48V Mild Hybrid Systems Market Needs and Technical Solutions
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48V Mild Hybrid Systems Market Needs and Technical Solutions Ulf Stenzel AVL Engineering and Technology Content ° 48V Market Situation & Needs ° 48V Powertrain Technologies and Challenges ° AVL’s Project Examples AVL UK Expo 2014 / Ulf Stenzel 2 Content ° 48V Market Situation & Needs ° 48V Powertrain Technologies and Challenges ° AVL’s Project Examples AVL UK Expo 2014 / Ulf Stenzel 3 Mild Hybrids – Global Market Overview Global xEV Production 7,000,000 6,000,000 In 2020 (10-15)% of 5,000,000 global xEV production 4,000,000 are Mild Hybrids 3,000,000 2,000,000 1,000,000 Vehicle Production[units] Vehicle 0 2013 2014 2015 2016 2017 2018 2019 2020 Year of Production Mild Hybrids , per Region Hybrid-Mild (incl. 48V) Hybrid-Full (incl. PHEV) EVs (incl. REEV) 800,000 700,000 600,000 Mild HEVs produced in NA in 2020 will most likely be dominated 500,000 by High Voltage Systems 400,000 300,000 200,000 In 2020 almost all Mild HEV’s Vehicle Production[units] Vehicle produced from European OEMs 100,000 are 48V Systems 0 2013 2014 2015 2016 2017 2018 2019 2020 Year of Production South Asia North America Japan/Korea Greater China Europe Source: IHS Q3 2013 AVL UK Expo 2014 / Ulf Stenzel 4 EU Mild Hybrids – Market Overview Europe Mild Hybrids produced in Europe (of which 98% is 48V in 2020) Per Regional Sales per Segment per Vehicle Brand Price Class Rolls-Royce 400,000 400,000 400,000 Nissan Smart 350,000 E-Segment 350,000 Luxury 350,000 Porsche 300,000 300,000 Premium 300,000 BMW D-Segment Mid Ford 250,000 250,000 250,000 Peugeot C-Segment Entry 200,000 200,000 200,000 Citroen Audi B-Segment 150,000 150,000 150,000 Mercedes-Benz 100,000 100,000 100,000 Dacia Renault 50,000 50,000 50,000 Production[units] Vehicle Vehicle Production[units] Vehicle Vehicle Production[units] Vehicle 0 0 0 2013 2014 2015 2016 2017 2018 2019 2020 2013 2014 2015 2016 2017 2018 2019 2020 2013 2014 2015 2016 2017 2018 2019 2020 ° No 48V applications in the A ° Large share of 48V applications in ° High share of German premium segment (e.g. Ford Ka, Chevrolet the Mid (e.g. Renault Clio, Ford OEMs Spark) forecasted until 2020 Mondeo) and Premium (e.g. BMW ° No share from Volkswagen ° Significant 48V shares in larger 7 series, Smart Forfour) segment projected vehicle classes and in the B ° Entry: e.g. Renault Duster, Dacia ° No share from Fiat (and it’s sub segment (e.g. VW Polo) Logan brands) forecasted until 2020 ° Early implementation in E segment ° Luxury: Porsche Macan, Rolls- vehicles (e.g. BMW 7 series, MB Royce Ghost E-Class) (see 2018) AVL UK Expo 2014 / Ulf Stenzel Source: IHS Q3 2013 5 German OEMs are pushing for 48V ° The LV 148 standard defines a 48V power supply system including its functions and interfaces. ° The standard describes all relevant electrical requirements and test procedures for the new 48V components ° It is defined by the big 5 German automakers and shows a clear trend out of Europe to push 48V technology towards production. ° These five OEMs have been involved: Audi AG BMW AG Daimler AG Porsche AG Volkswagen AG AVL UK Expo 2014 / Ulf Stenzel 6 EU Past and Future Progress to meet the 2020 Target ° Overall the required rate of progress to the proposed 2020 targets is slightly greater (4.1%pa) than the rate that has already been achieved over the past five years (3.6%pa). ° However, these figures do not include the effect of flexibilities (i.e. supercredits) that effectively provide free grams. Carmakers are therefore even closer to achieving targets than the data suggests. ° The clear conclusion is that the 2020 target is achievable for makers of all types and sizes of cars with appropriate planning and introduction of fuel consumption reduction measures. Source: European Federation for Transport and Environment (T&E) AVL UK Expo 2014 / Ulf Stenzel 7 EU Taxes and Incentives for Mild Hybrids in Europe AVL UK Expo 2014 / Ulf Stenzel 8 Definition of Hybrids according to Legislation by Region From ECE R101: … means a vehicle,…. that, for the purpose of mechanical propulsion , draws energy from both of the following on-vehicle sources of stored energy/power: (a) a consumable fuel; (b) a battery, capacitor, flywheel/generator or other electrical energy/power storage device EU USA CHN JPN KOR 12V ST/ST SIN OOOOO 12V ST/ST SIG w/o TA OOOOO 12V ST/ST SIG (1) (1) (2) with TA PP P P P 48V Alternator (aux. supply only) OOOOO 48V Mild HEV PP(1) P(1) P(2) P SIN…Start in Neutral SIG…Start in Gear TA… Torque Assistance (1) Yes, if energy storage is rechargeable (2) Yes, if rechargeable and kinetic energy converter AVL UK Expo 2014 / Ulf Stenzel 9 48V Main Drivers – Summary ° Reduction of CO 2 emission to meet future emission legislation ° Comfort enhancement and new functions ° Less integration effort, weight & cost, compared to HV systems (safety, battery) 48V systems have the potential to fill Production Production volume the gap between state-of-the-art 12V Start/Stop systems and high voltage hybrid powertrains. Source: Bosch on „48V Power Supply“ Conference 2013 AVL UK Expo 2014 / Ulf Stenzel 10 Content ° 48V Market Situation & Needs ° 48V Powertrain Technologies and Challenges ° AVL’s Project Examples AVL UK Expo 2014 / Ulf Stenzel 11 12V/48V Electrical Architecture 48V High-Power Consumer … PTC Heater Electric Pumps eBooster EPS / EHPS Roll Stabilization El. AC Compressor ... 48V Boardnet 48V 48V Starter/Generator 48V Battery System Classic 12V Boardnet DC/DC 12V AVL UK Expo 2014 / Ulf Stenzel 12 E-Machine Integration ° The integration of the E-machine defines the recuperation potential; the engine drag torque reduces the amount of recuperative energy (P2 versus P1/BSG) ° Cost advantage high speed E- machine (BSG) versus high torque (ISG); high torque density leads to higher cost ° Integration cost & effort; package (ISG, P2), transmission modification (P2) ° Preferred system architectures, functionalities and the resulting cost to benefit ratios are depending on vehicle class & vehicle application AVL UK Expo 2014 / Ulf Stenzel 13 BSG Integration Challenges - Impact on Engine ° FEAD Design ° Belt Durability ° Variable Belt Tensioner ° Increase tension during cranking and boost (machine to engine) ° Increase tension during recuperation (engine to machine) ° Reduce tension during normal driving to reduce friction loss ° NVH ° Belt chirp during cranking ° Crankshaft Main Bearing ° Durability AVL UK Expo 2014 / Ulf Stenzel 14 Powertrain Key Components - BSG System ° Besides the main requirements (EM power & torque) as well as packaging constraints the supplier selection also to take care of cooling requirements and NVH ° 48V BSG systems vary across different supplier ° As an independent partner AVL can provide comparable and consistent component characterization AVL UK Expo 2014 / Ulf Stenzel 15 48V Electrical Load Migration – Impact on eStorage 12V DC 48V 12V DC 48V DC DC 6 Ah >10 Ah SG SG CO 2 reduction only Electrical Load Migration Start/Stop, Boost, Recuperation Chassis Control, Climate Comfort, Engine Components Electrification, eBooster, etc… AVL UK Expo 2014 / Ulf Stenzel 16 Powertrain Key Components – eStorage System 12V 48V >>48V 200-800V Conv. Micro Mild Mild Full PHEV EV Flooded Lead Acid ° StrongEnhanced effort Flooded in the enhancementLead Acid of advanced carbonCarbon added added VRLA to meet 48VVRLA requirements ° Lead Acid + UCap could be an interimLead Acid solution + UCap ° Migration from High Voltage to 48V with Li-Ion Li-ion ° Ideally carry over modules from high power Li-ion HV battery packs NiMH ? Source: Adapted from Dr. Menahem Anderman (2013) Legend: Dominating Potential Candidate AVL UK Expo 2014 / Ulf Stenzel 17 48V Li-Ion Battery Technology Roadmap Lithium Titanate (LTO) ° The cell performance varies across cell Lithium Iron Phosphate (LFP) technologies Lithium Nickel Manganese Oxide (NMC) 2013 2020 Specific Energy 100 90 80 70 60 Specific Power 50 Costs 40 Source: AVL internal benchmarking (averaged values) 30 20 10 0 ° NMC & LFP cathode materials fulfil current 48V automotive requirements in terms of performance and safety and will be the Safety Lifetime dominating Lithium-ion technologies in 48V NMC applications LFP Performance LTO ° LTO (lithium titanate oxide) anodes show excellent life, low temperature performance, safety but lead to high system costs AVL UK Expo 2014 / Ulf Stenzel 18 Overview 48V Main Functions AVL UK Expo 2014 / Ulf Stenzel 19 ADV. 48V FUNCTIONALITIES IN LEGAL CYCLES – NEDC Hybrid States 120 100 80 60 40 20 0 0 200 400 600 800 1000 t [s] 50 40 v [km /h] 30 20 10 0 0 50 100 150 200 t [s] AVL UK Expo 2014 / Ulf Stenzel 20 ADV. 48V FUNCTIONALITIES IN LEGAL CYCLES – FTP Hybrid States 80 60 40 v [km/h] 20 0 0 500 1000 1500 2000 2500 t [s] Hybrid States 90 80 70 60 50 40 v [km/h] v 30 20 10 0 2000 2050 2100 2150 2200 2250 2300 t [s] AVL UK Expo 2014 / Ulf Stenzel 21 Content ° 48V Market Situation & Needs ° 48V Powertrain Technologies and Challenges ° AVL’s Project Examples AVL UK Expo 2014 / Ulf Stenzel 22 The “TWINS”: 12V and 48V LC Super Hybrid NEDC CO 2 Emission [g/km] Acceleration 0 - 100 kph [s] 180 12 Potential 160 Similar for further -12% -18%18 % 10 140 -24% Performance improvement 120 8 100 6 80 60 4 40 2 20 0 0 1,8-litre TSI 1,4-litre TSI with LC Super 48V Mild HEV 1,8-litre TSI 1,4-litre TSI with LC Super Hybrid 48V Mild HEV Start/Stop Hybrid Concept Start/Stop Concept AVL UK Expo 2014 / Ulf Stenzel 23 48V Advanced Lead Carbon Battery Diesel Hybrid Prototype Project Overview Features: 48V mild hybrid with Belt Starter Generator (BSG) & electric supercharger (VES) • +20% Power • -15% CO 2 Engine update for BSG Controls / Operating Strategy Demo Vehicle Built & Calibration Engine & Belt Starter Generator Lead Acid Vehicle E-Booster Battery AVL UK Expo 2014 / Ulf Stenzel 24 AVL Engineering Project History since 2002 Concept Study Concept Study „100mpg“ Demo Vehicle Start/Stop 48V Market evaluation 12V Testing Conti VW Touran 48V 42V SRM BSG Comp.