The background of V60 Plug-In Hybrid Concept as presented internally at Volvo Car Corporation in May 2008 Klas Niste Project leader for Advanced Project for HEV/PHEV 2006-2009 Volvo Car Corporation Research & Development Director, Vehicle Concept Engineering and Electrification Strategy

Volvo Cars, Plug-In Hybrid Concept Development

Why Hybrids & Electrification? And Why Now? (2008)

• 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 • Volvo need to come out of this as a winner

Global Warming • climate change

Energy Security • fuel availability • delivery conditions

Choice of Electrification Level

Desiree- 2000, V40 Full hybrid, powersplit, 3-cyl petrol

~Toyota, Lexus, Ford

HEV-98 -1996, 850 Plug-in hybrid, series 3-cyl petrol

~GM Volt

ISG -2001 Volvo S40/V50 (S80 mules) Mild hybrid, parallel, 4-cyl petrol

~Honda

Electrification levels (electric power, battery power/energy, functionality etc) Conventional vehicle w/ added electrification BEV w/ added aux power device

Stop/ start

Mild HEV Medium HEV

Full HEV

Plug-In HEV

BEV +

Range Extender

BEV

Choice of Hybrid Transmission Layout POWERSPLIT (basic single mode) Combustion engine power transfer to the wheels both mechanically (~2/3) and electrically (~1/3).

Toyota, Lexus, Ford

PARALLEL (several options) Combustion engine and electrical motor can propel the wheels either separately or in combination.

SERIES (Range Extender) The electrical motor propels the wheels. The combustion engine feeds energy to the electric propulsion or the battery.

GM Volt

GENERATOR

MOTOR

EngineEngine

GENERATOR

MOTOR

HVG

Engine

ISAC

ERAD

Tran

sEngine

Tran

s

ISAC

Modified Transmission

MOTOR

VCC PREFERRED LAYOUT: • Cycle & Real world efficiency • Performance • Base P/T installation flexibility • Commonality/volume flexibility w/ base during change over

Hybrid Battery Technology Comparison

LG Li-Ion HEV

GYC Li-Ion HEV

JCS NiMH HEV

PEVE NiMH HEV

JCS Li-Ion HEV

JCS Li-Ion PHEV

Sanyo NiMH HEV

Sanyo Li-Ion HEV

Hitachi Li-Ion HEV

Toyota Li-Ion HEV

Samsung Li-Ion HEV

LG Li-Ion PHEV

Sanyo Li-Ion PHEVAESC Li-Ion HEV

Kokam Li-Ion PHEV

0

500

1000

1500

2000

2500

3000

3500

0 20 40 60 80 100 120 140 160Specific Energy (Wh/kg)

Spe

cific

Pow

er (W

/kg)

NiMH HEV Li-Ion PHEV

Li-Ion HEV

Specific Energy [Wh/kg]

Battery Technology Development, from NiHM to Li-Ion

Even Li-Ion battery systems are critical for package in existing and future platforms

NIMH HEV

Li-Ion HEV

Li-Ion PHEV

Q1 2006:

- Full HEV - Parallell - Diesel -

– Top of the line power position

Decision History

Q4 2008:

- Plug-In HEV - Parallell - Diesel - V60

– Top of the line power position

Plug-in Hybrid Base Concept

HV Battery

HVG -> C-ISG ERAD (Electric Rear Axel Drive) Electric drive, electric boost, brake energy regeneration and el. AWD 50kW/200Nm peak 20kW 80Nm continous

HV Battery & On-board Charger Energy storage, Power buffer 11,2kWh nominal, 8kWh usable 60kW peak, 20kW continous 400V nominal

Electric A/C

Belt-ISG (Integrated Starter Generator) Warm starts stop/start function Supports el. loads, el. A/C and el. AWD 7,5kW continous, 11kW peak

Regenerative Brakes Blending friction and electric braking

Complete Vehicle Controls Updated controls architecture for HEV, conv. Incl S/S (and BEV)

Other systems Low temp cooling circuit for ERAD HV Battery cooling system

Issue date:

AC plug

High-voltage Traction battery

Electric motor Control unit

Combustion engine P/T

On Board Charger

HV Generator

PHEV systems

Issue date:

AC plug

High-voltage Traction battery

Electric motor Control unit

HV Generator

Charging the Traction Battery from 230V/10A-16A grid

Climate

On Board Charger

Combustion engine P/T

Charging Disconnect cable

Issue date:

High-voltage battery

Electric motor Control unit

On Board Charger

HV Generator

Driving PHEV on charged electrical energy(Charge depletion mode)

Climate

Parallel EV drive

Combustion engine P/T 30 %

100 %

0 %

SOC

time

Issue date:

High-voltage battery

Electric motor Control unit

On Board Charger

HV Generator

Driving PHEV on fuel energy (Charge sustaining mode)

Climate

Parallel Limited EV drive Brake Drive

Combustion engine P/T 30 %

100 %

0 %

SOC

time

Issue date:

High-voltage battery

Electric motor Control unit

On Board Charger

HV Generator

AWD traction support

Climate

AWD drive

Combustion engine P/T Press button

AWD

0

10

20

30

40

50

60

70

80

90

100

0 25 50 75 100 125 150 175 200 225 250

JapanEUUS

CumulativePopulation [%]

JapanEuUS

PHEV Electric traction needs for EuCD +

0

10

20

30

40

50

60

70

80

90

0 20 40 60 80 100 120

Vehicle speed [km/h]Tr

actio

n Po

wer

[kW

]

0m/s2(Constant speed)

PHEV Challenge – Multiple dependant solutions to be found

NEDC e-Range needed SUV ~ Z1 km Car ~ Z2 km

Battery energy needed for 50km NEDC e-Range SUV X1 Wh/km -> X2 kWh usable-> X2 kWh nom Car Y1 Wh/km -> Y2 kWh usable-> Y3 kWh nomY

Battery vehicle installation, packaging & weight SUV ~ max W1 kWh nom Car ~ max W2 kWh nom

CO2 target assumption < 50g

PHEV CO2 regulation (Eu)

Practical e-Range assumption 25-50km for all vehicles

Customer driving pattern (distance/day) Base vehicle CO2

Practical e-Drive Acceleration requirements

Assumption 2

Assumption 3

Assumption 1

2m/s20,6m/s2

Acceleration levels to be able to follow the traffic flow

E-Drive performance SUV ~ A1 kW(peak el) Car ~ A2 kW(peak el)

km

Energy optimised Li-Ion Battery Technology Available from suppliers starting ~ 2009

E-Drive performance B1 V/ A1 kW => 21 V/ A2 kW

2m/s20,6m/s2

Acceleration levels to be able to follow the traffic flow

N:o battery cells energy-Voltage

0

10

20

30

40

50

60

70

80

90

100

0 25 50 75 100 125 150 175 200 225 250

JapanEU

US

e-Range Dimensioning vs. Customer Driving Patterns (Source VMCC)

Cumulative Population [%]

Daily Driving Distance [km]

Japan Eu US

e-Range of 25 - 50km seems to be close to an optimum where more than 1/2 - 2/3 of the customer needs are met with a minimum battery size/cost. Charging twice a day will double the practical e-Range.

PHEV not charged Stop/start vehicle= Ref

50 100 150 200

[% of ref] NEDC

[km, NEDC]

Aver

age

Fuel

Con

sum

ptio

n

Driving distance

Certified Average Fuel Consumption vs. Driving Distance [NEDC] as a function of charging (~10-30°C, 50km e-Range)

De= 50km Dav = 25km

PHEV 1 charging

PHEV 2:nd charging after 50 + 25km Corresponding to certification process assumptions.

PHEV certification

0,85

0,3

1,0

75km = Total driving distance corresponding to certification process assumptions (at De = 50km)

Max Acceleration Performance Comparison (V60 PHEV data is estimated)

Combined > 200kW and 500-700Nm as a function of gear selection at low rpm

PHEV has potential to replace todays top of the line petrol performance offers!

Mild HEVC-sizedPetrol

S 400Petrol

E 300 Bluetec, Diesel X 5, Diesel

CR 7 seriesPetrol

S 300 Bluetec, Diesel

Jetta

Full HEV ML 450, Petrol A4 C 300 Bluetec, Diesel

S 400 Bluetec, Diesel

RX, Petrol GS, Petrol

Touareg, Petrol Q7 petrol X1 / X3

LS, PetrolX6, Petrol Cayenne, Petrol Panamera, Petrol

Prius, Petrol

Prius Next Generation, Petrol Infiniti 9-X

Civic, Petrol n.s., Petrol Hypos, diesel

Rio, Petrol Prologue, diesel

Accent, Petrol Golf, Diesel Fleet Trial

Golf, Diesel Small series

Golf, Diesel 2015 Series

Plug-in HEVPrius 2 PHV Fleet Trial Prius 2 PHV Volt, Petrol Flextreme,

Diesel

BEV City ? A1 Up

REVAie 500

Mini Kango, Megane Denmark only! A-Class

RoadsterLimited Numbers

Polo Cube = deleted or postponed

i MiEV Test stage Ze-O

Status: Nov 04, 2008

post 2012

till 2020: all models with hybrid technology

2008

Already available:

2009 2010 2011 2012 2008 2009 2010 2011 2012 2013/later

Medium HEV

Full HEV

Plug-In

BEV

• There is an opportunity for Volvo leadership in Europe (US) with a larger diesel based PHEV vehicle!

• The V60 PHEV vehicle will have great performance and ability for almost zero fossil fuel consumption, certified below 2l/100km.

Competition (Europe) and Window of Opportunity:

Thank You!