Fisker Karma and EV technologies. President Ilpo Korhonen Valmet Automotive Inc. ECT Forum 09 Sept, 23 rd 2009

Transcription

1 Fisker Karma and EV technologies President Ilpo Korhonen Valmet Automotive Inc. ECT Forum 09 Sept, 23 rd 2009

2 At the forefront of new vehicle technology Valmet Automotive today Automotive industry is changing Electrical future New projects of Valmet Automotive Fisker Karma Think Garia Electric concept vehicle 2

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4 Special cars for special customers 4

5 Valmet Automotive today 40 years of experience in car manufacturing; 1,1 million cars Total number of personnel over 800, 150 in engineering services Over 200,000 Porsche Boxster and Porsche Cayman in 12 years Engineering and manufacturing of electric vehicles Fisker Karma plug in hybrid vehicle Think City electric car Garia golf car Development of an electric concept car Engineering and expert services for automotive industry Manufacturing engineering Product development (convertibles, body structures, EV technologies) Logistics, quality and supplier management Creating new business models (EV, new entrants ) 5

6 Valmet Automotive strategy First class service provider of automotive industry in engineering, manufacturing and total programs We offer lean and flexible solutions to create success to our customers Strong partnership and customer satisfaction are our commitments Highly talented and innovative personnel, excellent quality in all operations, flexibility and continuous improvement are our assets 6

7 Automotive industry is changing Electrical future

8 Target to reduce CO2 emissions Europe (International Advanced Mobility Forum, Geneva March 2009): CO2 emission of cars max. 95 g/km by strategy: 20 % less greenhouse gases, 20 % more efficiency, 20 % more renewable energy Short and long term future in electricity Cooperation between electricity providers, car manufacturers and authorities to increase electric vehicles The benefits of electric vehicles Energy efficiency, low operating costs Zero emissions Availability of energy 8

9 Types of electric vehicles NEVs (Neighbourhood Electric Vehicles) CEVs (City Electric Vehicles) Smart EV, Think City, Mini erevs (Extended Range EVs) Chevy Volt, Toyota Prius PHEV, Chrysler Sedan HPEVs (High Performance EVs) Tesla, Fisker Karma, Venturi Fetish, Lightning GT 9

10 The development of EV markets In over 500,000 hybrid cars were sold globally (USA 70 %, Europe 10 %) Electric and hybrid vehicle markets are growing rapidly in the next years Estimate: 3 million hybrid and 350,000 electric vehicles are manufactured in 2015 Growing of the market share escalates after 2015 Selling of the EVs is first starting; challenges in battery development work and with the high pricing, governmental support needed Over 90 % of people use cars less than 100 km a day, that creates big potential for electric and hybrid vehicles 10

11 Valmet Automotive is developing engineering and manufacturing of electric vehicles Product development New ecological solutions for power sources Concept development Combination of lightweight and safe body structures with new electric systems New digital PDM (product data management) solutions are being developed to manage the engineering and manufacturing processes Process engineering Lightweight body structures and new materials need new joint techniques and create challenges to the paint process. Battery technology and requirements of power current must be adapted to the assembly process. Quality, safety and environmental issues are key elements in the process development. Flexible manufacturing of different vehicles, and small series production 11

12 New projects of Valmet Automotive Fisker Karma Think Garia Electric concept vehicle

13 Fisker Karma 13

14 Fisker Karma green luxury plug in hybrid The first four door luxury plug in hybrid vehicle Series hybrid, top speed 200 km/h Dual rear motors, rear wheel drive with mid mounted battery back and front/mid internal combustion engine (ICE)/Generator combination Electric Drive Motors: 2x150 kw (408 hp) Lithium ion battery pack Gasoline engine 265 hp, turbocharged 2.0 liter Ecotec direct injection Emissions 83 g CO2/km, economy rating of 3.5 l/100km (SAE) Range per full charge 80 km, total extended range of more than 480 km Photo: Fisker Automotive 14

15 Series hybrid Energy storage Electric motor + Charger Inverter DC/DC converter ICE DC voltage Inverter Generator+ Inverter Electric motor 15

16 Construction of Fisker Karma Differential Master Control Unit Electric Traction Motor Lithium ion Battery Pack 4 Cylinder Gasoline Enginei Generator Photo: Fisker Automotive 16

17 Valmet Automotive is engineering and manufacturing partner of Fisker Automotive Cooperation agreement 11/2008 First deliveries to Fisker Automotive in the end of 2009 Simultaneous Engineering Supplier chain management Planned production 15,000 cars per year, 500 jobs Concept development e.g. Karma Sunset retractable hard top With the help of 3D design the Karma is engineered both in the US and in Finland. 17

18 Karma Sunset retractable hard top concept Presented in Detroit, January 2009 Concept car of the year 18

19 The manufacturing process of Fisker Karma Body welding line Body parts are joined with MIG alike aluminum welding based on CMT technology and by riveting. CMT is a new technology, which produces less heath than traditional MIG welding. Challenges of aluminum welding are in temperature, joining and welding position. Paint process Valmet Automotive multi product paint process The treatment of aluminum and composite parts of the body Final assembly Valmet Automotive multi product assembly line Operational safety aspects of battery and hybrid technologies in manufacturing New testing methods 19

20 THINK City electric vehicle manufacture starts in 2009 Photo: Think 20

21 THINK City City electric vehicle, also suited for highways (CEV) Range per full charge 140 km Safe construction: combination body made of steel, aluminum and plastic First EV in series production Operations and distribution arrangements in Norway, Denmark, Sweden, Austria, the Netherlands, Finland and Spain Photo: Think 21

22 Valmet Automotive is engineering and manufacturing partner of Think Valmet Automotive is responsible for production transfer, manufacturing, logistics and participates in the product development The production will be launched in Uusikaupunki in 2009 Think orders are transferred to Valmet Automotive The plan is to produce several thousands of cars per year The project employs persons at Valmet Automotive 22

23 Garia golf car Photo: Garia A/S 23

24 Garia golf car Electric vehicle 3.0 kw /AC motor Batteries 6x8V as standard Range 50 km per charge Aluminum frame Luxury golf car Deliveries started in Sept 2009 Main markets USA, Middle East Production process Welding, final assembly Volume some thousands a year Employs some 50 persons Development possibility to a NEV car Photo: Garia A/S 24

25 Electric concept car The target is to develop an electric concept car and introduce it at the Geneva Motor Show seat electric city car with a range of up to 160 km per one charge Partnership with the energy company Fortum, developer of electric motoring and charging technologies A Finnish expert network will be created The new solutions developed will be included in the service providing of the partners for the automotive industry The aim is not to create a new electric car brand, but a concept car, which can also be developed to series production 25

26 At the forefront of new vehicle technology 26