Future Powertrain

November 2014 | Dr. Alexander Heintzel, Angelina Hofacker

Automotive Technology - Today and Tomorrow Changes and Challenges in Powertrain

and ADAS Development

Agenda

Two mega trends in the automotive industry:

1. Advanced Driver Assistance Systems (ADAS)

• Connectivity

• Automated Driving

2. Future Powertrain

• Optimization of combustion engines

• Electrification of powertrain

Automotive Technology - Today and Tomorrow | November 2014 | Dr. Alexander Heintzel, Angelina Hofacker


Figure: © Rinspeed

Advanced Driver Assistance Systems (ADAS)

• Road traffic deaths 2013: 1.24 million per year (WHO) European Union: Vision Zero

• Safety

• Comfort

• Connectivity


Figure: © Bosch


Anti-lock Braking System (ABS)

Electronic Stability Control (ESC)

Automatic Emergency Braking (AEB)

Lane Keeping Assist (LKA)

Pre-safe Brake/Collision Mitigation Brake System (CMBS)

Adaptive Cruise Control (ACC)

State-of-the-art systems:

• Safety & security

• Infotainment

Connected Car

5


Figure: © Serg Nvns | Fotolia

Risk: driver distraction


Figure: © Bosch


• From ADAS to Automated Driving

• Requirements:

Figures: © Valeo


• Evolution of driving assistance from the perspective of the end customer


• More than a third of all Germans can imagine a future in which they will drive automatically.

Figures: © 1941: Ulysses William O. Field; 2004: Bruce F. Molnia | Glacier Photograph Collection, National Snow and Ice Data Center/World Data Center for Glaciology

Starting Point for E-Mobility : Climate Change

Muir Glacier, Alaska (1941) Muir Glacier, Alaska (2004)



Figure: © IPCC

Greenhouse Gas Emissions by Economic Sector

Only integrated strategies will be successful!

Source: ICCT

Objectives for Passenger Cars


Source: ICCT

Overall and annual CO2 reduction rates required for passenger cars


Figure: © Daimler

Future Powertrain

• Technical portfolio of gasoline engines from Daimler


Figure: © Daimler

Future Powertrain

• Technical portfolio of diesel engines from Daimler


Future Powertrain

• Combustion engine

• Optimizing the overall system

• Optimizing the engine itself

• Exhaust gas recirculation (EGR)

• Downsizing or rightsizing (small-displacement engine, less cylinders, supercharging)

• Adjusting engine and transmission

• Lightweight

• Minimizing friction (material and lubricants)

• Alternative/synthetic fuels and lubricants

• Thermal management (charge exchange)

• Electrification


Source: Federal-Mogul

Future Powertrain

• Optimizing the engine itself: minimizing friction

• Spreading of the total energy over individual consumer loads or places at which losses occur using the example of a gasoline engine GDI TC 2.0 l 14 in NEDC


Share of each system in friction and auxiliary losses 2000 rpm Oil temperature 90 °C

Energy loss through heat and gas exchange

Mechanical work

Crankshaft group Mainly main bearing

Piston group Conrod bearing

Piston and piston pin

Ring lamination parcel

Mechanical work available on the output side of the engine

Friction and auxiliary losses

Other subsystems • Valve train

• Oil/water pump

• Spring balancers

• Timing belt

• V-ribbed belt

• Fuel system

Figure: Daimler

Future Powertrain

• Optimizing the engine itself: minimizing Friction

• Overview of relevant engine components and ways of reducing friction


Source: Daimler

Future Powertrain

• Optimizing the engine itself: minimising friction

• Example: bearings


Source: Mahle

Future Powertrain

• Optimizing the overall system: thermal management

• Example: integrated cascaded charge air cooling developed by Mahle for diesel engines


Figure: © BMW

Future Powertrain = Electrified Powertrain?


ca. = approx. bis = up to

* in the case of regenerative power generation

• Battery cells and accumulators as cost factors

• Weight of vehicle (rises disproportionately in relation to performance)

• Interaction of powertrain components (electric powertrain, power electronics, heating/air conditioning, auxiliary electric consumers

• Range (management of range)

• Infrastructure

Challenges for BEV


Figure: © Bosch

Figure: © APL Landau



Degree of Electrification

Electric range Electric engine

Combustion engine Electric support + boost

Potential to reduce CO2

Degree of electrification Pure electric drive

Figure: © Volkswagen


• Strategy of Volkswagen


Alternative / regenerative Combustion Alternative / regenerative

Gasoline

Fuel Cell

Battery Electric

Source: BDEW


• CO2 emission data for power generation

• 2010: 530 g CO2/kWh

• 2011: 560 g CO2/kWh

• 2012: 576 g CO2/kWh

• 2013: increasing


0

5

10

15

20

25

30

Hard coal Lignite coal Fuel oil, pump

storage and others

Natural gas Nuclear energy

Renewable energies

2014 19,4 25,5 5,1 10,6 15,4 24 2013 19,1 25,7 1,6 11,3 16,1 22,1

[%]

Gross electricity production by form of energy (Germany)

Figure: © Prof. Dr.-Ing. Ulrich Spicher, MOT GmbH

Combustion engine and electric drive: cost comparison • Comparison of VM Smart and e-Smart

Vehicle type: 1.0 l gasoline mhd 0.8 l diesel e-Smart Power output 52 kW 40 kW 35 kW (55kW) Consumption 4.2 l / 5.5 l 3.3 l / 4.3 l 15.1 kWh / 23.5 kWh (NEDC/real in liters/100km) CO2 emissions 108 g / 142 g 98 g / 128 g 0 g or 87 g / 135 g (NEFZ/Real in g/km) Purchase price € 10,825 € 12,095 € 18,910 without battery! Operating costs € 65 (43 l B) € 65 (47 l D) € 65 (rental fee for battery) (gasoline: € 1,50; diesel: € 1,37)

Range/€ 65 790 km 1,100 km 0 km Costs/month € 82 ( € 65 + € 17) € 59 € 138 (€ 73 for electricity) (at 1,000 km) (32 cents/kWh)

Total costs: € 15,745 € 15,635 € 27,190 (60,000 km in 5 years)

e-Smart




Source: APL Landau

Fossil fuels and uranium Regenerative primary energy carriers

Crude oil Natural gas Coal Uranium Water Solar radiation Biomass

Combustion engine Electric motor Fuel Cells

LPG Liquefied gas CNG Compressed natural gas LNG Liquefied natural gas DME Dimethyl ester OME Oligomeric polyoxymethylene dimethyl ester CGH2 Compressed hydrogen LH2 Liquefied hydrogen PME Vegetable oil methyl ester PTG Power to gas PTL Powert to liquid

Gasoline Vegetable oil/PME


• Several future powertrain technologies are available today. However, the question is: When will they achieve a sustainable market penetration?

• Today Combustion Engine

• Today - 5 years HEV, PHEV, RE, BEV

• 10-15 years FCEV

(Forecast: ATZ/MTZ)


Kaleidoscope of Powertrains

• There is no "one-fits-all" powertrain

• Real CO2 reduction through electric driving is only possible if the energy is produced from renewable resources

• The age of the internal combustion engine is not over yet. This technology will remain the major source of global mobility for the next two decades at least


Credits

• Daimler AG

• Volkswagen AG

• BMW AG

• Robert Bosch GmbH

• Mahle GmbH

• Federal-Mogul Corporation

• MOT GmbH

• APL Automobil-Prüftechnik Landau GmbH

• Rinspeed AG

• Valeo S.A.


Thank you for your attention!

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Future Powertrain