SMP Tech PHEV Forum: Trends and CVT Technology

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1 SMP Tech PHEV Forum: Trends and CVT Technology Joerg Ferchau, CEO May 11, E F F I C I E N T D R I V E T R A I N S I N C. C O N F I D E N T I A L

2 Major Trends U.S. Hybridization primarily occurring medium and heavy duty commercial vehicle segments with government support CAFE and emissions requirements are forcing OEMs into hybridization/electrification strategies for all vehicles Mostly HEVs, but new EVs and PHEVs being introduced this year (Leaf, Volt, Prius offering PHEV version too) Charging infrastructure is developing. Many consumers and most businesses have access to plugs Level 2 charging as a standard by SAE, but wiring issues with many older homes Initial smart grid focus is energy savings and monitoring

3 Major Trends China Has become world s largest and fastest growing automotive market heavy consumer orientation Significant government push to leap frog legacy vehicle technology and be leaders in electric vehicle technology Already leaders in 2 wheel EVs for cities (well over 50%) Strong position in rare earth materials for magnets/motors and processing for Lithium batteries Government has been emphasizing BEV for 5 years, but is now changing position somewhat to PHEV not HEV Most consumers do not have access to plugs Heavy support and incentives for vehicle OEMs to develop key EV technologies Huge renewable energy plans

4 The opportunity for innovation? Wide variety of PEVs beginning to enter the market GM Volt (40 miles AER, $41k USD, + extended range) Nissan Leaf (100 miles range, $31k USD, All electric) Fisker Karma (50 miles AER, $88k USD, + extended range) Tesla, Honda, many others Difficult to compare today, but as more vehicles emerge, the difference will be measured by: Acquisition cost (price to end user) Operating costs (energy efficiency, reliability, leases, lifetime) Performance (acceleration, top speed, hills, NVH, etc) Reducing costs and increasing efficiency- required to win

5 PEVs Where are the costs? Component System Conventional Vehicle* Series PHEV Parallel BEV Body Engine Transmission Chassis Vehicle Assembly Motors/Gens/high voltage High power electronics Batteries Total for electrification Total Cost (mfg - approx) $18,000 $32,300 $28,250 $34,850 -BEV range/performance not same as PHEV Share of Manufacturing Cost % MATURE OPPORTUNITY - Significant cost reduction need/opportunity - Huge commercial and technology opportunities (10K STARTUPS) - $240B market opportunity by 2020 (WB) * SOURCE: Argonne National Laboratories

6 PEVs Operating costs? Annualized energy costs: Conventional Vehicle* Series PHEV Parallel Gasoline $3000 $600 $500 BEV Electricity $576 $576 $510 Total energy cost $3000 $1176 $1076 $510 Assumptions: -15,000 annual driving miles -20 mpg fuel for Conventional -24 mpg fuel $4/gallon for PHEV - PHEV uses 80% electricity at $.12/kwh - BEV uses 100% electricity at $.12/kwh Total Annualized Energy Costs - Difference in energy cost is part of customer s ROI (currently 5 to 9 Reducing costs and increasing efficiency improves the ROI story * SOURCE: Argonne National Laboratories

7 Why we re evolving the CVT Continuously Variable Transmissions (CVT): Smoothly change gear ratios without discrete shift points - improved efficiency and the driver s experience Allow the internal combustion engine to run at its most efficient RPMs over a wide range of vehicle speeds - reduced fuel consumption and emissions Multiply the torque of the electric motors (benefits EV too) - downsizing for lower cost, size, and weight Increase battery pack life - reduced stress and current draw Ideal transmission choice for PHEVs/HEVs which require shifting more frequently but need high efficiency

8 Input Specifications Max Input Torque Max Input Speed EDI OCVT - MD TECHNOLOGY 700 Nm 4000 rpm Applications Front wheel / Rear wheel drive MD vehicles class 3-5 Conventional combustion engine Plug-In Hybrid Vehicles Hybrid Vehicles Battery Electric Vehicles Specifications OFF SET CVT Maximum Ratio (UD) Minimum Ratio (OD) Ratio Span 5.09 Peak Efficiency 95% C O N F I D E N T I A L

9 EDI ICVT TECHNOLOGY Input Specifications Max Input Torque Max Input Speed 500 Nm 4000 rpm Applications Rear wheel drive MD vehicles class 3-5 Conventional combustion engine vehicle Plug-In Hybrid Vehicles Hybrid Vehicles Battery Electric Vehicles Specifications INLINE CVT Maximum Ratio (UD) Minimum Ratio (OD) Ratio Span 5.69 Peak Efficiency 92% C O N F I D E N T I A L

10 Input Shaft Speed [RPM] Efficiency [%] Testing Results: 250Nm Constant Input Torque - 250Nm: 50% of Full Load Output Shaft Speed [RPM] C O N F I D E N T I A L

11 Medium Duty Inline CVT Sized for class 3 to 5 vehicles Very high efficiency (over 93% peak) Applications in HEV, PHEV, and EV markets Additional opportunities in industrial applications and wind energy generation Patents on form factor, control strategy, integration with vehicle drivetrains World s first medium duty inline CVT

12 Application: MD PHEV Drivetrain Design: 10,000 lb freight delivery van downsized engine from 6.7L gas to 2.5 L diesel 80 KW electric motor 35 KWH battery pack Inline CVT Results: Fuel economy from 8mpg improved to 15 mpg All electric range of 30+ miles C O N F I D E N T I A L

13 Application: HD PHEV/Industrial Project Objectives: 230 KW electric motors for bus and industrial applications Investigation to determine benefits to large/high performance electric motors Results: Ability to downsize motors and power electronics by 15% Increased drivetrain system responsiveness Better hill climbing, acceleration, and top speeds C O N F I D E N T I A L

14 Application: LD PHEV Drivetrain Design: 4400 lb SUV downsized engine from 3.0L to 1.6L 65 KW electric motor (front) 18 KWH battery pack LD CVT Optional 75 KW electric rear axle (AWD capability) Results: Fuel economy from 16 mpg improved to 30 mpg All electric range of 35+ miles C O N F I D E N T I A L

15 Thanks again for your interest! E F F I C I E N T D R I V E T R A I N S I N C. C O N F I D E N T I A L