Automotive Future: Electrified and Autonomous

The Transition of an Industry

EDSGN 100

Section 001

Design Team 5

Penn Engineers

Fall 2017

Nick Aboelenin

Tommy Kiefer

Sade Langa

Michael Papiernik

Submitted to:

Professor Berezniak

College of Engineering

School of Engineering Design, Technology and Professional Programs

Penn State University

Safe

Connected

Green

A society with zero road fatalities, zero injuries and zero accidents.

A world with 50% less emissions.

Pioneering advancements in intelligent vehicle technology to deliver a seamlessly informed, personalized and safer driving experience.

4 Dec 2017

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TABLE OF CONTENTS

SECTION 1. EXECUTIVE SUMMARY

SECTION 2. INTRODUCTION

2.1 Project Objectives 2.2 Project Background 2.3 Sponsor Background 2.4 Sponsor Target Areas

2.4.1 Safe 2.4.2 Green 2.4.3 Connected

2.5 Project Terminology 2.5.1 Autonomous Vehicles (AV) 2.5.2 Electric Vehicles (EV)

2.6 Customer Needs 2.6.1 Autonomous Vehicles (AV) 2.6.2 Electric Vehicles (EV)

SECTION 3. AUTONOMOUS VEHICLES (AV)

3.1 Problem Description and Critical Issues 3.2 Safety and Liability 3.3 Technology 3.4 System Components 3.5 “Connected” Vehicle Concepts 3.6 Traffic Management 3.7 Concept of Operations 3.8 Social Acceptance

SECTION 4. ELECTRIC PASSENGER VEHICLES (EV)

4.1 Problem Description and Critical Issues 4.2 Environmental Impact 4.3 Vehicle Component 4.4 Battery Types and Technologies 4.5 Vehicle Performance

4.5.1 Battery and Vehicle Efficiency 4.5.2 Energy Consumption 4.5.3 Battery Charging 4.5.4 Battery Lifetime 4.5.5 Battery End-Of-Life Issues 4.5.6 Operating and Life-Cycle Costs

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4.6 Vehicle Safety 4.7 Concept of Operations 4.8 Social Acceptance

SECTION 5. CONCLUSIONS

SECTION 6. RECOMMENDATIONS

SECTION 7. REFERENCES

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Automotive Future: Electrified and Autonomous

The Transition of an Industry

SECTION 1. EXECUTIVE SUMMARY We were tasked with integrating one or multiple of Delphi’s three target areas into our report. Those target areas are safe, green and connected. We saw these as recurring themes through our research and found ways to incorporate those values in our report.

SECTION 2. INTRODUCTION 2.1 Project Objectives. To Identify technologies and opportunities to achieve the vision of safe and connected electric and autonomous vehicles. 2.2 Project Background. Every day we’re hearing in the news about “vehicle of the future”, ones that will park themselves, drive themselves, talk to us, communicate with other vehicles and highway infrastructure, report data to insurance companies, and avoid accidents. In addition, many countries have announced recently that they will no longer allow the sales of gasoline or diesel automobiles after a certain date, e.g., Norway and The Netherlands in 2025, China and Britain in 2040. (Technically, the vehicles will need to be zero emission, which could include hydrogen and other technologies, but for the purpose of this project, the focus is on electric and autonomous vehicles). 2.3 Sponsor Background. Delphi delivers innovation for the real world with technologies that make vehicles and trucks safer, more environmentally friendly, smarter better connected, and more affordable ever before.

Delphi Automotive is a global automotive component design and manufacturing company—it is one of the world’s largest automotive parts manufacturers and provides technology solutions for electrical, electronic, and safety systems to the global automotive and commercial vehicle markets. Delphi operates over 100 manufacturing facilities and 15 technical centers across 46 countries, utilizing a regional service model that enables it to

serve its global customers. It has approximately 166,000 employees worldwide, including 20,000 engineers, scientists, and technicians. Delphi operates through two business

segments:

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Electrical / Electronic Architecture

Delphi provides complete design, manufacture and assembly of the vehicle’s electrical architecture, including connectors, wiring assemblies and harnesses, cable management, electrical centers and hybrid, high-voltage and safety distribution systems. Their products

provide the critical signal distribution and computing power backbone that supports

increased vehicle content and electrification, reduced emissions, and higher fuel economy.

Major products: Wiring harnesses, electrical centers, vehicle and cell phone wireless charging, data communication cabling, hybrid and all-electric vehicle charging systems.

Electronics and Safety

Delphi provides critical components, systems, and advanced software development for passenger safety, security, comfort, and vehicle operation, including body controls, infotainment and connectivity systems, passive and active safety electronics, autonomous driving technologies, and displays. Their products increase vehicle connectivity, reduce driver distraction and enhance vehicle safety.

Major products: Engine control module, advanced reception systems, navigation, displays, adaptive cruise control radar and camera systems, parking guidance systems.

2.4 Sponsor Target Areas. Each design team should choose one (or a combination) of Delphi’s three target areas—Safe, Green, Connected—as described below.

2.4.1 Safe. Delphi’s ultimate goal is to help make zero fatalities, zero injuries, and

zero accidents a reality. Protecting the driver and passenger is of utmost importance. Airbags are an example of a reactive safety feature after a crash occurs. Safety features now being designed into cars are more proactive to avoid the crash all together. Sensors are used to detect dangerous situations, and alert the driver or even take over control of the vehicle to avoid the situation. The future is to make vehicles autonomous such that they will be safer.

2.4.2 Green. They’re passionate about creating a world with zero emissions

Protecting the environment is also very important to the vehicles of the future. Hybrid and electric vehicles are becoming more popular as an alternative to traditional

vehicles. Other types of fuels such as hydrogen are being explored. However, simply reducing the weight of a vehicle or having products that make engines run smarter or more efficiently can dramatically improve fuel economy. Also the choice of materials used for manufacturing

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their products is important. What materials can they use that are environmentally friendly and reduce or eliminate the carbon footprint of the vehicle?

2.4.3 Connected. Delphi has the technology to allow seamless connectivity in the

vehicle—it’s what consumers want, and they can make it a reality. The vehicle of the future should be optimally connected to maximize the driver’s and

passenger's’ experience while minimizing the driver’s distraction. Connecting the vehicle itself and all its sensors to the outside world should not be overlooked. The vehicle of the future will have 100s of sensors collecting data, which may be very beneficial to others. For example, if a vehicle is doing 5 mph on a 65-mph interstate, an algorithm would determine a traffic jam was present and alert other approaching vehicles of the situation. The brakes could be applied for very close vehicles, or navigation systems could re-route approaching vehicles to avoid the congestion. Today’s driving assistance systems are the stepping stones to fully autonomous vehicles.

2.5 Project Terminology.

2.5.1 Autonomous Vehicles (AV). Autonomous vehicles use artificial intelligence

instead of human-decision making to successfully drive automobiles. Various sensors and cameras are connected to the car and absorb and analyze all the consequent data. LIDAR, similar to sonar, sends out pulses of energy and measures how long they take to return to the transponder, which allows a representation of the environment to be developed. In theory, the AI is programmed with guidelines for every possible situation on the road and will make the designed decision. This process eliminates the human ability for error, creating a safer and more functional driving experience for everyone.

The SAE J3016 levels of automation rate categorize the different amounts of control that a driver has on the road in their vehicle. Level 0 is complete driver control, level 1 allows the car to do some functions with the driver still doing the majority, and level 2 has the car do most functions while the driver does few, if any. There is a major change in between levels 2 and 3 as the driver reliance is eliminated in many road conditions in 3 and is only necessary with a system failure. Level 4 encompasses more road conditions and may only require the driver with extreme weather. Lastly, level 5 does not need a driver at all and can handle every road situation on its own.

2.5.2 Electric Vehicles (EV). There are three main types of electric vehicles, battery

vehicles (BEVs), plug-in hybrid vehicles (PHEVs), and hybrid vehicles (HEVs). Battery electric vehicles run solely on electric power, using external battery charging outlets and regenerative braking technology (converts heat from brakes into electric power) to generate its “fuel”. BEVs use only an electric motor for power, leaving the traditional gas tanks and exhaust pipes behind. Plug-in hybrid vehicles use a combination of petrol and electricity for power. PHEVs have both a traditional petrol engine and an electric motor, each being used for specific driving functions at different fuel and electricity levels. Similar to BEVs, PHEVs use both regenerative braking and plug-in power (hence the name) to charge its electric motor and battery components. The battery is also able to be partially recharged by petrol motor when the

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vehicle senses that its charge level is too low, increasing the mileage/range of the vehicle. Hybrid vehicles also use both traditional and electric motors, but only rely on regenerative braking to generate electric power. HEVs will use only the electric motor for low speed or low distance drives, then as speed and distance increase (monitored by internal computer system), the vehicle will switch to using the petrol engine as its primary power source. These main types of electric vehicles are being mass produced across the world, as their is a global effort to try to transition to a “greener” lifestyle. 2.6 Customer Needs.

2.6.1 Autonomous Vehicles (AV). The main point of concern from autonomous vehicle prospective buyers is that they are not sure of the legal issues that may arise in the event of an accident. However, with a level 6 automation, the passenger cannot possibly be liable. A car that is advertised to require no driver assistance cannot hold the passenger responsible for a possible failure in codev or the actions of another driver. The car essentially becomes another driver, similar to an Uber driver, but the actions of the car will reflect on the company and not the consumer.

2.6.2 Electric Vehicles (EV). The common scare among consumers is that, similarly

to their phones, their battery will run out in their car. While this is a major concern to be had, we have improving technology that is pushing the envelope allowing us to go farther than ever before. For example, the Nissan Leaf, is a battery car that has a range of 107 miles on the battery alone. That’s enough to get you into Maryland from State College. To address the concern, there are also many safety features, such as the one in figure 1, showing you how many miles you have left in the battery before it requires recharging. The other alternative is hybrids, which are more reliable but do depend on gas. These are not the ideal “green” cars but it’s a start for society and have become really popular in the us. these range from average cars such as the Toyota Prius or high-end sports cars such as the Lexus ES.

SECTION 3. AUTONOMOUS VEHICLES (AV) 3.1 Problem Description and Critical Issues. For autonomous vehicles, there are issues with how people perceive the safety, reliability, and technology that comes with a new era of automobiles. There are many questions concerning the actual intelligence of the driverless car, if it will perform properly whenever used, and if it is actually wise to put someone’s life in the hands of a computer. The only way to remove these questions from the public forum is to show the success of autonomous cars on the road and not have any incidents of failure, which would be made a very big deal by media outlets. 3.2 Safety and Liability. To autonomous car has a standard car chassis to maintain costs and has the necessary technological equipment built onto the car. A much more safer exterior would raise costs significantly, which many consumers do not favor. The car will endure countless hours of testing in the lab and on the road with engineers to map out every consequent situation that can occur. If a new situation is encountered while on the road, the AI

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will be able to act accordingly. As a result, the passenger of this car will have no liability if the car is being computer operated, which makes our job much more conducive and important. 3.3 Technology. Utilizing LIDAR, RADAR, and infrared camera on the front of the car, as seen in figure 6, are used to map the environment and surrounding cars. Figure 8 demonstrates the rooftop 360 camera, which sends imaging of everything around the car. The wheel encoder in figure 9 allows the car to control the speed of the tires. Figures 6 and 10 also show the front and rear cameras, which image what the 360 cameras cannot see near the floor of the car. 3.4 System Components. This autonomous vehicle design is that of a normal automobile so as not to scare consumers. The attached cameras and wave emitters are necessary to the design and are in the optimal locations, so as to have the best range for the cameras and minimizing the cost of each. 3.5 “Connected” Vehicle Concepts. All of the technology that is utilized records various types of data, which is then sent to the computer located in the car itself. This data is then sent from the car via the internet to the data hub. The collection of the data is important to the continued improvement of the system, and will need to be adjusted accordingly as more autonomous cars enter the transportation system. 3.6 Traffic Management. On just one trip, a car experiences many different traffic conditions and situations, ranging from one-lane roads to wall to wall traffic on the freeway. As demonstrated in Figure 7, the autonomous vehicle design incorporates a lane guidance system that keeps the car in its specific lane, so as not to accidentally drift. Several of the various technologies listed above are present simply to read the road metrics and the surrounding cars, as well as using satellite imaging to map the other cars. 3.7 Concept of Operations. The AV system requires all of the technology to be functional

and updated with the latest updates, so as to protect everybody the car encounters on the

roadway. Similar to when a computer needs an update, the car will detect a new update and

project the command on the dashboard upon car startup. On a daily basis, the passenger

needs only to start the car, put in the destination, and relax. Upon catastrophic system failure

or extreme weather, the vehicle will find a safe spot to pull over and compile data until the

conditions are safe again.

3.8 Social Acceptance. Autonomous vehicles will take away the human element of driving on the road. At the current time, many people would rather place their trust in other drivers instead of a computer, even if the computer is capable of making more informed decisions. The only way to do this is to put autonomous cars on the road and show people how successful and capable the driverless cars actually are.

SECTION 4. ELECTRIC PASSENGER VEHICLES (EV)

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4.1 Problem Description and Critical Issues. Some critical issues that are associated with

electric cars are cost, maintenance, battery lifetime, and dependability. If we want to have a

society dominated by electric cars we need to bring the cost of the individual cars down, and

that will come mass production and innovations in technology. The same can be said about

maintenance, the cost is incredibly high and may go down if electric vehicles weren't so rare.

Battery life and dependability are important factors that the public should be concerned with,

but again, new innovations will most likely be the only solution.

4.2 Environmental Impact. Depending on your local power grid, you might not be as green as you once thought. EVs are dependent on many other industries, for example, they need to be charged and if your grid is powered by coal, you are hurting the environment. While they are leaps and bounds ahead of traditional cars with producing greenhouse gasses and such, they are still not 100% green. We will never have completely green vehicles until we have a completely green way to charge them, but it’s a start. 4.3 Vehicle Component. Electric vehicles are essentially made up of 6 major components.

The battery is what holds the “fuel” of the car. It tends to be on the underbelly of the car to

shelter it from impact. The electric engine transfers the energy from the battery and essentially

turns it into energy that can spin the wheels. this is essential and typically does not have a lot of

wear and tear. Regenerative braking is the third essential part of the car, this allows the system

to take energy generated from the brakes and cycle them back into the car, increasing the

battery range. The last system is the drive system, this connects the electric engine to the

wheels, mechanically. This is very similar to the drive train for a traditional car, connecting the

engine to the wheels.

4.4 Battery Types and Technologies. The most common type is Lithium Ion batteries, these are the ones used by Tesla and Nissan. Although they have a bad reputation of catching fire, new advances have made them safer and safer even implementing safety systems. Another common battery concept is Solid state batteries. With these batteries, fire is not an issue, these batteries are used more by Toyota and Volkswagen. They also have a longer lifetime and are significantly less bulky. 4.5 Vehicle Performance. Electric vehicles have a wide range of vehicles that can perform in many ways. The Tesla model S can perform incredibly, alongside with some of the best traditional sports cars. The model X is a SUV that can perform alongside gas SUVs as well. No matter your taste, will always get performance such as you would from a gas vehicle.

4.5.1 Battery and Vehicle Efficiency. With new lithium batteries, we see batteries last longer than ever. With longer battery ranges we can move to an all-electric car.

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4.5.2 Energy Consumption. With regenerative breaking, energy consecration of energy and the recharge of the battery have come to the forefront of electric car technologies. This method uses the fiction created by breaking and turning it into energy that can

4.5.3 Battery Charging. Against common misconception, it does not take much to charge a

battery. If electricity costs $0.11 per kWh and the vehicle consumes 34 kWh to travel 100 miles,

the cost per mile is about $0.04. If electricity costs $0.11 per kilowatt-hour, charging an all-

electric vehicle with a 70-mile range (assuming a fully depleted 24 kWh battery) will cost about

$2.64 to reach a full charge.

4.5.4 Battery Lifetime. Depending on the type of battery and the usage, the battery can last anywhere from 3000 to 10000 charges. A replacement battery may be pricey but also be covered under warranty.

4.5.5 Battery End-Of-Life Issues. There is no currently “clean” battery to dispose, but

there are methods of disposing of such batteries. There has been a push for finding a way to recycle these batteries and has made progress. The ultimate goal is to never get rid of a battery, to have them be recycled.

4.5.6 Operating and Life-Cycle Costs. Maintenance has always been an issue for electric

cars. This is just goanna be an issue until your average mechanic knows how to handle and maintain electric vehicles. But until then they are going to be an issue until the network grows.

4.6 Vehicle Safety. Before an electronic vehicle hits the market, they must pass extreme safety screening. Actually, they have to perform better than traditional gasoline cars to help disprove the common misconception that they are not safe. One major concern is that during collision that the batteries might cause a chemical spill and this is one of the test they must pass before hitting the market. Because EVs usually have a lower center of gravity, they have a less chance of rolling over. Therefore, their batteries are on their underside, but companies are still required to plan for it if it were to happen. This rigorous testing causes these cars to be just as safe if not safer than your traditional vehicles. 4.7 Concept of Operations. The EV industry has a lot of moving parts and is very dependent on other industries, there are many factors pushing the industry forward. Innovations in battery technology and wireless charging are just a few that helped get it where it is today. These cars were made to work perfectly under ideal conditions but handle really well in conditions such as snow. Because of their all-wheel drive technology and great handling, they handle better in snow and ice situations than your typical sedan. When it comes to flooding, not so much, the lower center of gravity hurts them in this case and could be a hazard. A day in the life will involve plugging your car in at the end of the day and unplugging it at the start. The rest is traditional driving procedure. In figures 2 and 3 you can see a conceptual design for a charging station at home. In figure 3 you can see how we have integrated the bulk of the hardware to be hidden under the roof to make for a cleaner look and to not disturb the homeowner.

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4.8 Social Acceptance. The common concern with these cars is that the range will simply not be enough and when pushed to its limit, it will fail. While this concern is real, as stated earlier, technology is ever changing. The ranges on these cars will increase and increase until maybe someday, they are not even a factor in the buying decision. Like any other concept, it will take time for society to accept it.

SECTION 5. CONCLUSIONS Through an extensive amount of research, our design team concluded that as of right now electric vehicles are the better choice when looking at both electric and autonomous vehicles. In today’s day and age, electric vehicles are safer, greener and more connected than autonomous vehicles. To explain, electric vehicles are not ran by a man made system that could potentially crash or become hacked. Furthermore, these vehicles remain connected to society's demands by not emitting pollution which aids in society’s “Go Green” campaign. Although, electric vehicles are the better buy today we believe autonomous vehicles have the potential to take electric vehicles over in the near future.

SECTION 6. RECOMMENDATIONS As a group, we recommend that for the time being one should purchase an electric vehicle but to keep their eyes open for the autonomous vehicle’s perfection; if and when the autonomous vehicle is perfected families across the nation should make the switch.

SECTION 7. REFERENCES

Works Cited

“6 Important Components of Electric Cars.” NJIT Online RSS,

graduatedegrees.online.njit.edu/resources/msee/msee-articles/6-important-

components-of-electric-cars/.

“6 Important Components of Electric Cars.” NJIT Online RSS,

graduatedegrees.online.njit.edu/resources/msee/msee-articles/6-important-

components-of-electric-cars/.

“All-Electric Vehicles.” Www.fueleconomy.gov - the Official Government Source for Fuel

Economy Information, www.fueleconomy.gov/feg/evtech.shtml.

“Batteries for Hybrid and Plug-In Electric Vehicles.” Alternative Fuels Data Center:

Batteries for Hybrid and Plug-In Electric Vehicles,

www.afdc.energy.gov/vehicles/electric_batteries.html.

“Electric Car Safety, Maintenance, and Battery Life.” Department of Energy,

energy.gov/eere/electricvehicles/electric-car-safety-maintenance-and-battery-life.

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“Electric Car Safety, Maintenance, and Battery Life.” Department of Energy,

energy.gov/eere/electricvehicles/electric-car-safety-maintenance-and-battery-life.

Karsten, Jack, and Darrell M. West. “Five Emerging Battery Technologies for Electric

Vehicles.” Brookings, Brookings, 29 July 2016,

www.brookings.edu/blog/techtank/2015/09/15/five-emerging-battery-technologies-for-

electric-vehicles/.

Stephen Mraz 1 | Jan 23, 2017. “SAE's 6 Levels of Self-Driving Cars.” Machine Design, 25

Jan. 2017, www.machinedesign.com/blog/sae-s-6-levels-self-driving-cars.

“Types Of Electric Cars.” Ergon Energy, www.ergon.com.au/network/smarter-

energy/electric-vehicles/types-of-electric-vehicles.

Wade, Lizzie. “Tesla’s Electric Cars Aren’t as Green as You Might Think.” Wired, Conde

Nast, 31 Mar. 2016, www.wired.com/2016/03/teslas-electric-cars-might-not-green-think/.

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FIGURES

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Figure 1. Range notification for Nissan Lea

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Figure 2. Charging station I

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Figure 3. Charging station II

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Figure 4. Charging III

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Figure 5. Vehicle lifetime carbon emission

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Figure 6. Front view of car

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Figure 7. AV Lane Guidance System on door

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Figure 8. View of 360-degree camera

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Figure 9. Wheel Encoder

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Figure 10. Rearview cameras