Product Development in Motion 2017 - Home - avl.com

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PRODUCT DEVELOPMENT IN

MOTION 2017

Electrification

Product Development in Motion | M. Maier | 21. November 2017 | 2Public

MAJOR HIGHLIGHTS ELECTRIFICATION 2017


LEGISLATIVE VIEW EUROPE

UK2040

Scotland2032

Norway2025

Netherlands2030

Slovenia2030

France2040

Paris2030

Source: Auto, Motor, Sport 08-2017


Why should that matter today?

It is at least 13 more years to go


NEW YORK 5TH AVENUE - 1900

Source: Tony Sebawww.tonyseba.comBook: “Clean Disruption”

http://www.tonyseba.com/


NEW YORK, 5TH AVENUE - 1913

Source: Tony Sebawww.tonyseba.comBook: “Clean Disruption”

http://www.tonyseba.com/


AGENDA

1. Battery for EVs

2. Battery Testing incl. Cell Testing

3. Trends in E-Motor Development and Testing

4. Power Electronics – The Inverter

5. Beyond BEVs – The Fuelcell


AUTOMOTIVE ELECTRIFICATION CONCEPTS

kWh

kW

Dedicated HybridTransmissions

PlugIn Hybrid BEV FCEV

Replace fossil Fuels

8 - 16

450V

80-120

One Gear

35 - 100

Axle Split

75-270

Two Gear

800V

440

Parallel Hybrid / e-AxleAT, DCT, CVT

15 - 100

PEM

SOFC

Mild Hybrid Full Hybrid

Increase Efficiency

Electric Supercharging

0,4 – 0,8

48V

8-12

MT+ Belt

0,2

12V

1-4

MT + P2 Module + auto-clutch

0,8

15-50

e-Axle

DCT, CVT, AT


ELECTRIFIED POWERTRAINS

Electrified

Engine

Components

Micro & Mild

Hybrid

Full

Hybrid

Full

Hybrid

Plug-In

Hybrid

Range

Extender

Battery

Electric

Fuel-Cell

Electric

FossilFuels

ElectricalEnergy

0% 0%

100%100%

To

rq

ue

To

rq

ue

MechanicalDrive

Mechanical Drive with electric Assist Electrical Drive withmechanical Assist

Electrical Drive

Hydrogen


Achievable Range and installed Battery Capacity per Car show linear correlation

• The higher the installed capacity the higher the range

But: studies show, that a minimum range of 300km must be achieved to overcome range anxiety of car buyers

• Other studies even mention 300 Miles (480km)

• To chieve this, a battery capacity of at least 70kWh must be installed with today’s technology

BATTERY CAPACITY AND RANGE

BMW i3GM Spark

Fiat 500e

Honda Fit

Nissan Leaf

Mitsubishi MiEV

Ford FocusSmart ED

Mercedes B

Tesla S 60

Tesla S 85

0

50

100

150

200

250

300

350

400

0 10 20 30 40 50 60 70 80 90 100

BEV - Battery Capacity and Range (2016)

Battery Capacity [kWh]

Range [k

m]


Battery Cost is one of the major driving forces for further Battery Development

• 2017: Tesla claims to be at 190,- €/kWh

• 2020: Projection at 100,- €/kWh

From slide above: min. 70 kWh are needed

• At 190,- €/kWh = 13.300 €/car

• At 100,- €/kWh = 7.000 €/car

Battery determines the BEV parameters

• Cost (business case)

• Range

• Driving Performance

• Charging Time

• Safety and Security

BATTERY COST AS MAJOR DRIVER

Source: https://electrek.co/2017/01/30/electric-vehicle-battery-cost-dropped-80-6-years-227kwh-tesla-190kwh/


The Battery Cell and the used raw materials attribute to a large extent to the Battery Cost

To drive down Cost for Batteries means extended Research and Development on Battery Cells makes sense

BATTERY VALUE CHAIN

Component

Production

Cell

Production

Module

Production

Pack

Production

Vehicle

Integration

Vehicle

UseRecycling

Anode, Cathode activematerials, binder,

electrolyte, separator

Assembly ofSingle cells

Cells into largermodules including

Electronicmanagement

Integration topack with power,

Charging andTemperaturemanagement

Integration tovehicle

Including plugsMounts etc.

In-VehicleUsage

(Drive the Car)

Re-Use orDeconstruction

Attributes to ~50% of Cost Focus of most of EU Industry


AGENDA

1. Battery for EVs






BATTERY TEST LAB

Development Goals• Reduce cost• Increase Discharging Performance• Increase Charging Performance• Ensure Lifecycle• Optimise Safety

Variation Parameters• Materials (Anode, Cathode, Electrolyte)

Multitude of Combinations !• Cell Formation Process• Control Strategy (BMS)

Tasks for R&D

Requirements for Cell Testing Lab• Must support a large (even huge) number of cells under test combined (brute-force)

• clever Design-of experiments to handle to huge amount of variations possible• Must allow very accurate and fast measurement and cycling of cell

• Internal resistance of cell (Impedancy Spectroscopy)• Voltage and Current, fast temperature measurement to detect thermal runaway

• Must be safe• A cell with thermal runaway produces explosive gases

• Must allow efficient working processes to operate the lab and allow big data analysis


AVL BATTERY TEST SYSTEMS

AVL E-STORAGE

DigatronAVL LYNX

Climatic Chamber

Thermal Camera

T/P/U Measurement

AVL Santorin

Host for Parameters & Results

Concerto

Data Analysis & Reports

InMotion

Simulation

Safety Systems

Special

MeasurementEIS-Meter

Digatron

UUT-Cell


DESIGN-VALIDATION PLAN BATTERY

Parameter Test

Thermal Shock

Parameter Test

Mechanical

Shock

Parameter Test

Salt Spray

Parameter Test

Parameter Test

Damp Heat,

cyclic

Parameter Test

Vibration

Parameter Test

Dust and

Water

Protection

Parameter Test

Performance Tests Environmental Tests Lifetime

High

Temperature

Endurance

Temperature

Cycle Test

Real Driving

Cycle

Capacity and

Energy

Power and

Internal

Resistance

No-Load

Capacity Loss

Capacity Loss

at Storage

Cranking

Power

Energy

Efficiency

Others

12 V Testing

EMC Testing

Transport and

Abuse Testing

Software

Testing


BATTERY SAFETY INCIDENTS

Dendrites

Particles

Crash

Overcharge

Overdischarge

Overload

Overheat

Ext. Short

Circuit

Int. Short

Circuit

Gas

Ignition

Explosion

Fire

Thermal

Runaway

Gas

Fire

Explosion


AVL BATTERY TEST SYSTEMS

AVL E-STORAGE AVL LYNX

Climatic Chamber

Thermal Camera

T/P/U Measurement

AVL Santorin

Host for Parameters & Results

Concerto

Data Analysis & Reports

InMotion

Simulation

Safety Systems

Coolant Conditioning

Power Supply 12 V

UUT-Battery

BCU (BMS)

Rest-Bus Simulation


AGENDA

1. Battery for EVs






Top Trend: Higher Power per Vehicle / per Electric Motor is desired

P = M * Ω

To increase the Power while having the same size, two ways possible:

1. Increase the Torque increase Torque Density

Only possible with different materials (rare earth) cost increase

2. Increase the Speed increase Speed Density

Higher RPM requires dedicated Development

Low-end Driveability

Motor Design and Bearings

NVH and EMC

Vehicle Characteristics

TRENDS IN E-MOTOR DEVELOPMENT

Speed Density

Torq

ue D

ensity


Technical

1. The load profile is highly dynamic

2. The e-Motor determines how the car fulfills the desired driving characteristics

Customer / Car Buyer

1. Sporty car or Comfortable Car have very different Tip-In feelings

2. All-wheel Drive or 2-Wheel Drive?

THE CHALLENGE

Inverter

Battery

Macro Load Profile Micro


Solution

Test it early on in the development process including Simulation Capabilities

THE DEVELOPERS DILEMMA


AVL E-DRIVE TEST SYSTEMSTYPICAL TEST BED SETUP

Load Unit

Drive Shaft

Automation / Simulation

HCU

Mains Supply

Options:

- Stall Brake

- Angle Measurement

T / P / U

Measurement

Options:

- Climatic Chamber

- HV Battery Enclosure

Coolant

Conditioning

Test System

Mechanics

Speed, Torque

U, I

Dyno Inverter

Mains Supply

UUT-Inverter

or Universal

Inverter

UUT E-Motor

Battery Emulator

AVL E-STORAGE

Vehicle Simulation

Power Measurement

PUMA Open 2,ISAC,CAMEOCONCERTO,InMotion,

…


Testbed Capabilities

• Allow full simulation of vehicle

• Road profiles for macro and micro effects

• Playback of recorded data from a real testdrive

• Automatic run of Generated load profiles

MANOUEVER SIMULATIONSimulation Tool inMotion

Velocity cannot be defined precisely

Velocity is a result of road obstacles,

driver actions and vehicle

performance (e.g. rock cycle) based

on maneuver catalog

Easy integration of traffic obstacles

Road & Maneuvers

50

Velocity is precisely defined based

on distance (e.g. race circuit)

Profile is accomplishable

Easy integration of road obstacles

(gradient, curvature)

Track-based Profile

[m]

[km/h]

Velocity is precisely defined based

on time (e.g. legislative cycle)

Profile is accomplishable

Road obstacles (gradient, curvature)

are distance based events

velocity Profile

[Sec]

[km/h]


POWER MEASUREMENT

DC-voltage, 48V up to 800V

(with Hf-pulses from inverter-PWM*)

DC-current (pulsed) up to 1000A

3ph~AC-voltage, up to 1000V

20kHz-PWM pulsed,

AC-current up to 1000A, 0-2 kHz

Mechanical Power

(n, M: speed and torque)

speed up to 20.000 rpm

=

Battery or Fuel Cell Inverteror Universal Inverter

E-Motor Load Unit

Drive Shaft

O

DC

Power

3~AC

Power

Losses(heat)

(Efficiency up to 97%)

Losses(heat)

(Efficiency up to 95%)

mech.

Power

+

_

+ n, M2 Ch.: U,I 6 Ch.: U,I8 Signal Channels:

Power Flow:

*) PWM…

Pulse Width

Modulation

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Movies/COUP E MASTER 003 low.mp4


AVL E-DRIVE TEST SYSTEMSTIER I TESTBED EXAMPLE

Example:

Axle-Motor


E-DRIVE EMC TESTING

• Capable of full performance range testing

• AVL Partner for the chamber

• AVL special EMC dyno, shaft and UUT support

Frontloading: from vehicle to component testing


E-AXLE NVH TESTING

• E-Axle NVH configuration (2WD)

• Optional gearbox for E-Drive test

• Also direct driven configuration available for high speed E-Drive

Frontloading: from vehicle to sub-systems


E-POWERTRAIN NVH TESTING

• 2WD and 4WD configurations

• Test powertrain only or complete vehicle

• Extension to E-Integration testbed

Frontloading, from vehicle to sub-systems


AGENDA

1. Battery for EVs






Operating Modes

An has basically two tasks

Convert 2-Phase DC from Battery to 3-Phase AC for the Motor and control Motor Power while Driving

Convert 3-Phase AC to 2-Phase DC while generating / recuperating

Major Challenges and Goals for E-Motor Development

1. Optimize the Control Strategies

2. Optimize the Efficiency

3. Optimize for New Functions and Features enabled by Inverter & E-Motor

INVERTER AS THE HEART OF IT ALL

InverterBattery


MAJOR CHALLENGES FOR INVERTER DEVELOPMENT 1/2

1. Optimize the Control Strategies

Development Goal

Signal conversion: convert torque command from vehicle to 3 phase AC current command

Vector control (max. torque / field weakening)

Power conversion: Based on the 3phase AC command, convert DC from battery to 3 phase AC PWM control

2. Transient and Dynamic Behavior for Driveability

Development Goal

Switching loss is power consumption, mainly due to transient characteristics of voltage and current in switch on/off. It brings decrease in inverter efficiency and increase in power transistor temperature (lifetime)


MAJOR CHALLENGES FOR INVERTER DEVELOPMENT 2/2

1. Optimize for New Functions and Features enabled by Inverter & E-Motor

Example: Vibration Control

An Electrical Motor has a high dynamic Response to torque demands

A Powertrain Setup can cause vibrations due to Mass-Spring-Damper

Vibration Control can be applied to actively Damp the resulting vibrations


Mains Supply

Baseline

Measurement

Options:

- Climatic Chamber

- Climatic coolant cond.

Coolant

Conditioning

U, I

Option: Switch rack

(failure insertion)

Automation / Simulation

Speed & angle

position signals

AVL e-Motor Emulator (e-ME)

with E-Storage power supply

option : DC Load

Power supply 12VUUT-Inverter

Battery Emulator

AVL E-STORAGE

Inverter tableVehicle

Simulation

AVL INVERTER TEST SYSTEMSTYPICAL TESTBED SETUP

Power Measurement

PUMA Open 2,CameoCONCERTO,InMotion,

…


PUMA Open + CAMEO + X-ion team play =up to 80% time reduction in calibration process

• Duration reduction from 6-10 weeks to 2-3 weeks

• Available: customer-specific from Q1 2017, standard from End 2017

AUTOMATIC E-DRIVE CALIBRATION


AGENDA

1. Battery for EVs






AVL FUEL CELL SYSTEM TESTBED SETUP

• Powerful and well known AVL’s automotive test tools chain

• Integrated application expert knowhow for FC diagnostics (eg. SOH, degradation speed, etc..)

• Modular and flexible testbed design

Success based on interplay

AVL PUMA Open 2,AVL CAMEO,AVL CONCERTO,AVL InMotion,AVL Testbed.CONNECT

…


AVL & GREENLIGHT COOPERATION

• AVL has 25% ownership and one seat in the management board

• Greenlight as world leader in cell and stack development and validation

Gaining access to new customer areas due to Greenlight’sexisting network and product portfolio

Fuel Cell - Cell Testbed Fuel Cell - Stack Testbed


BUILDING A COMPLETE PORTFOLIO

PUMA Open for Fuel Cell

Fuel Cell Electric VehicleFCEV

Chassis Dyno

Fuel Cell Propulsion SystemFCPS

Powertrain Dyno

Fuel Cell SystemFCS

FC System TB

Fuel Cell StackFC Stack

FC Stack TB

Single Fuel Cell

FC TB

Emerald

AVL to develop its own fuel cell specific measurement solutions


WORLDS MOST ADVANCED FUEL CELL SYSTEM TESTBED

Advanced & FC optimized Measurement Equipment

Adv. Test Automation & Virtual Environment

State of the ArtEnvironmental Simulation Climatic Chamber

3x4x3 m

FlowSonix

THDA

F-FEM & CVM

XION

-40 to 85 °C

up to 160 kWPicture from the opening event

Fuel Cell System Test Bench

Test capabilities

• Environmental Tests (Cold-Start Test, etc.)

• Durability Test (24/7)

• Driving Cycle’s (NEDC, FTP75, WLTP, etc.)

• User defined tests (sequences, DoE etc.)

• FCCU Calibration and Optimization (CAMEO, etc.)

• Etc.

www.avl.com

THANK YOU

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Product Development in Motion 2017 - Home - avl.com