Solutions for electrification of transport systems

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1 Solutions for electrification of transport systems Karl Klang Electric Propulsion Systems, Volvo Cars Elkraftdagen CTH

2 Overview Introduction Electrification history within Volvo Cars The Plug In Hybrid Electric Vehicle & Challenges Q&A Page 2

3 CO 2 -development over time new cars EU Worldwide legislations on CO 2 emmisions 130 g/km g/km 2020 Source: icct (the international council on clean transportation) Page 3

4 Why Hybrids & Electrification? Up to today Global Warming climate change delivery conditions 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 Page 4 Energy Security fuel availability

5 Electrification image step 1 Generation 1 Decent performance Slight improvement in fuel efficiency No revolutionary attributes Huge marketing effort! Page 5

6 Electrification Image step X Tesla High performance electric vehicle Message: Electric performance can be competible with normal cars! Page 6

7 25 Years ago. Flywheel mounted Starter alternator Test bench 1990 Page 7

8 VCC electrification programmes and studies 1992 ECC - Environment Concept Car at Paris Autoshow Concept: Series Plug-in Hybrid Gas Turbine High Speed Generator Page 8

9 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 DC/AC DCDC converter Converter 1,4 L 3 cyl Gasoline engine EL AC compressor Drive unit Field Wound Synchronous Generator + regulator Page 9

10 Desiree Concept: Power Split Hybrid Showed at Geneva Auto Show 1999 Performance ,5s Electric Range 1-2 km Top speed 150 km/h Base Vehicle: S40/V40 Added weight: 183 Kg Page 10

11 Desiree Technology Dual Inverter Transaxle unit Demonstration objective: Study vehicle attributes and system implications of power split technology in VCC platforms Engine 1.4 litres, 56 kw Electric motor 55 kw Generator 25 kw Battery 2.5 kwh, 300V, 55kW NiMh 3cyl ICE with electronic throttle Water cooled NiMH battery DCDC converter AC compressor Page 11

12 ISG Vehicle 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 Base Vehicle: S80 Added weight: 60 Kg Performance: Improved Enables downsizing Top speed: No change 42 V Battery Fuel tank Air conditioning Integrated Starter Generator Page 12

13 ISG Technology 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 ISG Machine ISG Converter incl DCDC conv. Electric Air Condition during engine stop, mechanically driven while engine is running Hybrid AC Compressor ISG Automatic transmission ISG Battery Pack Page 13

14 Volvo C30 BEV Research project to build knowledge Focus on safety/battery packing Test fleet km/h on 10.5s - 4 seats + luggage - safe as all Volvos km range - max 130km/h Page 14

15 C30 Electric-Powertrain Inverter PDU (Power Distribution Unit) Rear battery 12kWh Tunnel battery 12kWh DC DC converter 12V On board charger 230V El. motor 82/40 kw Electrical ACcompressor 8kW 230V AC harness Charge Inlet Page 15

16 V60 PHEV D6 World-first Diesel PHEv with 48g CO2/km and 50km pure electric range Page 16

17 DIM EH PAS ABS SBA SM ECM BCS ICM CCM ELAC HVG BCM BCM Overview of vehicle systems affected by electrification El Modified systems EL El El Ch EL PT PT PT El B&T El El El 0A Cpl Electrical System Incl GVCA PT Design structure New systems EL EL EL 1 1 C Electrical Low voltage Architecture Energy (L V & HV) Management 1 VMM (OMM) (Start) 2E Steering System 3 x F21 Transmission 3 x I5D ICE FEAD 3 x 4 Front End Driver +Rear End Information cooling 5A/5F Climate Control Parking Climate 6 C Usage Auth 7 Info- Tainment Trans func Ratio Man Mode coord 3B Hybrid Driveline Eq to SRD Powertrain Trq Man Eng Speed ctrl Enrgy Man Diagn Dep Sub-Spec s 3_X 1L HV Electric Drive System 1N HV Battery System Chassis EL 1L2 HV On Board Charging System WP ACCM EPS OP TCM OBC OBC WP BCM (CEM) Air ABS DIM ICM CCM BECM VIT HV BATT Air IHG IEM ISC MCU DCDC DCDC ERAD EM DCC 2A, 2C SBA Brake system Stability & 4x4 Traction control Hybrid Driveline Page 17 HEV Torque management HEV Energy management

18 V60 Plug-in Hybrid Electric Vehicle Tech facts 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 Page 18

19 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! Page 19

20 The Plug In Hybrid Electric Vehicle - Challenges performance COST SAFETY Package space Cooling LiFE SPAN Integration competence Durability Efficiency Charging time/km Page 20

21 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 working) platform to build on New (hard) requirements on magnetic fields EMC requirements for China and US Compared to V60 PHEV in all categories and must minimum perform to that level Page 21

22 XC90 PHEV EPS parts Page 22

23 Electric Rear axle IEM = Inverter Electrical Rear Axle Drive Module Inverter (IEM): Operating voltage: Vdc Peak (10s) power: 65 kw ( Vdc) Average (5m) power: 31 kw ( Vdc) Operating temperature: ºC Maximum coolant temperature: +70 ºC Electric machine (ERAD EM): Peak torque: 240 Nm Peak power: 60 kw Page 23

24 CISG + DCDC CIDD (Combined Inverter DC/DC) Working name SPA G2 Dual function part Inverter for the CISG and DC/DC Inverter: V HVDC Full performance V HVDC Limited performance 125Arms continuous 250Arms peak (10s) DCDC: V HVDC Full performance V HVDC Limited performance 260A (5s, 50% duty, 12V) 220A (10min <0C, 14V) 160A continuous (14V) CISG: Peak torque: 180 Nm Peak power: 34 kw Page 24

25 XC90 T8 PHEV Tech facts Production start in 2015 No compromise: high performance & low CO 2 High performance 400 HP and 650 Nm Low emissions that complies with Euro 6 and TZEV standards. Low CO 2 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 25

26 Q&A Page 26

27 We want you as a power engineer! Issue date: , Security Class: Public Elkraftdagen CTH, Electric Propulsions Systems, Karl Klang, kklang 27

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