Challenges and Opportunities for 48V Hybrid

Systems

AESIN2015

Ryan Maughan, Managing Director, AVID

Technology Limited

Copyright AVID Technology Group 2015

AVID Technology & Products

8800 г. Сливен, ул. Софийско шосе 1, РО Box 123;; тел: + 359 44 666 207;; тел./ факс: + 359 44 62 22 91;;

web site: www.dynamo-bg.com; email: dynamo@dynamo-bg.com; отдел "Продажби" тел: + 359 44 624 975;email: sales@dynamo-bg.com; отдел

“Електродвигатели” тел: + 359 44 623 325; email: dcmotors@dynamo-bg.com

Произвежда: Генератори и стартери за автомобили, постояннотокови двигатели за автоматизирани устройства и

управление за тях, постояннотокови двигатели и комплектни електрозадвижвания за металорежещи машини с ЦПУ

и с общо предназначение.

Brushless alternator P270

Rated Voltage V 28

Rated Current A 270

Weight kg 28

CONNECTION DIAGRAM PERFORMANCE CURVE

ePumps eFans eFan Micro Hybrid

Systems

Power

Series

Alternators

Custom

Motor /

Controller

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Electrification of engine ancillaries to improve efficiency and performance

Currently all 12 or 24V designed specifically for the heavy duty vehicle market

eFan Micro Hybrid System is a replacement for the standard cooling system on a bus and has been shown

to deliver fuel savings of 5 to 15% on urban driving cycles

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eFan Micro Hybrid CV Examples

Aftermarket solutions covering a wide range of vehicles all common buses in the EU &

Mining Equipment all 24V applications

OEM programs underway with several Transit Bus and Off Highway OEMs

System proven to deliver fuel savings and reliability improvements as well as other

benefits

Typical 10% fuel saving on transient (Urban) driving cycle

Electrification of Main Engine Coolant Pumps

BMW pioneered electric coolant pumps

for several years

Undertook complete redesign of the

engine to reduce pressure drop seen by

the pump from > 250kPa to <100kPa

Required to facilitate feasible pump

power for 12V system of <500W

Reduced parasitic load of the pump

better fuel efficiency

Improved controllability ~ improved

engine thermal management ~

efficiency + aftertreatment effectiveness

Improvements mainly seen in real world

driving conditions !

What is the required investment to re-

design the engine ?

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48V Hybrid ?

CAGR of 81.45%

Renault HYDIVU LCV

Comparison Ancillary Electrification

2.0 TD Passenger Car Commercial Vehicle 6.7L Transit Bus

System 12V 48V 24V 48V

Coolant Pump 80A 20A 80A 40A

Power Steering 60A 15A 180A 90A

Cooling Fan 60A 15 25A x 6 12.5A x 6

Air Compressor N/A N/A 360A 180A

15kW Crank Assist Generator

1,250A 312A 620A 312A

Main Engine Oil Pump

160A 40A 300A 150A

Gearbox oil directed lubrication

? ? 30Amps 15Amps

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Systems electrification is effective because of the large amount of power used by

parasitic systems in Real Driving Environment

Other Benefits of 48V Electrification

Helps RDE performance of vehicle as components are decoupled

from engine

Supports Start Stop Engine Operation as functions can operate when

engine is not e.g. coolant or oil circulation

Enabler for engine down sizing torque in fill and reduced parasitic’s

Improved thermo management for after treatment systems through

improved “cooling” system and direct heating

Improved safety = reduced cost and complexity compared to higher

voltage hybrid systems

Enabler for future technologies e.g electronic valve actuation,

eBoosting, WHR

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To DC or not DC?

Typical configuration for 48V Hybrid involves a DC/DC converter

How does the cost and weight of the DC/DC compare to a low power 12V alternator?

Additional smart e-machine provides opportunity for low cost energy recovery but means belts are still needed!

Bosch 350W DC/DC from their website

750W 12V Alternator

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What are the Key Changes 12/24V to 48V?

1. Power Management

2. Motor Controller

3. Microprocessor

4. 3 Phase + CP MOSFET’s

5. CAN communications

6. Capacitors

1

2

3

4 4 5

6

Key Challenges Moving to 48V Architecture

Emerging standard for 48V systems

LV148 is not fully developed

Energy storage system

High efficiency & cost effective

automotive grade power electronics -

limited choices

Dealing with transients and EMC at a

component and system level

Systems level approach lacking,

tending to think of the hybrid e-

machine & PE in isolation from other

systems

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Summary

Significant benefits are available in CV and Passenger Car through

electrification of ancillary systems

Impact of RDE driving is that these benefits are now being fully

recognised

Move to 48V enables deeper electrification giving real world

performance, comfort and emissions improvements

Higher voltage hybrid systems will still be present, but in terms of

volume of vehicles LV hybrids will dominate

Copyright AVID Technology Limited 2015

Ryan Maughan – Managing Director

AVID Technology Limited

3D Admiral Business Park

Nelson Industrial Estate

Cramlington

Northumberland

NE23 1WG

United Kingdom

w. www.avidtp.com

e. ryan.maughan@avidgr.com

p. +44 (0) 7976 531340

Copyright AVID Technology Limited 2015