The Volkswagen Hybrid Strategy

The Volkswagen Hybrid Strategy - Hybrid Tour with MainFirst Bank 28 th March 2006 Dr. Tobias Böhm Volkswagen AG

Sustainability Based Aspects in Mobility Energy Greenhouse Gases CO 2 Exhaust Emissions CO,NOx,HC,PM 1995 2000 2005 2010 2015 2020 2025 2030 2

Non-Renewable Energy Availability 2000 2050 2100 2150 Source: BGR 2002 Petroleum (conventional and non conventional) Natural Gas (conventional and non conventional) Coal 62 157 Reserve Resource 64 756 207 1425 Brown Coal 198 1264 Uranium 42 527 0 50 100 150 >200 >1000 Years 3

Development of Passenger Car Emissions (Germany to 2020) kt/a 1600 1400 1200 1000 800 600 400 200 Bil. km/a 900 800 700 600 500 400 300 200 100 0 0 1980 1985 1990 1995 2000 2005 2010 2015 2020 CO [kt/10] CO 2 [kt/100] HC [kt] NOx [kt] Particle [kt x 10] (Diesel) Distance traveled [bil. km] Source: IFEU, TREMOD 3.0 4

Self Commitment of EU Car Manufacturers CO 2 -Emissions [g/km] 200 new passenger car fleet 180 gasoline + diesel 160 140 diesel -25% target 140 g/km 1995 2000 2005 2010 5

Key aspects Proactive Incremental Improvement of Powertrain Efficiency with Simultaneous Emission Reduction Inclusion of alternative Energy Sources in Fuel Production Development of CO 2 -neutral Vehicle Usage 6

New Volkswagen Powertrain Generation - TSI 7

New Volkswagen Powertrain Generation - TSI Reduced Fuel Consumption Downsizing Concept Double Charging Fuel consumption A-Class Benchmark Fuel consumption [l/100km] 125 kw TSI in the Golf GT Power [kw] 8

Volkswagen Double Clutch Transmission - DSG 9

Volkswagen Fuel and Powertrain Strategy Diesel, Petrol fossil TDI, FSI SynFuel GtL Hybrid, TDI, TSI SunFuel renewable BtL Bioethanol Combined Combustion System Hydrogen renewable Fuel Cell 10

Volkswagen and Audi Hybrid History Jahr Bild Fahrzeug Struktur V-Motor E-Motor Batterie 1991 Chico Hybrid Parallel 1-Welle Otto 2 Zyl. 25 kw ASM 9 kw NiCd NiMH 72V / 30Ah 72V / 30Ah 1991 Audi duo II Parallel 2-Achsen Otto 76 kw PSM 21 kw Pb-Gel NiCd 252V / 32Ah 252V / 47Ah 1995 Golf Hybrid TDI Parallel 1-Welle TDI Diesel 66 kw ASM 19 kw NiMH 120V / 60Ah 1996 Audi duo III Parallel 2-Wellen TDI Diesel 66 kw PSM 32 kw Pb-Vlies 264V / 38Ah 2002 1-Liter Auto Parallel 1-Welle DI-Diesel 6,3 kw PSM 2 kw NiMH 180V / 6,5Ah 2003 Bora Hybrid TDI Parallel 1-Welle TDI Diesel 55 kw ASM / PSM 25 kw NiMH 288V / 6,5Ah 2004 Golf Hybrid TDI Parallel 1-Welle TDI Diesel 85 kw PSM 15 kw NiMH 144V / 6,5Ah 11

Efficiency: Demonstrating the feasibility VW 1-Litre Car 0.3 l SDI 1cyl. 6,3 kw (8,6 HP) 0,99 l/100 km = 235 mpg Euro 4 limits 12

Project targets development of an optimized powertrain for our mass production cars Volkswagen Golf and Passat and their derivatives => optimized combustion engine => hybridization => new gearbox technologies => new control concepts no car optimization (weight, air resistance and rolling resistance like series car) no performance disadvantages power: ~ 85 + 15 kw top speed: > 190 km/h 0... 100 km/h: ~ 11 s 13

Powertrain 1.4 l - 85 kw - TDI - engine DC DC 15 kw - electric motor & engine clutch 144 V NiMH battery 12 V dual clutch transmission 14

Electric motor and engine clutch electric motor crankshaft engine clutch maximum power 15 kw maximum torque 130 Nm length 85 mm outer diameter 285 mm clutch torque > 1000 Nm 15

Transmission technology dual clutch transmission electro-hydraulic actuators 16

Battery technology NiMH-battery maximum power 15 kw @ 144 V weight < 35 kg 17

Energy management function based energy management depending on state of charge power / moment / current (schematic) P_max_char. charge/ generator mode discharge / motor mode P_max_dcha r. 0 % start load leveling dyn. power limits hysteresis boost_short sync_down recuperation sync_up electr. driving boost function limit adaptation 100 % state of charge 18

Software architecture environment and driver detection environment driver detection detection topology factors function energy wheel torque management management strategy actual values central torque manager operative software desired values, function flags shifting starting procedures procedures actual torque, torque prediction torque control sources & sinks engine control Tengine motor control Tmotor shifting strategy clutch control TC0 desired torque clutch control TC1 clutch control TC2 19 strategic software sportiness factor

Torque addition 300 torque limitation 250 200 Torque [Nm] 150 100 50 torque 1.9 l TDI torque 1.4 l TDI torque 1.4 l TDI + electric motor 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Engine rpm [1/min] 20

Concept features potential of hybridization start / stop - function: ~ 5 % recuperation (electric braking): ~ 5 % electric driving: ~ 5 % additional potentials: downsizing / supercharging: ~ 6 % gearbox technology: ~ 4 % overall results: optimization of fuel efficiency: ~ 25 % fuel consumption (NEDC): ~ 3.8 l / 100 km 62 mpg 21

Golf TDI Hybrid at Challenge Bibendum 22

Fullhybrid - Powertrain Concept 1.4 l - TSI engine DC DC 20 kw - electric motor & engine clutch 187 V NiMH traction battery 12 V DSG-gearbox (dry clutches) 23

Volkswagen Mild Hybrid Pel. < 15 kw 80 Nm U < 60 V DLC+PbA - storage 24

Parallel-Hybrid s from Volkswagen <= 1L-car (TDI-Hybrid) <= Golf TDI Hybrid Touran TSI Hybrid 25

Thank you for your attention! 26