EVs Under the Skin. Dr. Markus Hirvonen Manager, Electric Powertrain Valmet Automotive Inc.

Transcription

1 EVs Under the Skin Dr. Markus Hirvonen Manager, Electric Powertrain Valmet Automotive Inc.

2 EVs Under the Skin 1. How cars are developed and manufactured? 2. What are technical differencies between ICE car, HEV and EV? 3. How development and manufacturing of EVs and HEVs differs from conventional cars? 2

3 How cars are developed and manufactured?

4 Car A Complex mechatronic machine system 4

5 Development areas of cars Test & validation Body Chassis Functional safety E/E Legal requirements HMI Integration Powertrain NVH & comfort Thermal management Safety Simulation 5

6 Integration level Automotive development process DEVELOPMENT 3-5 years SOP Production ~7 years Car Target setting Concept development Production hand-over Integration and validation System Part Serial development Readiness level 6

7 Automotive development process Target setting - Technical and economical feasibility clarified for concept development Quality Target framework Product positioning Concept development - Integration of requirements - Virtual development Service needs Production / assembly Legal requirements Characteristics Weight Serial development - Car producible in high volumes - Validation of simulation models - Virtual plant Innovation Brand profile Equipement Technical function Variants 7

8 Automotive development process 8

9 Assembly of cars Main functions: Body welding Painting Final assembly Manufacturing engineering Maintenance Quality Production scheduling Logistics Supplier cooperation 9

10 What are technical differencies between ICE car, HEV and EV

11 Differencies between ICE car and EV E/E Exterior Body Safety Chassis Powertrain Interior HVAC 11

12 12

13 Role of software in automotive 70-90% of all innovations in vehicle development is nowadays based on embedded systems 35-40% of the price of a modern vehicle is caused by embedded electronics 50-70% of the overall development cost of electronic control units is attributed to software development Challenges in Electric and Hybrid Vehicles: - Greater level of system s integration - New failure modes of components 13

14 Role of software in automotive 14

15 Efficiency of electric powertrain Electric drive motors have a high degree of efficiency of up to 96% compared with internal-combustion engines that have an efficiency of 35 40%. 15

16 Well to wheel efficiency 16 Source: Toyota

17 ICE vs. Electric motor Torque output Electric drive motors have excellent torque and output characteristics. They develop maximum torque from standstill. This allows an electric vehicle to accelerate considerably faster than a vehicle with an internal combustion engine producing the same output. 17

18 Powertrain architectures Full Hybrid Plug-in Hybrid EV Range Extender EV FCV 18

19 Powertrain architectures of EVs 19

20 Powertrain architecture - BEV 20

21 Powertrain s electrical architecture - BEV 21

22 Electric motors Electric motors/generators used for propulsion are usually water-cooled. - Air cooling would also be possible but complex due to space and the amount of heat generated. In full hybrid vehicles (HEV), the electric motor/generator also functions as the starter for the combustion engine. Three-phase synchronous motors are often used as the electric motor/generator. - The advantage of synchronous motors compared with asynchronous motors is the more precise control of the motor in automotive applications. 22

23 HV safety Vehicles with high-voltage systems (HV) have components that work with voltages above 120Vdc or 50Vac. The HV systems in cars work usually with direct voltages between , some applications up to 650Vdc. Some of the components in these vehicles require a high level of electrical power. 23

24 HV safety HV isolation The isolation of the high-voltage system and 12 V onboard supply is designed to prevent unintentional shortcircuits with the vehicle ground. This isolation of the high-voltage system from the body ground is also called electrical isolation. To achieve this isolation, the highvoltage system has its own equipotential bonding. The high-voltage system and the 12 V onboard supply are electrically isolated from each other so that there can be no accidental short-circuit and a flow of current to the body ground. 24 Source: WV Basics of Electric Vehicles

25 HV safety HV relays The protective relays are only switched by the high-voltage system. If the contactors are deenergized, they open and the high-voltage battery is disconnected from the highvoltage system in the rest of the vehicle. The command to open can be triggered by different situations. If you turn off the vehicle and remove the ignition key, this also opens the contactors and activates the other safety systems. 25 Source: WV Basics of Electric Vehicles

26 HV safety The pilot line The pilot line is a completely independent safety system that determines if all high-voltage components are correctly connected to the high-voltage system. The pilot line is a lowvoltage system. The pilot line connects all highvoltage components. The system checks whether the high-voltage connections of the components in the pilot line are correctly connected. 26 Source: WV Basics of Electric Vehicles

27 HV safety Crash detection Deactivation of the high-voltage system and the de-energization of the high-voltage system is important for occupant protection in accidents, the safety of rescue personnel and safety of accident vehicles that have been brought in for repair. As a result, the high-voltage safety is linked to the crash detection system via the airbag control module. 27 Source: WV Basics of Electric Vehicles

28 How development and manufacturing of EVs and HEVs differs from conventional cars

29 Development of EVs Vehicles must comply with specific safety requirements when they are built as electrically driven vehicles. - Uniform regulations for the approval of electric vehicles (UN/ECE regulation no. R100.01) - Tests and requirements related to electromagnetic compatibility (EMC, UN/ECE Regulation R10) There are also plenty of regulations for separate subsystems like batteries, user interface, diagnostics, communication and wiring. Also different markets (US, China, etc.) have own unique regulations which must be taken into consideration already in engineering phase. Functional safety plays very important role in electrical vehicles due to higher integration level of powertrain system. 29

30 Manufacturing of EVs There is no big difference in assembly process between conventional car and EV/HEV. Battery is assembled in separate factory and in car factory it is handled like other critical components HV connector of battery is connected in the end of assebly line, when the vehicle becomes functional after this only trained people can make rework of cars in the manufacturing 30

31 Valmet Automotive

32 Leading automotive service provider Over 45 years experience of development and manufacturing 32

33 Facts and figures Quick facts Established 1968 Revenues: Over 300 MEUR Over 2,000 employees Capacity: 100,000 cars/year Over 1.2 million vehicles built since 1969 ~ 1/3 convertibles Over 1.2 million roofs built since 2001 References Owners Investment companies Pontos Group and Finnish Industry Investment (both 47,5%) Company management (5%) 33

34 Service offering Project management Ecosystem orchestration Quality management Supply chain management Engineering Services Manufacturing Services Roof Systems Business Services Complete vehicles Roof systems and components Premium vehicles Electric vehicles Components and Soft tops Retractable hard tops Concept design Business plans Vehicle distribution EV solutions parts Components and and spare parts Process engineering parts 34

35 Valmet Automotive - In the frontline of electric vehicles RESEARCH & DEVELOPMENT EVA Hub motor concept Frame car EVA II Battery and BMS technology Testing and analysis ENGINEERING ICE to EV Conversion AWD powertrain concept LSV powertain concept Heavy duty battery system Marine powertrain concept Racecar battery management system LIGHTWEIGHT BODY Garia golfcar / LSV Fisker Karma prototype serie AWD sports car concept Fisker Surf MANUFACTURING Garia golfcar / LSV Think City Fisker Karma

36 THANK YOU! Dr. Markus Hirvonen Manager, Electric Powertrain Product Development Valmet Automotive Inc. P.O.Box 4, FI Uusikaupunki, Finland Mobile