für Automobilzulieferer 05. Feb. 2013 TU Braunschweig Dr.-Ing. Dirk Hoheisel 1
Agenda Introduction Bosch Group Market trends and success factors Systems s and implementations e Chances and challenges Summary 2
Ownership structure t Robert Bosch Stiftung GmbH 92% share of equity No voting rights Bosch Family 7% share of equity and 7% voting rights Robert Bosch Industrietreuhand t d KG 93% voting rights Robert Bosch GmbH 1% share of equity No voting rights 3
Bosch Group key figures 2010 2011 2012* Total sales [EUR bn] 47.3 51.55 52.3 Sales outside Germany [%] 77 77 77 Number of associates 283 500 302 500 306 200 in Germany 113 620 118 800 119 300 outside Germany 169 880 183 700 186 900 R & D expenditure [EUR bn] 3.8 4.2 ~4.5 4 *) 2012 preliminary figures
Distribution ib ti of sales by business sector, 2012* Consumer Goods and Building Technology total: t EUR 52.3 bn EUR 13.4 bn 26 % Industrial Technology EUR 8.0 bn 15 % 59 % Automotive Technology EUR 30.9 bn 5 *) 2012 preliminary figures
Agenda Introduction Bosch Group Market trends and success factors Systems s and implementations e Chances and challenges Summary 6
Market penetration ti of EV / HEV / PHEV E-Mobilität - Chancen und Legislative framework Herausforderungen CO 2 fleet emission targets (EU, CN) Fleet consumption targets (CAFE) EV/PHEV fleet share targets (CARB) Customer requirements Mobility needs Willingness to pay Image associated with vehicle Reduction of fuel consumption EV / HEV / PHEV market volume Government incentives R&D subsidies Direct subsidies Fleet purchasing programs Technology Advances in reduction of emissions and consumption of ICE vehicles Cost, range, reliability, and comfort 7 EV: electric vehicle; HEV: hybrid electric vehicle; PHEV: plug-in hybrid electric vehicle
Powertrain market development 2020 Sales PC & LCV<6t (mio. vehicles) * 7.8 51.4 78 104 115 76.7 CNG/LPG 09 0.9 EV 0.1 HEV/PHEV 1.1 22.2 55.4 CNG/LPG: 1 HEV/PHEV 4 27.6 57.2 98.4 103.33 EV 3 PHEV 3 HEV 6 EV PHEV HEV CNG/LPG GDI PFI Diesel Pure ICE 17.8 23.7 27.0 2011 2015 2020 In 2020 ~10 % of global passenger car sales to EV/PHEV/HEV * Prognosis RB EV: electric vehicle; HEV: hybrid electric vehicle; PHEV: plug-in hybrid electric vehicle CNG: compressed natural gas; LPG: liquid petroleum gas; GDI: gasoline direct injection; PFI: port fuel injection; ICE: internal combustion engine 8
Natural gas in the focus The Wall Street Journal The Wall Street Journal Future market shares of natural gas might be underestimated 9
CO 2 reduction potential ti gasoline / CNG Basis: Compact Class (1400kg); NEDC (New European Driving Cycle) Gasoline (and also diesel) powertrains still with further CO 2 -reduction potential even w/o electrification. CNG could be a cost efficient alternative. 10 PFI Port Fuel Injection; DI Direct Injection; DZ Downsizing; Hom Homogenous
Powertrain diversity it and convergence gasoline diesel gasoline diesel alternative fuels gasoline diesel alternative fuels hybrid EV / range extender EV / battery EV / fuel cell EV (battery / fuel cell) hybrid EV / range extender 1997 2015 future 11 HCCI: homogenous charge compression ignition; EV: electric vehicle
Intermediate t Steps to pure electric driving i Mild Hybrid Strong Hybrid Plug-In Hybrid Electric Vehicle Electric Power 5 15 kw 20 60 kw 40 80 kw 15 150 kw Voltage 100 150 V 250 V 350 V 400 V Battery type medium power high power high energy Energy 0,6 1,8 kwh 5 15 kwh > 15 kwh Cell size 5 Ah 20 40 Ah 40 60 Ah Function Start/Stop regenerative braking, torque support same as Mild HEV + El.-driving same as Strong HEV + grid charging fuel reduction 15% fuel reduction 25% fuel reduction 65% pure electric driving Fuel Fu el no Fuel Fuel Hybrid as bridge technology from conventional to electric vehicle 12
Challenge: Volatility of the market Many ways one goal Parallel Axle Split Serial(-Parallel) Power-Split Torque Split Touareg / Cayenne 3008 Volt Prius devel. /investig. w/ DCT or CVT OEM focus EV EV@REX Effects on OEM & supplier $ Diversified development strategy & wide range of system know how Broad product spectrum to operate different systems Production sites in the region REX: range extender; DCT: dual clutch transmission; CVT: continuously variable transmission 13
Global l automotive ti R&D locations and resources North America emission reduction value for money Western Europe CO 2 reduction driving pleasure active safety Europe 24 17,700 China high value electrification fuel consumption Asia Pacific w/o India 13 3,500 Americas 9 1,900 South America ethanol / flexfuel India cost efficiency i low-price-vehicle two-wheeler India 4 6,300 Japan di driving i comfort hybridization country with one or more R&D sites. R&D sites with 50 associates R&D associates in region As of June 2012 Diversified development with 50 engineering centers in 17 countries 14
Agenda Introduction Bosch Group Market trends and success factors Systems s and implementations e Chances and challenges Summary 15
E-mobility requires more than components Powertrain components Charger Inverter Electric motor Control Unit Battery High-voltage battery Charging infrastructure E-Mobilität - Chancen und Regenerative Herausforderun braking system Eco-routing Automotive workshop Charge spots gen Navigation Diagnostics Bosch core competence: Systems Integration 16
2010: World s first strong parallel l hybrid with IMG Clutch 1 Clutch 2 (T/Con) engine e-machine: IMG AT VW Touareg / Porsche Cayenne Gasoline Engine V6 3,6 TFSI 245 kw /440Nm Electrical Drive 38 kw / 300 Nm ECE consumption ~8,2 l / 100km Bosch Components for edrive System E-Machine: - IMG 300mm Power Electronics: - INVCON DI-Motronic MED17, clutch, clutch actuation and SW for engine, hybrid management and clutch control IMG: integrated motor generator; INVCON: inverter with DC/DC converter 17
Modes of operation: Parallel l hybrid Conventional Driving with Combustion Engine Tank Torque Support by E-Machine Combustion engine E-machine/ Generator Transmission + - Battery DC/AC Inverter 18
Modes of operation: Parallel l hybrid Regenerative Braking Tank Combustion engine E-machine/ Generator Transmission + - Battery DC/AC Inverter 19
Modes of operation: Parallel l hybrid Pure Electrical Driving with E-Machine Tank Combustion engine E-machine/ Generator Transmission + - Battery DC/AC Inverter 20
Bosch edrive Components E-Machine: IMG 300 max. speed: 6.700 rpm Power Electronics: INVCON max. speed (shorttime): 8.500 rpm Voltage Range: up to 400 V DC Peak-Power: 38 kw Peak Current: 370 A Peak-Torque: 300 Nm Cont. Current: 300 A Weight: 34 kg DC/DC-Power: 3,0 kw (without clutch 14 kg and cable 2 kg) Weight: 13 kg Concentric windings / Integrated clutch 373 x 250 x 154 mm (w/ connectors) Position sensors: 3 x digital hall sensoren IMG: integrated motor generator; INVCON: inverter with DC/DC converter 21
2011: World s first axle split diesel hybrid engine clutch rear edrive BASM AMT EDTM Peugeot 3008 Hybrid4 Diesel Engine 2.0 HDI 120 kw Electrical Drive 27 KW / 200 Nm ECE consumption ~3,8 l / 100km Bosch Components for edrive System E-Machine: - SMG 180mm - SMG 138mm Power Electronics: - INV2CON SMG: separate motor generator; INV2CON: dual inverter with DC/DC converter 22
Peugeot 3008 Hybrid4: Axle split hybrid Internal Combustion Engine High Voltage Battery Front edrive: BASM Belt Alternator Starter Machine Rear edrive: EDTM Electrical Drive Train Machine HPCU: Hybrid Power Electronics and Control Unit 23 Source: The Electric Axle-Hybrid System made by PSA and Bosch (PSA: Chehab, Le Neindre, Deutrich; Bosch: Küsell, Willke, Barth, Lichtermann)
Modes of operation ZEV Mode Acceleration ZEV Mode Deceleration N S N S N S N S Improved Longitudinal Performances Added up pp power of ICE (118 kw i.e. 163 HP) and rear motor (27 kw i.e 37 HP) for a total of 200 HP Sport Mode eawd Mode N S 24 N S ZEV: zero emission vehicle N S Source: The Electric Axle-Hybrid System made by PSA and Bosch (PSA: Chehab, Le Neindre, Deutrich; Bosch: Küsell, Willke, Barth, Lichtermann) N S Access to 4WD motivity ability to Take-off on low adherence roads (snowy or muddy roads) for slopes up to 25%
Bosch edrive Components BASM: SMG 138/80 Low inertia, high speed: 15.080 rpm Peak-Power: 8,5 kw Continuous: 7,5 kw Peak-Torque: 52 Nm Weight: 11 kg Concentric windings EDTM: SMG 180/120 Low inertia, high speed: 7.500 rpm Peak-Power: 27 kw Continuous: 11 kw Peak-Torque: 200 Nm Weight: 30 kg Distributed windings Position sensor Resolver 25 HPCU: INV2CON Voltage Range: 150V 270V DC Peak Current: 340 / 120 A Cont. Current: 150 / 60 A DC/DC-Power: 2,5 kw 310 x 190 x 156 mm (w/ connectors) SMG: separate motor generator; INV2CON: dual inverter with DC/DC converter; HPCU: hybrid power electronics and control unit; BASM: belt alternator starter machine; EDTM: electrical drive train machine
26 E-Mobilität - Chancen und Herausforderungen Power modules for HEV- & EV- inverter DC/AC-Inverter focus: costs, power-density, box-volume, weight power-density, costs, EMC, robustness Multi Chip Power Packages (MCPP) focus: thermal-ait Rth, Zth electric-ait inductance robustness temp. cycles Power-Switches (IGBT, SiC) focus: static & dynamic power-losses, tailored for MCPP integration Bosch power electronics cover the entire value chain from silicon to modules and systems AIT: assembly and interconnect technology, IGBT: insulated-gate bipolar transistor; SiC: Silcon carbide EMC: electro-magnetic compatibility cooling-effort, energy-efficiency, mileage & costs
Semiconductor Technologies SiC application area 100.000 10.000 MOSFET IGBT application area SJ-MOS Middle Power Devices High Power Devices Current (A) 1.000 100 10 Low Power Devices Automotive Applications ebike EV PHEV HEV DC/DC Charger MCPP Discretes 27 1 10 100 1.000 10.000 100.000 Voltage (V) SJ-MOS: super junction mosfet, IGBT: insulated-gate bipolar transistor, MCPP: Multi Chip Power Packages SiC: silicon carbide
Range management for electric vehicles Prediction of energy usage and active drivetrain control based on Example 21 C destination SOC 10 40 % Route information (topography, speed limits) Learned driver behavior FCS FCS 12 kwh fast route Current traffic situation 19 kwh FCS Climate and weather forecast ECO route 12 kwh 28 19 C start SOC: 95 % Electromobility drives networking of vehicles and new business models based on access to vehicle data SOC = state of charge, FCS = fast charging station
Bosch service platform for e-mobility Driver Fleet Service Provider Utility OEM Bosch Charging Station Charging g Access Telephony Surveillance Billing Third Party Charging Station Dynamic Applications e-mobility Core Third Party Interfaces Billing Charging Station Info Utility / Smart Grid Electric Vehicle Business Ecosystem Location Based Incentive Charging Access Billing Location Based Integration 29
Implementation: ti project Singapore Infrastructure service provider for electric vehicle charging infrastructure 2011-2016 Support 50+ electric vehicles Provide, install, and maintain up to 60 charging stations Collect charging data with smart meter Billing and pricing plans Customer interfaces Use CEPAS for identification contactless e-purse application (CEPAS) is used for bus, metro, taxi, road toll, parking, retail, and other services. 30
EV as part of a smart home / smart grid ventilation with heat recovery heating appliance Router solar thermal PV panel Meter gateway BSI certified CCU DW WM freezer electric vehicle (EV) use of waste water buffer battery for PV & EV thermal storage charge spot Li-ion battery 31
New competences for e-mobility Chemistry Electronics Automotive Manufacturing Standardization Smart Grids Law conditions Internet of Things Batt ery Cloud Computing Smart Cities 32
Agenda Introduction Bosch Group Market trends and success factors Systems s and implementations e Chances and challenges Summary 33
Funding future powertrain concepts reallocation of budget reduced spending in non-powertrain domains external funding government subsidies and incentives coexistence various powertrain concepts additional invest in PT domain reduction of component costs by economies of scale standardization optimum allocation of value add in supply chain (volume concentration) alliances large global platforms (OEM & supplier product lines) 34
EUR bn 5.0 E-Mobilität - Chancen und Herausforderungen Bosch Group R&D expenditure Automotive ti Technology 13.2 Bosch Group 4.5 12.3 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 00 0.0 9.2 8.8 8.8 7.1 2.5 2002 7.3 2.7 2003 7.2 2.9 2004 9.6 7.4 3.1 2005 10.1 10.2 7.7 7.7 3.3 2006 3.6 2007 9.4 10.7 gross R&D rate [% of sales] 10.8 86 8.6 81 8.1 81 8.1 3.9 2008 3.6 2009 Bosch R&D expenditures in e-mobility 2011: ~400 Mio. EUR 3.8 2010 42 4.2 2011 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 35
Battery technology as key enabler E-Machine Power Electronics Battery Weight Volume Cost Electric motor: 60 kw Battery: 20 kwh 36
Energy density & price - Learning from CE cells 300 670 Wh/l 240 Wh/kg 2,500 200 360 Wh/l 135 Wh/kg 570 Wh/l 200 Wh/kg 2005 2010 2,000 1,500 1/3 200 Wh/l 100 75 Wh/kg 1.8x 2000 2.7x 1.8x 1990 500 100 200 300 400 500 600 700 Energy Density [Wh/l] 1,000 $1,560/kWh $1,010/kWh $480/kWh 1/3 $300/kWh 1995 2000 2005 2010 Year 37 Within 10 years, Li-ion consumer cells (type 18650) advanced as follows energy density doubled price per kwh reduced to one third production poducto volume ou increased ceasedfivefold eod CE: consumer electronics
Battery performance status t and outlook 250 AD 1800 AD 1860 AD 1989 AD 1990 AD 201X AD 100.000 Bagdad d battery Volta battery Lead acid battery Ni-MH battery Lithium-ion i battery Lithium-air i battery 10.000 ecific Pow wer, W/kg 1.000 100 Sp 10 1 0 100 200 Pb b-acid 300 400 500 600 700 800 900 1000 1100 1 Specific Energy, Wh/kg 38
Battery safety design Cell Materials Cells Pack Vehicle Safe Materials Design & Manufacturing Safety Functions Safety Functions e.g. shut down separator based on polyethylene (PE) e.g. integrated safety devices: ceramic coated on electrode e.g. battery state detection and prediction e.g. thermal management 39
Battery price vs. fuel price (US example) Changes in fuel and energy storage costs and increases in the efficiency of electrified vehicles could alter the total cost of ownership 40
Agenda Introduction Bosch Group Market trends and success factors Systems s and implementations e Chances and challenges Summary 41
Design thinking for e-mobility: Success Factors system Know How HMI compact drive unit consumer cells feasible viable technology business case high volumes established industry structure affordable battery costs Desired Customers successful product desire ebike buyer electrical drive experience mobility in golden ager sport comfort, design, coolness, fancy, stylish 42
Fascination ebike It s a lifestyle product We sell an experience It s e-mobility It s Bosch emotor battery system functions powerful reliable drive performance 43
E-Mobilität - Chancen und Herausforderungen F Fascination i ti ebike Bik k b d w// Bosch h Bike brands ebike-system in 2012 44 City Trekking MTB
Overview Electrification ti at Robert Bosch E-Machines and Battery Navigation Systems User-centered EV HMI Power Electronics for Hybrids and EV ABS, ESP, Brake-Booster Booster Powertrain for ebikes / escooter Charging Stations for Electric Vehicles Components for CV Electrification Starter and Generators for Start/Stop Systems FUTURE Research and Advanced Engineering for future Electric Vehicle Concepts Software for Infrastructure Integration Diagnostic for Service 45
Summary The future belongs to e-mobility. However, high up-front investment required to develop new technology. Systems competence is an enabler for mastering electric vehicle technology. Cost of EV technology is an important driving force for market penetration. Industry can join forces to achieve a competitive cost position. Learning from other industries (e.g., consumer cells) speeds up learning curve. Bosch is paving the way for electro-mobility, with the development of innovative electric drive systems and the economic implementation of innovations in the market. 46
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