DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN Gerhard Vosloo, Rimac Automobili d.o.o. IPG Apply & Innovate 2020 AGENDA ‒ Introduction ‒ Background and motivation ‒ Development process ‒ Targets ‒ Use case: longitudinal performance ‒ Use case: track performance ‒ Use case: range and efficiency ‒ Correlation and validation IPG Apply & Innovate 2020 DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 2 WHO WE ARE − Founded: 2009 (first employees in April 2011) − Team today: 700+ people (400+ in R&D) − Completed B2B projects: 30+ − Developed, produced and delivered world’s fastest electric supercar − Tier 1 supplier to 10 Global OEMs − Total investment so far: ~€140M − Deloitte technology fast 50: 10th place 3 Offices in Croatia 4 consecutive years amongst top 100 Zagreb − Awarded as the best employer in Croatia Osijek − European Business Award Split - Joint Venture in China signed - Dealer network expansion in - World Premiere of the - First car delivered - Rimac builds Nobuhiro three continents – North Concept_One, world’s - Intense development and Monster Tajima’s race car first all-electric supercar America, Europe and Asia - Rimac Automobili is testing of Rimac All Wheel for the Pikes Peak - 10 employees - 250 employees founded in Sveta Nedelja, Torque Vectoring System. International Hill Climb. - Hyundai Motor Group becomes a shareholder Croatia. - 100 employees - 500+ employees - Porsche increases stake in Rimac 2008 09 10 11 12 13 14 15 16 17 18 19 20 - Mate Rimac converts his - Mate Rimac breaks 5 - Rimac completes its first - The Concept_One becomes FIA - Contracts with major OEMs - World premiere of Rimac’s next - Testing and BMW E30 into an Guinness and FIA World B2B project for IDIADA. Formula E’s official Race Director - Production model of the generation hypercar, the C_Two development of electric race car and the records for the fastest First revenues. car Concept_One introduced. - Porsche becomes a shareholder the C_Two idea is born accelerating electric car. - First OEM projects - First production vehicle contract - Significant expansion of - 400+ employees continues - First profitable year - A-round completed facilities - further expansion of production - More than 700 facilities employees - Opening of offices in Split and Osijek - Launch of the Xianyang JV location OEM PROJECTS Development of an powertrain Development of an electric system and electronics of version of Hyundai Motor’s N Automobili Pininfarina Battista brand midship sports car and electric hypercar. a high-performance fuel cell electric vehicle. Development and production of Development and manufacturing the Aston Martin Red Bull batteries and power distribution Valkyrie supercar hybrid battery units for the Koenigsegg Regera system, infotainment and hypercar. connectivity system Development of full EV system for CUPRA (SEAT) e-racer Developed an electric version of prototype the iconic Jaguar E-Type, which was used as the groom and bride car for the Meghan Markle and Prince Harry’s royal wedding. VEHICLE ENGINEERING HYPERCARS TECHNOLOGY A new approach to high performance Technology developed from the ground through technology and innovation up, driving the electric revolution HYPERCAR | 2.5 sec 14 sec 1224 hp 355 km/h 1600 Nm 350 km 0-100km/h 0-300km/h 900 kW Electrically limited From 0 to 6500rpm On a single charge Debuted at the 2011 Frankfurt International Auto Show HYPERCAR | 1.85*sec 1914 hp 412 km/h 2300 Nm 550 km 0-100km/h 1400 kW Electrically limited From 0 to 6500rpm On a single charge C_TWO • Globally homologated • 4 independently controlled electric motors power each wheel • Rimac all-wheel torque vectoring • Full carbon fibre monocoque with structurally integrated battery pack • Active Aerodynamics • Autonomous driving capabilities • Driving Coach OUR SERVICES BACKGROUND & MOTIVATION ‒ Hypercar EV segment ‒ Low volume ‒ Less cost conscious ‒ Incorporates latest and most advanced EV technology ‒ Electric vehicles (EV) are undergoing exponential growth and development ‒ Electric motors ‒ Inverters ‒ Battery Cells ‒ Battery pack design and cooling ‒ Architecture IPG Apply & Innovate DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 11 2020 THE CHALLENGE FOR EV HYPERCARS Rapid prototyping and flexibility to adapt and include latest EV technology … or risk being left behind by competitors! “If you aren’t first you’re last” – Ricky Bobby IPG Apply & Innovate DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 12 2020 THE DEVELOPMENT PROCESS IPG CarMaker Design iteration Powertrain Overall vehicle Performance Targets Layout & other Battery Inverters Motors status Parameters Component level test data Subsystem (e.g. front powertrain) Vehicle level test data IPG Apply & Innovate DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 13 2020 TARGETS* *Targets listed does not represent actual targets of the Rimac C_Two ‒ Performance: ‒ Longitudinal e.g. 10 x 0-100-0 km/h without overheating/de-rating ‒ Track e.g. 1 lap of Nürburgring, Nordschleife without any power de-rating ‒ Range: e.g. 550+km on WLTP IPG Apply & Innovate DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 14 2020 LONGITUDINAL PERFORMANCE Performance analysis at lower SoC NOTE: Results are given as an example, data is not representative of current, nor previous status IPG Apply & Innovate DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 15 2020 TRACK PERFORMANCE ANALYSIS: Nürburgring Nordschleife Performance comparison of different battery pack designs Nürburgring Nordschleife Difference in Battery pack Simulated Lap Time design [s] 1 0.0 2 -20.3 3 -6.8 4 -17.3 NOTE: Results are given as an example, data is not representative of current, nor previous status IPG Apply & Innovate DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 16 2020 ELIMINATE BOTTLENECKS FOR A HOLISTIC DESIGN Improved cooling performance Higher sustained Increased thermal Higher demand on power output and durability rest of powertrain from battery requirements Improved cell chemistry/design IPG Apply & Innovate DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 17 2020 RANGE AND EFFICIENCY ON WLTC CYCLE Consumption and identifying losses WLTC consumption, range and losses Consumption XXX.X Wh/km Powertrain efficiency Range XXX.X km based on WLTC cycle Aerodynamic Losses 23.4% Battery 1.5% Front Rear Powertrain Inverters 11.8% Motor 92.0% 91.0% Losses Motors 13.5% Inverter 96.0% 95.0% Gearbox 6.8% Gearbox 97.6% 97.5% Friction Brakes 2.8% Tyre Rolling Resistance 31.9% Contribution of Losses Contribution Auxliary 8.3% NOTE: Results are given as an example, data is not representative of current, nor previous status IPG Apply & Innovate DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 18 2020 CORRELATION AND VALIDATION OF SIMULATIONS Increased variables and complexity COMPONENT SYSTEM LEVEL VEHICLE LEVEL LEVEL • Battery • Front and/or Rear Axle • Full system integration with all control systems • Motor & Inverter • Controlled operating conditions • Variable operating conditions • Gearbox • Controlled cooling environment • Driver in the loop • Limited control IPG Apply & Innovate DEVELOPMENT AND OPTIMIZATION OF AN ELECTRIC HYPERCAR POWERTRAIN 19 2020 For any additional information you might need, feel free to contact me. Gerhard Vosloo Vehicle Dynamics Engineer M +385 91 3336 506 [email protected] Rimac Automobili d.o.o. Ljubljanska 7 10431 Sveta Nedelja rimac-automobili.com 20.