Powertrain Technologies Strategies for Advanced Propulsion Rob Rickell Senior Vice President Global Engineering, GKN Driveline Principal Engineer, GKN plc
Drivers for technology change are significant, well established, and bring both threats and opportunities Engines Combustion efficiency Thermal efficiency Downsizing Alternative fuels Transmissions Higher efficiency More speeds Optimised shifting Smart systems Proliferation of electronics, sensing and controls Growing use of smart systems Drivelines Light-weight & efficient Disconnect AWD Electrification of AWD Niche wheel motors Progressive electrification Multiple hybrid systems Niche Evs Lower cost energy storage Motors & power electronics 2015 130g CO2 2020 95g CO2 Legislation, driving low emission drivetrains 2030 <75g CO2? Electronics, computing & communication: relentless improvements in cost, capability and performance Processes & Materials 96
Internal Combustion Engine Smaller engines, running at lower speeds Forced induction, with ever higher boost pressures to provide the torque and power of a larger engine, but with the part throttle efficiency of a smaller one Push boundaries of performance, whilst controlling costs and making cars acceptable to drive " Turbochargers (multiple) " Superchargers (mechanical, electrical) " Turbo-compounding (mechanical, electrical) " Petrol direct injection " Variable valve timing and lift " Cylinder on demand " Advanced thermal management " High temperature materials 97
Hybridisation Complement ICE with electrical power " Motor/generator " Electrical energy storage " Power & control electronics " Software Energy storage Optimise for power or energy Batteries Supercapacitor Flywheel Hybrid battery Electrical machine types Radial flux Axial flux Transverse flux Position & integration in drivetrain Flywheel/engine Axle Gearbox Wheel motors Power & control electronics Voltages Storage options Generation options Drive options Software Safety Strategy 48v? 98
Advanced Transmissions Greater number of ratios " Enables engine to operate at most efficient rpm " Several alternatives different cost, performance and driver appeal " Control system gear selection bias towards emissions control " Transmission increasingly more integral to the control of vehicle efficiency " Integral to electrification; managing dual power sources power split. Prius CVT (multitronic) 7 speed DCT (ZF) " Electrification has potential to improve driveability of automated manual (and downsized engine) 9 speed automatic (ZF) 7 speed automated manual (BMW SMG) Electric machine integrated into automated manual transmission (FEV) 99
Electronics and Telematics Greater capability and complexity " Internal car systems " External integration with other vehicles and networks " Supports optimisation of vehicle performance, both in isolation and also as part of wider transport system " Pervasive impact on all vehicle systems and components " Changing consumer relationship with car & transport generally Increasing driver assistance Restrictive intervention Autonomous vehicles Change in ownership models Self-driving car concept from Google 100
Summary progressive electrification of the powertrain " Reduced weight & improved efficiency " Engine downsizing " 8+ speed transmissions " Reducing parasitics: aerodynamics; tyres; energy-, thermal-, climate-management " Affordable electrification, stop-start " Multitude of hybrid solutions no clear winner Trends to 2025 " ICE powertrains stay predominant " Growth of various hybrid solutions " Hybrid predominant solution for premium vehicles " Pure EVs marginal with focus on city use Source: IEA Global energy report 2010, Siemens. Trends beyond 2040 " Pure ICE powertrains insignificant " 60 %+ hybrid solutions " 40% + pure EVs (1-2 speed transmissions) 101