Hybrid at Daimler Trucks – Technology for the World Current Status and Working Direction
Hybrid at Daimler Trucks – Technology for the world Current status and working direction
4. Fachtagung Hybridantriebe für mobile Antriebsmaschinen Karlsruhe, 20. Februar 2013 Stephan C. Treusch S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final
1 Contents
1.1 Daimler and Daimler Trucks
2.2 Hybrid at Trucks – System concept, Vehicles and Organization
3.3 Engineering working direction – Modularity, Components and Controls
4.4 Other Challenges – Customer and standardization
5.5 Summary
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 2 Daimler (Trucks) 1 Daimler consists of five divisions
Note:S. Treusch 2011: - Revenue hybrid at GroupDaimler € 106.5- KIT Febr. bn; Employees: 2013 - fina l 271,370; sales organization 49,699, Corporate/Others 5,836 Daimler Trucks 3 Daimler (Trucks) 1
Daimler Trucks worldwide vehicle portfolio
Mercedes-Benz
Western Star Freightliner FUSO
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 4 Daimler (Trucks) 1 Trucks with high variety: Actros with more than 2.500 base variants
Engine Cabs Axles & GVW** Total Performance Wheel Bases Variants
9 (x)*4 (x)*28 (x)*7 = 2.583*
Plus countless further combinations of fuel economy relevant options (e.g. aero devices, axle ratios, tranmission options, …)
In total more than 4.000 variants available for all MB Trucks products * not all theoretically possible variants are actually offered ** GVW = Gross vehicle weight
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 5 Daimler (Trucks) 1 Trucks are international: China as the biggest market worldwide, every second truck is sold there Sales Trucks (> 6 t in thousands of Sales Cars (in millions of Units) Units)
China USA WEU
USA Japan India Brazil WEU India Brazil Russia Russia Japan
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 6 Daimler (Trucks) 1 Trucks are clean: In the past 20 years, emissions have been reduced by almost 100 % - what‘s next?
„Era Emission“ „Era CO2“
From Euro 0 to Euro 6 (Emissions in g/kW) Particulars (PM) Euro 0 1 (1990) 1) -20%
0,8
0,6 - 99% 0,4 Euro 1 (1993)
0,2 Euro 2 (96) Euro 3 (01) 0 Euro 5 (09) Euro 4 (06) 0 1 2 3 4 5 6 7 8 9 10111213141516 Euro 6 Fleet consumption (2014) Stickoxide 2020 - 97% (NO X)
(1) Average Truck before EURO1 S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 7 Contents
1.1 Daimler and Daimler Trucks
2.2 Hybrid at Trucks – System concept, Vehicles and Organization
3.3 Engineering working direction – Modularity, Components and Controls
4.4 Other Challenges – Customer and standardization
5.5 Summary
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 8 Hybrid at Trucks - concept 2 Fuel consumption is influenced by different things - truck technology is only one lever
Use profile / Vehicle technology Infrastructure
Significant influence Engineering competence of Daimler Trucks
Driver Vehicle condition
Up to 25% fuel consumption e.g. tire pressure and condition, correct position of aero devices
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 9 Hybrid at Trucks - concept 2 As conventional options are becoming scarce, we investigate alternative drivetrain options as well
Driving strategy* 2 1 HVO, BTL, etc.*
H2*
Battery technology* Hybrids Fuels CNG*
Performance Storage concepts* Fuel economy Electrical motor* Reliability Costs Exhaust heat* Fuel cell* Electrical Energy driving recovery Driving strategy* Coolant heat Battery technology* 3 4 *) Synergies within Daimler S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 10 Hybrid at Trucks - concept 2 Full electrical drive not an option for trucks in the near future due to low energy density of batteries
[Wh/kg] Gasoline 10,000 Biodiesel Diesel Ethanol Liquid fuels 1,000 10 kWh = ~1l / ~1kg
(1) density Batteries Factor approx. 60 – 100 100 Li-Ion Nickel-metal- 10 kWh = ~50l / ~100kg Lead
Weight related energy energy relatedWeight hybrid 10 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 [Wh/L] Volume related energy density
Range Diesel 100% electric with Li-Ion battery
0.4 m 3 75 Liter 130 km range 800 km range 0.6 t Vito 64 kg 80 km/h V 36 kWh max
100 Liter 3 500 km 85 kg 2,6 m 5,2 t 12 ton distribution
3000 km 990 Liter 837 kg 26 m 3 40 ton 52t long-haul
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 11 Hybrid at Trucks - concept 2 Evaluation of hybrid architectures lead to P2 as most promising option for Trucks
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 12 Hybrid at Trucks - vehicles 2 Broad range of vehicles with hybrid technology
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 13 Hybrid at Trucks - vehicles 2 Atego BlueTec Hybrid is the first hybrid series vehicle available in Europe
Till today, about 120 vehicles in the hands of customers
P2 Hybrid 44 kW E-Motor, 420 Nm 1,9 kWh Li-Ion battery
First European series hybrid truck Contribution to sustainable mobility Fuel Savings of 10-15%
Significant CO 2-, NOx- und particle emission reduction Significant reduction of noise emissions Increases know-how in alternative and innovative powertrain applications in Mercedes-Benz Trucks
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 14 Hybrid at Trucks - vehicles 2 New Canter TF EcoHybrid represents the second generation of hybrid products at Daimler Trucks
2006 2008 2011 From 2012
From 2006: From 2008: NEW Canter TF EcoHybrid Canter TD EcoHybrid 10 TD Canter EcoHybrid vehicle All-new hybrid powertrain based introduced into market test fleet in London on new Canter TF More than 1.000 vehicles sold About 450.000 km total testing Significant progress to customers achieved Improved performance First hybrid truck available with Up to 15% better fuel economy (Power, Fuel economy) Li-Ion battery Improved Comfort 15-30% improved fuel economy Reduced weight in Japanese applications Reduced costs
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 15 Hybrid at Trucks - vehicles 2 Highlights – “DUONIC with Hybrid Motor” Wins 2013 RJC Car of the Year Special Award
SOS Limited SOP @ SoP @ MFTE SoS of export Preview IAA RJC award May/18, 2012 MFTE on July on Aug markets 1
S-FQCM for Sales events in Olympic game IAA motor show Ireland award Olympic game May/Jun @ Japan on May/11 • First in History for Commercial Vehicle Manufacturer to Win One of RJC Car of the Year Awards. • LIFT HEV project will come to QG0 till at the end of this year. RJC ：Automotive Researchers’ & Journalists’ Conference of Japan
IAA Motor show 20 th to 27 th Sep RJC car of the year special award Fleet Transport Green Commercial of the Year Award
Support to LONDON Olympic game 2012
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 16 Hybrid at Trucks - vehicles 2 Broad HEV portfolio as technology base for future series vehicles – more than 5.500 sold as of today
Japan Europe NAFTA Fuso Super Great HEV MB Econic HEV FL Cascadia P4
HDT
MB Atego 12t HEV FL MT45/55 FL M2e HEV MDT
Fuso Canter HEV Fuso Canter HEV Technology vehicle LDT Series vehicle
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 17 Hybrid at Trucks - organization 2 To ensure the worldwide market success for Trucks, a global development organization is essential
Germany Portland Detroit 2.500 Japan 500 Turkey 300 100 1.250
Brazil 350
More than 5.000 engineers worldwide working together on future products and innovations S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 18 Hybrid at Trucks - organization 2 Global Hybrid Center Trucks (GHC) delivers hybrid trucks to all Daimler Truck brands worldwide
GLOBAL : All Daimler Truck brands worldwide Provides hybrid systems with standardized, modular components common E/E interface HYBRID: Target configuration is P2 Diesel-electric Hybrid System for easy vehicle integration Provides system functionality CENTER (Trucks) for application & calibration in From light duty truck (3,5 tons) to heavy duty truck each regional project (40 tons) Standardized powertrain Leverages global presence of Focus is main high volume models Daimler Trucks for new (and a possible use in bus coach) technology applications
Realize synergies within Daimler
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 19 Hybrid at Trucks - organization 2 Daimler Trucks with integrated worldwide hybrid development to realize synergies
Only the integration of all worldwide hybrid activities in one organization leads to synergies in budget and cost. If this is done right, this allows at the same time vehicles with market and brand-specific benefits. Collaboration and alignment with key-partners leads to further improvements.
… Hybrid System … Development … Configuration of Hybrid Systems, operations strategy and components
Vehicle Projects Vehicle Projects Vehicle Projects Fuso Trucks & Buses MB Trucks Freightliner Trucks
Japan Germany USA
Development and application of vehicles S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 20 Hybrid at Trucks - organization 2 A successful global R&D network requires strong intercultural skills
私たちは、三菱ふそうの国際的な経営陣として 三菱ふそうとダイムラークライスラーが持つ異なる文化・ビジネスモデル・伝統を互いに認め、尊重するが、 新しい三菱ふそうを共に築くために、異なる文化的背景を持つ相手に対応する際は以下のことを考慮する。
日本人以外日本人以外////ダイムラークライスラーダイムラークライスラーダイムラークライスラー側への側への側へのヒント：ヒント： １）ディスカッションでは、まず相手の言い分を聞く。 ２）注意：沈黙は必ずしも合意ではない。 ３）注意：自分ではアイデア・提案・意見のつもりの発言が、相手には命令と受け取られているかもしれない。 ４）相手の論旨の背景を考えてみること。 ５）結論を急がずに、オープンで同等な立場でのディスカッションを心がける
日本人日本人////ふそうふそうふそう側への側への側へのヒント：ヒント： １）言葉にしなければ伝えたことにはならない。 （自分の気持ちや言いたいことを相手が察してくれると期待してはいけない。） ２）自分の真意を伝えること。（本音と建前） ３）報告をする際は、まず結論から始めること（そのあとに説明）。 ４）よくわからない時は質問（確認）すること。 ５）ふそうにいるDC派遣者もふそうの一員。 ６）親（株主）に対しても自分の意見は明確に説明すること。
＞英語はドイツ人にとっても日本人にとっても外国語 ＞CVDのビジネスユニットは「兄弟」（同じレベルのパートナー）であり「親子」ではない。
> 私たちは同じ船に乗り、共通のゴールに向けて船を漕いでいる
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 21 Contents
1.1 Daimler and Daimler Trucks
2.2 Hybrid at Trucks – System concept, Vehicles and Organization
3.3 Engineering working direction – Modularity, Components and Controls
4.4 Other Challenges – Customer and standardization
5.5 Summary
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 22 Engineering - modularity 3 Platform and module strategy to leverage scales in powertrain and vehicles of Daimler Trucks
Common platforms for all brands
Engines
Transmissions Common powertrain Exhaust after-treatment components
Axles
Cabin
Chassis Shared vehicle modules Mechatronics
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 23 Confidential Engineering - modularity 3 Three systems can cover all Daimler Trucks HEV – components partly scalable
High Power System (HPS) HV-Battery
Vehicle CAN G211 AMT e-motor
P/T CAN CPC x Mid Power System (MPS) MCM TCM
G90 AMT e-motor Inverter
Vehicle CAN Light Power System (LPS) HV Battery
DATAMT e-motor engine control TCM & HCU
Inverter S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 24 Engineering - modularity 3 Due to yearly mileage, CO2 reduction effect of long- haul HEV is up to 5 times higher than in distribution
Light Duty Truck HEV Based on city delivery application for Optimized system Fuso Canter (without ESS*) specification and hybrid Quantity of annual CO2 control strategy bring reduction high potential of recuperating energy even on highway 2ｔｔｔ Actual measurement GVW: 5 t Mileage: 30.000km p.a. results on typical Japanese road and application show about Heavy Duty Truck HEV Based on long haul application (highway only) for HDT (25t) (without ESS) 10 % fuel consumption reduction compared to Quantity of annual CO2 the conventional diesel reduction truck
11 ｔｔｔ
GVW: 25 t Mileage: 150.000km p.a.
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final * ESS = Engine Start-Stop Daimler Trucks 25 Engineering - system 3 Hybrid systems consist of different elements
• A hybrid system consists mainly of HV components, cooling and control elements • Some of these are already today available commodities (like cooling systems), others will be with the increased volumes in the automotive industry (e.g. HV cables, eMotors) • Only a few are critical for best performance HEV monitor Housing Cooling unit
READY ＨＥＶＨＥＶＨＥＶ
Engine E.Motor
Low Full
Battery
Ave ECO 0 5 10 0.0 km/l km/ ｌｌｌｌ
HV-cable / plugs
inhouse
HCS (Software) E-motor Inverter HV-Battery commodity
Key component
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 26 Engineering - system 3 Various and partly opposing requirements have to be considered for the specification of the HV-Battery The HV-Battery is a complex component, combining electrical, chemical, mechanical and performance elements. With the boundary conditions in a truck, the right combination has to be defined.
I2T : 180sec A
B s) 2
t (A t +180 2 i 2
2 ×= tItI I 180 ∑ ii Lifetime =ti i Decrease due to 50%-driving power Safety
Cost Cell chemistry
Ambient conditions
Cooling system Cell type
Vehicle integration Power/energy E/E interface control
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 27 Engineering - system 3 Simulation process to evaluate feasible system configuration • Energy Analysis: simulation tool for the basic dimensioning of hybrid systems (dimensioning of power and energy). • I2t limitation study: process to consider battery limitations and lifetime restrictions • Consideration of route specific driving/recuperation characteristic
1. Route definition 2. Power profile by vehicle 3. Lifetime study simulation
•Route profile has to be defined for •Power profile is calculated by •I2t is calculated by power profile relevant key-applications vehicle simulation •I2t as limit for battery spec or usage •If I 2t exceeds the criteria, change to Battery hardware or hybrid control
600 150 500 400E+4 400 100 300 300E+4 50 200 200E+4 100 Altitudem 0
0 Power kW 100E+4 -100 0 5000 10000 15000 20000 25000 30000 35000 0000E+0 -200 -50 [A^2*sec] I^2t(180sec) -300 0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600 -100 Distance [km ] Distance m Time sec
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 28 Engineering - control 3 Depending on circumstances, the fuel effect of a hybrid may even be negative
Fuel Savings [%]
Usage profile:
hard (hilly terrain)
medium (typical long haul) Medium-easy (“Landstraße”)
easy (Autobahn without hills)
Power hybrid system [kW]
A hybrid for truck must be carefully selected depending on its usage!
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 2929 Engineering - control 3 The hybrid control strategy is a major lever for defining the success of a hybrid truck
HEV Conventional Engine E-Drive Hybrid drive Recuperation Sailing feature drive start-stop
Topo- graphy
battery
FE* Long haul
FE* City delivery
• Most relevant features for HD hybrid differ significantly from other applications
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 30 Engineering - future 3 Future hybrid functions have to consider engine-off and PHEV functionality • The focus of hybrid development is today on classic hybrid functionality. Advanced hybrid functions will consider the shut-down of the Engine • pZE and plug-in operations available in cars, and partly for LDT. • Additional functionality might be required by the customer (ePTO, ZE), or by law (LEZ-ZEZ). • In addition, synergies with existing components of other Daimler BU might be possible.
Market - PHEV Advanced hybrid functions
Lead to …
ZE – PHEV evaluations
Legislation - pZE Synergies – Daimler xBU
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 31 Engineering - future 3 There are many topics than can be evaluated once the hybrid system is realized Hybrid relevant Control component sub-system System
• Rare earth substitution
• New sys • Next Gen. Energy Management System • Optimized design • pZE/ZE Sys, ePTO • Optimized ENG & ATS
New materials • Driver’s guide • Optimizing /Telematic System all vehicle systems
• Waste heat recovery systems
• Electrical auxiliary • Total Energy Management
• Integrated Brake Systems
• Combined Hybrid Control with existing compo/sys
• Latest PT systems
• Assured life-time Gen2
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 32 Contents
1.1 Daimler and Daimler Trucks
2.2 Hybrid at Trucks – System concept, vehicles and Organization
3.3 Engineering working direction – Modularity, Components and Controls
4.4 Other Challenges – customer and standardization
5.5 Summary
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 33 Challenges - customer 4 Besides technical challenges, different buying motivations exist - only one is stable for development • Customers buy a HEV Truck for different reasons. They want to be eco-friendly (e.g. green image), they have to (out of legislation or access restrictions) or because of a monetary benefit (subsidies or by better TCO). • Most trucks are bought to make „Must“ „Can“ + - money. The decision is simple: Emission & Legislation Incentives - how much does it cost? Emission standard EEV buying incentives CO 2 emission reduction Regional funding by cities - How much do I get (in a reasonable Noise emission reduction Communal announcements time)? NOx / particle emission Free access to city center reduction Customer • Besides legislation effects, a hybrid truck has to deliver real monetary „Green“ Benefit „Want“ benefit to get high volume. Green Image Monetary Benefit Environmental friendly image Fuel consumption early use of alternative, reduction • At the same time, the usage of the future technologies maintenance reduction vehicle should not be restricted by CO 2-balance Range increase (carbon-footprint) the system (same durability, payload, functionality, performance, …).
• As a result, a hybrid system has to be integrated in a way, that keeps the capability of the truck unchanged.
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 34 Challenges - standardization 4
Das Grund-Dilema einer globalen Elektromobilität sind die unterschiedlichen, hundertjährigen Elektizitätsnetze
•Verschiedene Elektrizitätsnetze haben unterschiedliche Ladesysteme zur Folge …
AC Laden Typ 1AC Laden Typ 2 AC/DC Laden „Combo“ Typ 1/2 DC Laden „Chademo“ etc…
Die Fahrzeughersteller entwickeln die Fahrzeuge in unterschiedlichen Szenarien
Beispiel: Nissan Leaf AC Laden Typ 1 oder 2 DC Laden „Chademo“ Induktives Laden*
Source: Daimler Corporate Standardization
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 35 Challenges - standardization 4 Die Einigung auf wenige internationale Standards reduziert die Entwicklungs- und Produktions-Kosten
optimales Region Aktuelle Situation AC/DC Fahrzeug Inlet Szenario IEC Combo 1 (AC + DC) 1 passend für IEC Type 1 (AC) und Combo 1 (AC + DC) Connector 1
2 IEC Combo 2 (AC + DC) 2 passend für IEC Type 2 (AC + DC) und Combo 2 (AC + DC) Connector
3 IEC Type 1 (AC)4 CHAdeMO (DC) 1
National Standard (AC) National Standard (DC) 5 6 2 GB Part 2, ähnlich IEC Type 2 GB Part 3 National Standard (AC) National Standard (DC) 7 8 1 Ähnlich IEC Type 1 Ähnlich CHAdeMO Anzahl Varianten 8 2
Source: Daimler Corporate Standardization
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 36 Contents
1.1 Daimler and Daimler Trucks
2.2 Hybrid at Trucks – System concept, vehicles and Organization
3.3 Engineering working direction – Modularity, Components and Controls
4.4 Other Challenges – customer and standardization
5.5 Summary
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 37 Summary 5 By continuously reducing cost and increasing the hybrid benefit, the magic moment is close To reach the “magic” moment”, two levers have to be used: • The monetary benefit can be influenced mainly by vehicle development and improvements in operations strategy and vehicle integration. As shown with the different models of Canter EcoHybrid, the performance can be significantly improved by fine-tuning (with unchanged system hardware and cost). • The system costs are directly linked to the volume of hybrid components that depend on the development of the automotive industry and the component specification. Governmental subsidies can help to bring volumes up. • Today, the magic moment can only be reached with subsidies. This will drastically improve in the next few years.
FE Potential*
TCO reduction 5 % by HEV - system costs Monetary Benefit >20 % -60% - -80% Additional vehicle price for HEV today
with subsidies x x + 10 years *: depending on vehicle and application S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 38 Summary 5 Summary
Trucks have specific boundary conditions • Money driven business (TCO) • Weight and packaging sensitive • High variety in vehicles and usage - worldwide
Key success factors for hybrid systems in Trucks • Optimized, modular system architecture and cost • Individual operating strategy and seamless vehicle integration • Strong network for synergies in functions, budget and time • Target is the best performance/cost ratio!
Boundary conditions / challenges • Most challenging component: HV battery • Biggest uncertainty: governmental / City administrations priority • Standardization as key driver for component cost and volume
Outlook • HEV is the future for Trucks. But success and schedule are not in engineering responsibility
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 39 Daimler Trucks We are Shaping Future Transportation …
Thank you!!!
S. Treusch - hybrid at Daimler - KIT Febr. 2013 - final Daimler Trucks 40