12V / 48V Hybrid Vehicle Technology Steven Kowalec www.continental-corporation.com Powertrain Division
Powertrain Electrification Technology Sy ystem Costs CO2 Reduction Potenttial Mi Micro-hybrids h b id to t BEVs BEV Fuel ue saving sa g with t low o voltage o tage technology Fuel saving and electric ue sa ga de ect c driving 100 electric 00 % e ect c driving Degree of Electrification Steven Kowalec Continental AG 2
Electrification Tailored-to-Fit Mild Hybrids - True Fit With Every Segment Electric Vehicle Plug-in Hybrid 60-150 kw 100% 60-120 kw 50-75% High Voltage Axle Drive Full Hybrid 20-40 kw 20-30% High Voltage Power Electronics 48V Mild Hybrid 5-15 kw 13 % 48 V DC/DC Converter 48 V Belt Starter Generator 12V Micro Hybrid < 5 kw 3-4 % Voltage Stabilization System E-Motor Power A B C D E CO 2 Saving Potential in Vehicle Segment NEDC Indicates segments in which the technology is most often applied. Steven Kowalec Continental AG 3
Micro-hybrid Technology Voltage V lt Stabilization St bili ti System S t (VSS) and d Dual Battery Manager (DBM) VSS DBM (example) Secondary energy storage Steven Kowalec Continental AG 4
Powertrain Outlook 2030 Peak Combustion Expected in 2025-2027 Global PV/LV Production* Propulsion Split Global PV/LV Production* Electrification View 120 Peak Vehicle Electrification is making a decisive step forward 100 Cost optimized 48V solutions will be found in 80 each Mid class car in mature markets. [mn. vehicles] 60 40 20 Long term pure EV will win the race against hybrid solutions 0 2015 2020 2025 2030 2015 2020 2025 2030 EV 48V Gasoline EV PHEV FHEV 48V PHEV CNG/LPG M/FHEV Diesel * Source: IHS, own estimates Steven Kowalec Continental AG 5
Powertrain Outlook Global l PV/LV Engine Production (2015-2030) 2030) [mio-units] 120,00 100,0 80,0 60,0 1% 2% 1% 20% 9% 14% 4% PHEV+EV 4% 1% 18% 10% 29% 3% 4% World Combined View 4% 3% 5% 13% 2% 14% 6% 48V 11% 3% 7% 22% 2% EV PHEV M/FHEV 48V CNG/LPG Diesel 40,0 GDI (TC) 20,0 49% 4% 30% 2% 12% 4% 22% 1% GDI PFI (TC) PFI 27% 21% 17% 0,0 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 Source: Continental, IHS Rounding may cause percentages not to sum up exactly to100% Steven Kowalec Continental AG 6
48V Technology More than a Mild Hybrid Strategies t Over and Above CO 2 Reduction 48V electrification is primary driven by CO 2 reduction Future powertrain topologies with 48V enable even higher CO 2 savings Regenerated energy can be utilized for safety, comfort and efficiency functions Allocation of electric components to the 12V and 48V board net must be considered Maximum benefit can be achieved with a predictive driving strategy via connected energy management Steven Kowalec Continental AG 7
48V Hybrid Vehicle Technology 12V 48V Adaptation ti Conventional 12V boardnet 12V with additional 48V boardnet P0 implementation shown Steven Kowalec Continental AG 8
48V Topology BMS DCDC C BMS, Converter, t IInverter, t M Motor/Generator t /G t Steven Kowalec Continental AG 9
48V Technology 48V Battery B tt M Managementt S System t (BMS) Protect the energy storage system against over-current, over-discharge, over-load 14 Cell measurements and balancingg Battery pack and 48V DC link measurements Current and thermal measurements Contactor(s) and Fan control circuitry State-of-Charge (SOC) 48V BMS State-of-Health (SOH) State-of-Function (SOF) 500Wh battery used in Conti 48V demonstration vehicles Steven Kowalec Continental AG 10
48V DC/DC Scalability Modular Concept 48V/12V DC/DC 800W to 3.2kW 800W 1600W 2400W 3200W 1 Phase 2 Phases 3 Phases 4 Phases Bi-directional operation (voltage/current controlled) Precharge functionality for 48V DC link Steven Kowalec Continental AG 11
48V Technology Belt Starter t Generator (BSG) Parameter Maximum Start Torque Typ. & (@-25 C, 0.5s) Motor 1 Motor 2 60mm 40mm ~50Nm ~30Nm Max. peak power ~13 kw mot ~13 kw mot ~14 kw gen ~14 kw gen Cont. Power Cooling Fluid Temperature ~6 kw mot ~7 kw gen -40 C +115 C ~6 kw mot ~7 kw gen -40 C +115 C Communication Interfaces CAN, LIN, FlexRay Weight ~13kg ~10kg Dimensions Length: <200mm Diameter: <180mm Length: <180mm Diameter: <180mm Integrated Inverter Steven Kowalec Continental AG 12
48V Technology Belt Starter t Generator (BSG) General Functions: Combustion engine start (standard cold and warm start) Boost (electrical assistance) Recuperation (regenerative braking) Generator IC Engine Shaft positioning IC Engine Operating point shift Integrated Inverter Steven Kowalec Continental AG 13
48V Technology Belt Starter t Generator (BSG) Configurations P0 P2 CO 2 potential: -13% CO 2 potential: -22% 48 volt introduction Integration in existing belt drive architecture Maximum recuperation capability Electrified auxiliaries, eparking, ecreeping,.. Steven Kowalec Continental AG 14
48V System BSG Operating Statest * elaunch * Charge * Boost * Sailing * Coasting * Recuperation Steven Kowalec Continental AG 15
Connected Energy Management (cem) Di Driver Guiding Functions Static eh Connected ehorizon Backend Dynamic ehorizon Topology ADAS HD Map and Localization Dynamic Data Deceleration Assist Traffic Light Assist Slope Assist Curve Assist Steven Kowalec Continental AG 16
48V In the Real World Coasting as significant ifi fuel-savings strategy t Steven Kowalec Continental AG 17
48V Technology Additional fuel-saving strategies t Due to the limitations on the existing 12V boardnet strategies, t the market may soon decide that adoption of 48V consumers is necessary to provide customers with features desired. Component PTC Heater 4kW AC Compressor Electronic Roll Control (ERC) Smart Cooling Pump Fluid Pumps Front Windshield Heating EH-Brake System E-Compressor E-Steering Peak Power [W] 3.5 kw 3 kw 400 W ~ 200 W 700 W 900 W 3 kw - 7kW 2 kw Steven Kowalec Continental AG 18
48V Hybridization and Electrification Summary 48 volt technology is entering the mass market 48V P0 architecture offers significant efficiency improvements with acceptable cost and integration effort Additional efficiency improvement and electric launch capability with 48V P2 architecture Much better efficiency potential in urban driving comparison to FTP and WLTC Advanced functions available like boosting, sailing, coasting, electrical parking Electric torque assist for significant improvement of acceleration Optimization of Electrical Architecture re 12 V vs. 48 V Steven Kowalec Continental AG 19
Thank you! Steven Kowalec Continental AG 20