Powertrain & Thermal Systems - Mov'eo...Property of Valeo – Duplication Prohibited Flins 15...

Powertrain & Thermal Systems

Flins 15 Décembre 2016 1Property of Valeo – Duplication Prohibited

Électrification des fonctions et des auxiliairesFlins - 15 Décembre 2016

L'électrification et composants 48V des fonctions moteur et auxiliaires

O. COPPIN – N. DEVIENNE

Agenda

Drivers for hybridization

Low voltage Hybrid systems and functions

Alternative boosting : electric supercharger

Function electrification


Function electrification

Low voltage Road-Map

Conclusion

Driver for hybridization : CO2 regulationsMain issue of hybrid / electric: COST!

China 2020(cars only):106


Diesel : the upper limit customers are willing to pay � To develop in mass-market, hybrids need to be cheaper : Why 12V+12V and 48V make sense

Powertrain Solutions for CO 23 main technical Areas


Internal Combustion

Engine Downsizing

•Turbocharger/Supercharger•Gasoline Direct Injection•Gasoline Cooled EGR•Variable Valve Activation•Thermal management

Electrification

• Stop-Start• Mild Hybrid• Full Hybrid• Plug-in Hybrid• Range Extender• Battery Electric Vehicles• Energy management

Downspeeding &

Automation

• Double Clutch Transmission• Automatic Early lock-up• Downspeeding

1 2 3

Hybrid Architectures

P2 P4P4

P4

P0

P3

P0 / P1 P2 P4P3

P1


E-motor linked to ICE

E-motor decoupled from

ICE, at same speed

P0 / P1 P2E-motor in

driveline or in rear axle or in

wheels

P4E-motor

decoupled from ICE, at a speed

multiple than ICE

P3

48V can address all hybrid architectures and enhanc e hybrid functions benefits48V can address all hybrid architectures and enhanc e hybrid functions benefits

Functions availability

P0 Belt 12V P0 Belt

« 12V + 12V »

P0 Belt« 12V + 12V »

+ eSC

P0 Belt 48V(+ eSC)

48V P2/P3/P4

Cold start o o o o / ● o / ● (P2) Change of Mind ● ● ● ● ●Stop & Start ● ● ● ● ●High Efficiency generator ● ● ● ● ●Durability (1mcy) ● ● ● ● ●Comfort Start ● ● ● ● ●Stalling help ● ● ● ● ●Coasting o / ● ● ● ● ●Regenerative braking o ● ● ● ●


o : Limited● : Possible

: Impact on fuel savings

Regenerative braking o ● ● ● ●Torque Assist o o ● ● ●Torque Monitoring o o ● ●Downspeeding ● ● ●Engine Dowsizing ● ● ●ZEV o / ● ●Electrical Take off o / ● ●

Voltage increase will enhance hybrid functionsP2, P3, P4 architectures increase hybrid energy man agement benefits

Voltage increase will enhance hybrid functionsP2, P3, P4 architectures increase hybrid energy man agement benefits

Why 48V Hybrid is affordable

Low voltage � Small battery � Cheap battery

Belt Starter-Generator

All-in-one : Just replaces the alternator with integrated inverter

Standard powertrain architecture

Limited power : air cooling possible if

Peugeot 308 48 Volt Electric AWD : Essencyele.

Association of a 48V P0 belt machine and a 48V electric rear axle

All Hybrid functions including electric driving

Cost effective thanks to 48V

P4 hybrid architecture efficiency

Up to 22%* CO2 emission reduction on NEDC, up to 16%* WLTP

AWD mobility function as added value for end customer.

Funded project

Flins 15 Décembre 2016 8Property of Valeo – Duplication Prohibited* Valeo estimate based on simulation, will vary per vehicle application

Alternative Boosting : efficiency analysis

17,4

100 > 100100 > 82,6

Mechanical supercharger Electrical supercharger


With e-Supercharger there is no friction while boosting.

Energy is free while recovered during braking

High mechanical losses, only 82% of generated torque goes to the wheels

No Mechanical losses. 100% of the generated torque is transferred to the wheels

Interest of alternative boosting : efficiency

5 kW

Hybrid system Electrical supercharger

25kW25kW25 kW


To get 25kW on the wheels, need ~5 kW on the air thanks to combustion COP.

With 300Amps limit , 48V is far enough

To get 25kW on the wheels, need ~25 kW from the e-motor.

With 300Amps limit , 100V necessary

With the electric supercharger there is fundamental ly efficiency benefit linked to combustion COP

For the same power at wheels, the hybrid voltage ca n be reduced from high voltage to 12V or 48V: the electric system, includi ng batteries, is then far

cheaper.

26

Electric Supercharger = instantaneous response

16

18

20

22

24B

ME

P (

bar)

26

Turbo engine

Electric supercharger

after 0.5sTurbo after 2.0s

Turbo after 1.0s


8

10

12

14

BM

EP

(ba

r)

500 1500 2500 3500 4500 5500 6500Engine speed (RPM)

Naturally aspirated engine

Turbo after 0.5s

The higher the downsizing, the longer the turbo lag @ low RPM. The turbo isunable to compensate the lag. Response time is the key parameter

Renault Fluence: SURAL -HYSupercharging system for hybrid gasoline

engines with high downsizing

Integration of 1.2L

Electric supercharger3 kW, 12 Volts

Funded project


Integration of 1.2L Renault turbo engine

with the Electric Supercharger

Design and integration of a larger Turbo to achieve

100kW / L

Partial 'free' power boost, symmetry braking phases: energy recovery

and energy use with 12V

Engine downsizing and downspeeding thanks to eSC in tegration

12V NiZn battery eSC dedicated Gearbox

downspeeding(15%)

More Power

Electric Supercharger – 3 main applicationsLess pollutantsBetter Fuel Efficiency


Audi RS5 TDI 386HP

Volvo eDrive 450HP

Valeo NA Democar 8% FE

Ricardo HyBoost 20% FE Valeo-FEV : Euro6 w/o SCR

48V 12V Diesel

Electrical board net : modular building 12V -> 48V

12V Battery 1

12V Sensitive

Loads

12V NON Sensitive

LoadsStarter

Optional Piloted switch

12V Battery 2

12V “clean” network12V “regen” network

12V + 12V Basic Set

Reversible Machine Starter + Alternator 12V

Optional Piloted switch


Reversible Machine Starter + Alternator 12V 12V NON


12V + 48VStarter

Reversible Machine 48V

DCDC48-12 V

eSC


48V Battery

12V Battery

12V Sensitive

Loads48V NON Sensitive

Loads

12V + 12V Extented Set

12V Battery 1Starter 12V

Battery 2

Starter + Alternator 12V12V

Sensitive Loads

12V NON Sensitive

Loads

eSC

Future steps

Develop P2, P3 & P4 48V application to enhance efficiency

48V : a way to address low cost small electric vehicle ?

Power level compatible with 80 to 100 km/h max


Autonomy up to 100km by battery sizing

Keep cost and component modularity with 48V hybrids

12+12V & 48V Road MapFirst 12V application : Stop & Start

60

70

80

% C

O2

Red

uctio

n

Systems CO2 gains / cost position


0

10

20

30

40

50

60

% C

O2

Red

uctio

n

system cost

STT

12+12V & 48V Road Map

60

70

80

% C

O2

Red

uctio

n


48V mild hybrid : more power and more energy availa ble

First and easier step : belt e-machine.


0

10

20

30

40

50

60

% C

O2

Red

uctio

n

system cost

12+12V & 48V Road MapA better cost / CO 2 gain ratio than high voltage systems

48V : An increasing potential with boosted hybrid a nd power devices electrification

A continuous extension : accessories electrificatio n, P3/P4 hybrid architectures, new concepts….

60

70

80

% C

O2

Red

uctio

n



0

10

20

30

40

50

60

% C

O2

Red

uctio

n

system cost

12V systems have a limit around 4 kW (~300 Amps max )

48V board net opportunity : more power available

8000

10000

12000

Lights

BoardFuel Pump

ABS, CBC and DBC Actuators

Small Power consumers

Blower

Fan

BMW 750i Diesel 3.0L – WLTC 40°C + comfort function ON


0 200 400 600 800 1000 1200 1400 1600 18000

2000

4000

6000

time (s)

Pow

er (

W)

Fandefog (front and rear screen)

Compressor Power

Estimated limit of 12V systems

2 500

3 000

3 500

4 000

4 500

Pow

er (

W)

Mean/Max power per load

Electric mean

power

Electric max

power

Mechanical mean

power

Mechanical max

power

Vehicle measurements and analysis of load power during use (WLTC @ different conditions / static tests)

Measures on WLTC (nominal conditions)

Static tests

Measures on WLTC (specific conditions)

C, c

old

star

t

Accessories for belt suppression

Accessories with 48V electrification

potential

Analysis of vehicle measurements

C, h

ot s

tart

C, h

ot s

tart

C, c

old

star

t

Real mountain

THS VDA testTamb. = 45°C40% humidity


0

500

1 000

1 500

2 000

Pow

er (

W)

Power Devicesfor comfort

Small Power Machine & Devices

Electro-hydraulic Machines

Controllers

** CBC & DBC: Cornering Brake Control & Dynamic Brake Control

Est

imat

ed

Tam

b. <

15°

C, c

old

star

t

Est

imat

edT

amb.

< 0

°C

Tam

b. =

28°

C, h

ot s

tart

Tam

b. =

28°

C, h

ot s

tart

Tam

b. =

-7°

C, c

old

star

t

mountain road

* Windshield included

Comfort Auxiliaries

12V + 48V

Reversible Machine 48V

DCDC 48-12 V

eSC


48V Battery

12V Battery

48V NON Sensitive

Loads

12V Non Sensitive

Loads

12V Sensitive

Loads

48V 12V

StarterEfficiencyWeight


Weight

Switching Auxiliaries from 12V to 48V allows to gainWeight

DC/DC Efficiency

Additional gains

Wire harness weight and costs

Resistive losses in wires

Other gains to be confirmed

Efficiency in electrical machines thanks to finest wires and copper density increase

48V – 12V / DiversityOn the same vehicle several Power train are co existing.

Voltage of components shall be manage as a version

� Common mechanical interfaces

For several years 48V components won’t reach the same production volume

�Production cost difficult to converge with 12V

48 V12 V- Adapted MOSFET- Driver 48V

A major stake is to communalize Industrial tooling between 12V and 48V


Winding adaptation (wire gage, nber turns, …)

•Power electronics

Adapted to connectors design

- Driver 48V- Adapted Inductor- Adapted Capacitor

• PCB lay out• New Connectors with CPA

Dedicated to each HVAC application

Dedicated to each HVAC application

Carry over

Carry over

Carry over

Conclusion

0

20

40

60

80

Hybridization: a necessity for CO2 reductionCost is always a driver :

Affordable cars require simpler / cheaper solutionsModular Electric Architectures & topology as way to reduce integration cost

Extended 12V & 48V mild hybrid systems address basis hybrid functions and allow superior fuel economy for best value equation


12V Battery 1

12V Battery 2(AGM/NiMH)

12V

Sen

sitiv

e lo

ads

12V

NO

N S

ensi

tive

load

s

i-Stars

Starter

Piloted switch

functions and allow superior fuel economy for best value equation

Low voltage dual battery architectures are gateway to

Extended regen capability

Extended boost with electric supercharger

Coasting and valuable driver functions

Electrification can also address new board net functions


Thank you for your attention

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