Increasing city-zones 14 mio. Bosch EV Scenario 13,8 mio. C. Ghosn (Interview) 8 mio. 1.500.000 CSM Evs Bosch "economy case" EV Globalinsight EV 8 mio. Frost & Sullivan "Bottom Up" MAGNA Scenario "Saturation" MAGNA Int./Magna Steyr Estimate "Realistic" 1.000.000 500.000 0 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 MAGNA sees a potential of ~ 1,1 Mio. EVs in 2020. This of course can be increased by solving open technological and functional issues. 11
7. Summary Investigation on alternative fuels for cars is motivated by lots of influences, such as social changes and climate changes. Changes can lead to electrification of the powertrain. Customers are very sensitive and do not accept disadvantages compared to conventional vehicles in terms of technology and personal interests. Only basic changes will reduce compleity of modern cars in terms of weight and costs. There will be comple interim solutions. Suppliers can provide with own smart solutions, can industrialize concepts or make them mature for serial production and the use in costumer hands, if there is an agreement about the basic direction. Thanks to lots of discussions with OEMs and national and international groups or public authorities MAGNA STEYR has long-term roadmap for Hybrids and Electrical Vehicles. Recognizing the importance of energy storages MAGNA STEYR started to develop storage systems for hydrogen. First automotive serial hydrogen storage system worldwide has been made by MAGNA STEYR. Most important system for EVs is the battery system. Therefore main focus of MAGNA STEYR is on developing and integrating battery systems for all kinds of automotive application. With decades of eperiences in developing complete cars, MAGNA STEYR and partners from research and industry built a complete hybrid concept car. MAGNA s strong interest in pushing electrification of cars according to costumer demands into the market has born the MILA EV a car concept which gives several options for using Alternative Propulsion Systems. MAGNA sees a potential of ~ 1,1 Mio. EVs in 2020. This of course can be increased by solving open technological and functional issues. 12