Experience from 40 years with Volvo Cars efficiency and Electrification Robert Eriksson Senior Technical Leader Volvo Car Corporation FFI Elektromobility Elektriska fordon I fokus Lindholmen 3:e sep 2013 1
The journey o Background and Reasons o Milestones in Efficiency and Electrification o Volvo V60 Plug-In Hybrid o Conclusions 2
Why not then - why now? 1970 s Concerns about fuel price and limited availability of fuel. (Proved to be incorrect!) No market request for efficiency but awareness of emissions Lack of mature technology Knowledge gaps 2012 Increased public awareness about global warming and energy resource limitations Market awareness of possible improved attributes Major steps in technology development (batteries, power electronics, machine control) Regulations on fuel economy and emissions Technology Timing 3
Major activities Concept vehicle Internal studies Test fleet Mass production Knowledge build Range Ext EV Pure EV Plug-In Hybrid Full Hybrid Mild Hybrid Micro Hybrid Electric car1976 Paulus 1979 ECC Stop/start ISG HEV 98 HEV 98 ReCharge 3CC S40 Power split Ford ESCAPE HEV ISG/42V Soft Hybrid Stop/start ESM V70 PHEV Stop/start ESM C30 electric V60 Plug-In ISG/48V Mild Power supply 48V/12V Emission control Λ-Sensor (1 st OEM) ISG / 48V 1989 42V/12V PZEV (Early intro) 48V/12V Total efficiency & Light weight Paulus 1979 LCP 1983 LWD 3CC DrivE M-KERS 1970 1980 1990 2000 2010 2020 4
Efficiency studies 5
1976 Volvo Electric car Technical data Volvo Electric Car 1976 Background Fuel availability and price. (1970 s oil crises) Objective Efficient transportation of passengers and goods. Results 2 versions were built and tested in real traffic. City Taxi Mail delivery vehicle Vehicle Length 2,68 m Weight 1200 kg Top speed 70 km/h Electric drive power 9,5 kw Electric drive version 1 series wound 72 VDC Electric drive version 2 Shunt motor with CVT transmission 60 VDC 6
1979 Flywheel concept Objective Optimise engine load point Brake regeneration ICE Aux drive CVT Flywheel Technical data Volvo flywheel project Paulus) Result The driveline was installed and tested in a 260 series vehicle. Vehicle demonstration Volvo 260 Engine V6, 2,7L Transmission CVT Flywheel weight 128 kg (steel) Power 30 kw Inertia 2,75 kgm 2 Speed 14000 rpm Diameter 0,59 m Energy storage 3 MJ
2012 M-KERS Flywheel revival Project Advanced material research and component refinement (composites, bearings and use of SW-based control) Increased rotational speed Less size and weight Minor problems with inertia or gyro effects Volvo S60 - M-KERS research Vehicle (Mechanical Kinetic Energy Recovery System) Rear wheel drive system Demonstration package Technical data Volvo flywheel project (M-KERS) Vehicle demonstration Volvo S60 Fuel consumption 10-12% reduced (NEDC) Acceleration 20-30% reduced (0-100 km/h) Engine I5, 2,4L Transmission AT FWD M-KERS unit RWD Flywheel weight 6 kg (composite) Power 60 kw Inertia 0,0275 kgm 2 Speed 60000 rpm Energy storage 0,54 MJ 8
1983 Light Component Project (lcp) Objective Demonstration of future concepts with new materials, design and production methods to reach requirements of future efficient transportation. Result: The LCP (Light Component Project) vehicle Light weight component design 3 cyl. turbo diesel with direct injection and CVT Technical data Volvo LCP 2000 Concept - 1983 Vehicle Length 3,98 m Weight (curb) 707 kg Top speed 180 km/h Acceleration 0-100 km/h 11 s Fuel consumption -city 4,2 l/100 km Fuel consumption -highway 2,9 l/100 km 9
1996 Light Weight Design Objective To investigate how far weight reduction in a full scale vehicle could go if adopting the latest materials and production methods. Project 850-850 To build an Volvo 850 with total curb weight of 850 kg. LWD weight reduction project 1996 Vehicle Volvo 850 Volvo 850 std % reduction Lucia Weight target 850 1401 36 Body 335 529 40 Engine 123 154 20 Transmission 66 78 16 Chassis 246 403 42 Interior 143 170 15 Electrical 44 55 19 Other 4 12 10
Feature Growth 11
1990 isg + dual voltage architecture Problem Limitations in power supply for future customer demands Solutions explored Dual Voltage system 24/12V and 48/12V. High power alternators ISG (Integrated starter alternators) Result Base for development in 12V power supply and mild hybrids Battery sensing, energy management, Power electronics Later used for stop/start investigations 12
1998-2001 42V Soft Hybrid Vehicle ISG Soft Hybrid ISG (Integrated Starter Generator) 42V/12V Dual Voltage System 1999 Results Fuel consumption reduction: -11% on Auto, -15% on Manual versus base vehicle Demonstrated for 150 Journalists Seville, Spain 2001 13
42V standard moving to 48V 1999-42V Standard Volvo argument 2011- New 48V proposal 3x12V Lead Acid No regen. braking Mild HEV Adv battery (NiMh) Regen braking Mild HEV Adv batteri (Li-Ion) Regen braking 14
Emission reduction "HC" g/mile SOP of major emission steps 0,30 0,25 HC 0,25 0,20 0,15 TLEV 0,10 LEV 0,05 0,00 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 ULEV PZEV 15
The hybrid evolution 16
1992 Environmental concept car Objective Meeting the ZEV mandate with a safe, environmentally optimised and comfortable family car for the 21st century Result Advanced technology Plug In hybrid Design inspiration for first generation S80 16 kwh Battery Inverter 90 kw Electric drive unit High speed generator 17
1993-1996 Serial Hybrid HEV 98 Objective Development set up for low volume manufacturing of a Plug-In serial hybrid. (Meeting the ZEV mandate) Result Fully integrated hybrid vehicle 3 cyl 1,5L APU w 38 kw generator 90 kw electric drive unit w 2 speed transmission Fuel efficient despite the big weight increase DC/AC DCDC converter Converter EL AC compressor Under hood layout 1,4 L 3 cyl Gasoline engine Drive unit 90 kw AC ind machine 2 step transmission 90 KW Drive system, 2 stage transmission Starting point: Electric Vehicle to study the attributes Field Wound Range extender built on a trailer Synchronous to study Generator hybrid + functions regulator and energy management 18
1999 Desiree power split Objective Study vehicle attributes and system implications of power split technology in VCC platforms Results The S40/V40 Desiree vehicle S40 hybrid - Geneva Auto Show 1999 Technical summary Power Split Hybrid 1999 Concept Power split Added Weight 1513 kg (+183 kg added) Engine 3 cyl. petrol 56 kw Generator 25 kw PM Machine Electric motor 55 kw PM Machine Battery NiMh 2,5 kwh, 55 kw, System Voltage 300V Performance 0-100 km/h in 13,5 sec. Fuel efficiency -44%/-40% in NEDC (5,2 L/100 km measured) 19
Plug-in research STUDIES Objective Plug-In technology research Study customer acceptance and driving behaviour Results C30 Re-Charge - Range extender serial hybrid. City commuting 0-100 km/h in 9 seconds V70 PHEV Parallel Hybrid test fleet. Feedback from driving under real conditions Input for development programs 20
2011 C30 Electric Objective 2008 Volvo Cars made a strategic decision to produce a fully competitive EV car in the luxury segment. Best possible vehicle for this purpose was the C30. Result Technical data - Volvo C30 Electric 2011 Vehicle Type C30-3 door hatchback 4 seats + Luggage Performance 0-100 km/h 10,5 s Electric Range (NEDC) 150 km Top speed 150 km/h Electric drive power 82 Kw Battery Energy 24 kwh Charging System On board charger - 230V/16A 21
V60 Plug-in Hybrid V60 Plug In Hybrid, YM 2014 22
V60 Plug-In Hybrid facts 3 main driving modes PURE Up to 50 km range HYBRID 48 g/km CO2 POWER 0-100 km/h in 6.1s Additional modes SAVE for later use AWD active and passive Technical data ICE 5cyl 2.4L Turbo diesel (215 hp/ 4000rpm, 440Nm /25-50 rps. 6 speed Automatic Transmission Electric motor (ERAD) 200Nm, 50 kw Li-Ion battery 11.2 kwh ISG On board charging IEC 61851-1 mode 2,3 Charging connector IEC 62196-2 Type 2 Performance Fuel consumption 1,8 ( L/100 km ) NEDC (hybrid) CO2 hybrid mode 48 ( g/km ) NEDC (hybrid) Electric Range up to 50 ( km ) Total Range 900 ( km ) Acceleration 0-100 km/h 6,1 ( sec ) Charging time 3,5-4,5-7,5 ( h ) (16A-10A-6A fuse) Climate system Pre conditioning Smartphone apps (cooling and heating) 23
V60 Plug-In Hybrid HMI Graphic Info display Energy flow demo in display Smartphone App Eco drive statistics Mode selection 24
Media reception of the V60 Plug-In Hybrid
Conclusions Long Time Experience Volvo Cars has focused on development of Efficiency, Alternative Technologies and Electrification for a long period of time. Technology is the Enabler Technologies in areas like Li-Ion Batteries, Power Electronics and Electronic Hardware and Software were not developed for automotive use 40 or 20 years ago which explains the long time to market. Extensive Research and Development Working with new technologies means refinement of the state of the art technology but does not always mean that it is made available on the market. The Volvo V60 Plug-In Hybrid is now available to customers This car is the result of a massive research and engineering effort over time, where different parts from the long history of research has been matured, further developed and put into a completely new vehicle. 26
The journey continues... Volvo Cars will continue with an Extensive Investment in Electrification and Hybridisation to meet every coming Environmental and Customer requirements. 27
Thank You! Robert Eriksson Volvo Car Corporation 28