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ELECTRIFICATION OF VEHICLE DRIVE TRAIN –
THE DIVERSITY OF ENGINEERING CHALLENGES
A3PS – Conference, Vienna
Dr. Frank Beste AVL List GmbH
Motivation for Powertrain Electrification
Global Megatrends:
Urbanization and mobilization
Environmental Care
Demographic Challenge
Motivation for Powertrain Electrification:
Replacement of energy generated by an ICE by regenerative electric
energy supplied by the electric network
Maximising the recovery of braking energy during vehicle deceleration
Reduction of power consumption of auxiliaries by strictly demand
oriented operation
Shifting of engine operation points towards map areas of best BSFC or
lowest specific pollutant emissions
Customer oriented new vehicle package concepts
3 Hybrid Types and Functionalities
IC Engine
Transmission
Fle
xib
ility
high small mediu m≈ C
os
t,
Co
mp
lex
ity
& R
isk
Control
Battery
Electric Motor
10 SI Powersplit Hybrid Battery IC Engine Trans-mission Electric Motor Control Strategy Flexibi lity Fully Variable SI Engine
+ Man. Transmission Standard IC Engine + Autom. Transm. Battery IC Engine Trans-mission Electric Motor Control Strategy Flexibi lity Battery Trans-mission Electric Motor Control Strategy Flexibi lity Electric Vehicle + Range Extender Battery IC Engine Trans-mission Electric Motor Control Strategy Flexibi lity
Internal Combustion Engine Electric Motor
Battery
E- Motors Battery
ICE Battery E- Motors
ICE
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Typically non linear optimization task
Often there is no single optimum
Optimization methodology, development,
production, operation boundaries and recycling
bias the technical solutions
Changing cost structure of electric components
will redirect the technical solutions
Legal requirements might influence the size of
energy storage units
AVL electric vehicle
Plug-in vehicle demonstrator designed for mega-city driving
AVL Range Extender System for at least 250km driving range
Demonstrator
Î No passenger compartment restrictions
Î Acceptable cost of energy storage system
Î Competitive driving performance
Î No performance restrictions with Range-Extender operation
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Drive Distance [km]
0% 1% 2% 3% 4% 5% 6% 7% 8% 9% 2,50 27,50 52,50 77,50 102,50 127,5045% of vehicles do not exceed 30 km and account for 20% of total driving
>70% of vehicles do not exceed 50 km (50% of annual mileage)
30 50 100 [km]
City Vehicle (EV)
All Purpose Vehicle
City Vehicle (EV) + RE
Reference: IVT, 2004
€ 0 € 2.500 € 5.000 € 7.500 € 10.000 € 12.500 € 15.000 € 17.500 € 20.000 € 22.500 € 25.000 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 500 € / kWh 250 € / k Wh
Battery Costs - based on energy consumption of 20 kWh / 100km
Range [km] 12.200 € Saving 5.400 € Saving AER pure EV > 300
Total Range
with RE
AER with RE RE Cost RE CostAER = All Electric Range Battery Cost Comparison
18 100 %
State Of Charge
Run time
Technical Minimum
Energy Reserve
Energy Reserve - Recharging StrategyIf RE starts here: RE performance according to E-Drive If RE starts here: performance according to max.
1. NVH, Comfort
2. Reliability
3. Package and Weight
4. Costs
5. Performance / Efficiency
20 Concept Study: Direct Drive
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Engine configuration: Single disk rotary engine Displacement : 254 cc
Power: 18 kW @ 5000 rpm Fuel consumption: 260 g/kWh
Generator concept: Permanent magnet synchronous machine Thermal management: Single circuit liquid cooling
Controller: AVL rapid prototyping control unit
Software: Module embedded SW and CAN interface Electric output: 15 kW @ 320 – 420 V (12 kW above 250 V) Max. performance scaling potential: up to 36 kW electric output (= 240%)
1m averaged sound pressure: 65 dBA
System box dimension (L x H x W): 490 mm x 400 mm x 980 mm Engine – generator unit weight: 29 kg
Module weight: 65 kg
29 System Integration
Acoustic Optimization
65dB(A) 65dB(A)
31 Vehicle Integration
Range Extender integrated
in vehicle back
Battery system in front of rear axle
and in middle tunnel
75kW traction motor in vehicle front:
- acceleration 0 – 60km/h: 6sec
- top speed 130km/h
AVL Pure Range Extender
High Voltage Li-Ion Battery Traction Motor
Development Content
BATTERY DESIGN AND SIMULATION
BATTERY INTEGRATION
BATTERY TESTING AND VALIDATION
AVL ELECTRIC VEHICLE
with Range Extender
AVL ELECTRIC VEHICLE
with Range Extender
Optimized, reliable and fully integrated battery system development to maximize vehicle fuel economy potential:
Requirement development
Design and integration of battery system Function and software development
Robustness and safety
Testing and validation Battery benchmarking
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Simulation Approach
Thermal performance analysis of battery modules
•Current and temperature distribution •Identification of hot spots
•Definition of cooling requirements
Thermal-electric cell characterization
•Empirical Cell Model
•Thermal-Electric FE - Analysis
Vehicle simulation (AVL-CRUISE™)
•Determination of load pattern
•Optimization of hybrid-/ electric-control strategy
Battery thermal management simulation
(FLOWMASTER)
• Improved thermal management strategy •Improved battery cooling system
•Improved battery performance and lifetime -20 -10 0 10 20 30 40 50 60 0 200 400 600 800 1000 1200 Time [s] Po w e r [ k W ] -20 -10 0 10 20 30 V e lo c ity [m /s ] E-motor_mech_power <W> Velocity <m/s> Battery Circuit AC-Circuit
• General material properties • Cell performance specification • Cell geometry
• Cell charge / discharge characteristics
• General material properties • Cell performance specification • Cell geometry
• Cell charge / discharge characteristics
Input
Simulation
Æ
A key discipline within the requirement engineering process …
From Cell-Level to Battery-Pack37 Contact
