vehicle electrification focus and challenges · elkraftdagen 2016 - cth, electric propulsions...
TRANSCRIPT
![Page 1: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/1.jpg)
Vehicle electrificationfocus and challenges
Karl Klang
Electric Propulsion Systems, Volvo Cars
Elkraftdagen 2016 - CTH
![Page 2: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/2.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 2Issue date: 2016-03-22, Security Class: Public
Overview
• Introduction
• Vehicle electrification challenges of today
• Volvo cars electrification – history and present
• Q&A
![Page 3: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/3.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 3Issue date: 2016-03-22, Security Class: Public
Why Hybrids & Electrification? Up to today
Political and market forces limiting CO2 emissions and usage of fossil fuels
Electricity as a main track for cars and light trucks- Efficiency- Infrastructure and conversion flexibility
Global Warming
• climate change
Energy Security
• fuel availability
• delivery conditions
![Page 4: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/4.jpg)
Electrification – image step 1
Generation 1
• Decent performance
• Slight improvement in fuel efficiency
• No revolutionaryattributes
• Huge productplacement effort!
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 4Issue date: 2016-03-22, Security Class: Public
![Page 5: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/5.jpg)
Electrification – Image step X
Tesla
High performance electric vehicle
Message:
Electric performance can be competible with ”normal” cars!
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 5Issue date: 2016-03-22, Security Class: Public
![Page 6: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/6.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 6Issue date: 2016-03-22, Security Class: Public
Worldwide legislations on CO2 emmisions
130 g/km 2012
95 g/km 2020
CO2-development over time – new cars EU
Source: icct (the international
council on clean
transportation)
![Page 7: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/7.jpg)
Automotive electrification today
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 7Issue date: 2016-03-22, Security Class: Public
• Electrification strategies adopted by many car
manufacturers and many models are already available
• Expected legislated emissions decreases steadily
• Incentive programs for electrification are ramping out
![Page 8: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/8.jpg)
Automotive electrification today
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 8Issue date: 2016-03-22, Security Class: Public
• Electrification strategies adopted by many car
manufacturers and many models are already available
• Expected legislated emissions decreases steadily
• Incentive programs for electrification are ramping out
The “chasm”
![Page 9: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/9.jpg)
Focus and challenges today – the MarketExtremely competitive market, relatively untested for these applications, where the standard questions are to be answered:
• What do customers want?
• How much is it worth?
• At the expense of what is it still desirable?
• How do we brand whatever level we chose to offer?
• What does customers not yet know that they want?
• How and at what time will the infrastructure adapt?
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 9Issue date: 2016-03-22, Security Class: Public
![Page 10: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/10.jpg)
Focus and challenges today – industry vs automotive
Automotive applications requires:
• Capability to handle harsh and varying environmental conditions
• Documented fulfilment of “appropriate” standards for liability and/or legal reasons
Suppliers typically comply with industry “best practice” standards + Automotive industry standardization is lagging Brand/model unique solutions, low volumes, long lead times and expensive development
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 10Issue date: 2016-03-22, Security Class: Public
![Page 11: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/11.jpg)
Focus and challenges today – Functional safety vs robustness
• ISO 26262 introduced as an automotive “best practice” standard
• High (documented) confidence levels are required for applications where very little quality data is available
• Failing to fulfil the required confidence levels might mean that you have to go to a safe state where the electric propulsion ability is typically either not available at all or greatly reduced.
• Consequence of lost function increases as the utilization of electric propulsion increases
• Some market enforce very strict penalties for setting faults too often while still requiring action on all present faults
• No customer is happy with a car that has highly noticeable faults (at any point)
• Limited operation strategies where some functionality is maintained even though the system is not fully operational are required!
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 11Issue date: 2016-03-22, Security Class: Public
![Page 12: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/12.jpg)
Focus and challenges today – Platform preparations
• Adapt the platform to enable optimized electrification from the start instead of adapting the electrification to fit the platform available
• Extremely high investments
• Uncertainties/risk due to the market situation
• Crucial in order to reduce cost and staying competitive
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 12Issue date: 2016-03-22, Security Class: Public
![Page 13: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/13.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 13Issue date: 2016-03-22, Security Class: Public
25 Years ago…. Flywheel mounted
Starter alternator
Test bench 1990
![Page 14: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/14.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 14Issue date: 2016-03-22, Security Class: Public
VCC electrification programmes and studies
1992 ECC - Environment Concept Car at Paris Autoshow
Concept:
Series Plug-in Hybrid
Gas Turbine
High Speed Generator
![Page 15: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/15.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 15Issue date: 2016-03-22, Security Class: Public
HEV 98 – Demonstration Vehicles
Integration of Hybrid systems into target vehicles.
Battery: NiMH 20 kWh
Drive system: 90 kW AC induction motor
+ 2step transm
APU: 3cyl 1,4L ICE, 30 kW generator
Onboard Charger
EL AC compressor
DCDC converterDC/AC
Converter
Field Wound
Synchronous
Generator + regulatorDrive unit
1,4 L 3 cyl
Gasoline engine
![Page 16: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/16.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 16Issue date: 2016-03-22, Security Class: Public
Desiree
1998 - 2000
Concept: Power Split Hybrid
Showed at Geneva
Auto Show 1999
Performance 0-100 13,5s
Electric Range 1-2 km
Top speed 150 km/h
Base Vehicle: S40/V40
Added weight: 183 Kg
![Page 17: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/17.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 17Issue date: 2016-03-22, Security Class: Public
Desiree Technology
· Engine 1.4 litres, 56 kW
· Electric motor 55 kW
· Generator 25 kW
· Battery 2.5 kWh, 300V, 55kW NiMh
Demonstration objective:
Study vehicle attributes and
system implications of
power split technology in
VCC platforms
Dual Inverter Transaxle
unit
3cyl ICE with electronic throttle Water cooled NiMH battery
DCDC converter AC compressor
![Page 18: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/18.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 18Issue date: 2016-03-22, Security Class: Public
ISG Vehicle
1998 - 2001
Concept: Mild Hybrid ISG (Integrated Starter Generator)
42V/12V Dual Voltage System
>10 Vehicles built 760/S/V40/S80/Ford (1st built 1988)
Demonstrated for 150 Journalists Seville Spain 2001
Performance: Improved – Enables downsizing
Top speed: No change 42 V Battery
Fuel tank
Integrated Starter
Generator
Base Vehicle: S80 Added weight: 60 Kg
Air
conditioning
![Page 19: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/19.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 19Issue date: 2016-03-22, Security Class: Public
ISG Technology
ISG Machine ISG Converter incl DCDC conv.
ISG Battery Pack ISG Automatic transmission Hybrid AC Compressor
· ISG Electric machine12 kW
· DC/AC- and DCDC-converter 140A
· Battery NiMh 36cells, 0,7 kWh 15kW
· Both manual and automatic application
Induction and PM Synchronous
technology
· Electric Air Condition during
engine stop, mechanically driven
while engine is running
![Page 20: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/20.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 20Issue date: 2016-03-22, Security Class: Public
Research project to build knowledge
Focus on safety/battery packing
Test fleet
- 0-100km/h on 10.5s
- 4 seats + luggage
- safe as all Volvos
- 120 - 150km range
- max 130km/h
Volvo C30 BEV
![Page 21: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/21.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 21Issue date: 2016-03-22, Security Class: Public
DC DC converter200A @ 12V
Electrical AC-compressor 8kW
PDU (Power Distribution Unit)
Inverter
Rear battery12kWh
Tunnel battery12kWh
On board charger16A @ 230V
El. motor 82/40 kW
230V AC harness
Charge Inlet
C30 Electric-Powertrain
![Page 22: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/22.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 22Issue date: 2016-03-22, Security Class: Public
V60 PHEV D6
World-first Diesel PHEv with 48g CO2/km and 50km pure electric range
![Page 23: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/23.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 23Issue date: 2016-03-22, Security Class: Public
On the EU market 2012
Lithium Ion battery 12 kWh energy
Chargeable from power network - on board charger
Electric motor 50 kW (70 hp)
Combined with an efficient premium diesel 150 kW (205 hp)
Start/Stop system included
Regenerative braking system
Electrical air condition
Electric / hydraulic power steering
V60 Plug-in Hybrid Electric Vehicle – Tech facts
![Page 24: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/24.jpg)
Why Hybrids & Electrification? today
Legislation and environmental impact, but also:
• Performance option
• New/improved driving attributes
• Relatively low complexity to add features
• Cost savings?
• Electric drive feeling!
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 24Issue date: 2016-03-22, Security Class: Public
![Page 25: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/25.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 25Issue date: 2016-03-22, Security Class: Public
The Plug In Hybrid Electric Vehicle - Challenges
COST
Package space
Cooling
Efficiency
Durability
SAFETY
LiFE SPAN
Integration
performance
competence
Charging time/km
![Page 26: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/26.jpg)
XC90 PHEV - Challenges for the ”second” project
• Extremely high attribute requirements
• Platform based dimensioning of all main components
• Added flexibility and more efficient developement of vehicle near functionality – strategic SW components developed inhouse
• No pre-existing (already stabilized) platform to build on
• New and hard EMC requirements
• World wide introduction
• Compared to V60 PHEV and required to be better or equal in all categories
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 26Issue date: 2016-03-22, Security Class: Public
![Page 27: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/27.jpg)
XC90 PHEV – EPS parts
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 27Issue date: 2016-03-22, Security Class: Public
![Page 28: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/28.jpg)
XC90 T8 PHEV – Tech facts
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 28Issue date: 2016-03-22, Security Class: Public
Production start in 2015
No compromise: high performance & low CO2
High performance 400 HP and 650 Nm
Low emissions that complies with Euro 6 and TZEV standards.
Low CO2 64 g/100km and fuel consumption 2,7 l/100 km.
Up to 50 km electric range
Battery capacity: 9,3 kWh
Electric AWD
“Designed around you” … three cars in one … you decide
![Page 29: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/29.jpg)
Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang
Page 29Issue date: 2016-03-22, Security Class: Public
Q&A
![Page 30: Vehicle electrification focus and challenges · Elkraftdagen 2016 - CTH, Electric Propulsions Systems, Karl Klang, kklang Page 23 Issue date: 2016-03-22, Security Class: Public On](https://reader034.vdocuments.site/reader034/viewer/2022042405/5f1d6162c0acb170d839750f/html5/thumbnails/30.jpg)
We want you as a power engineer!