Post on 10-Feb-2021
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
Flins 15 Décembre 2016 2Property of Valeo – Duplication Prohibited
Function electrification
Low voltage Road-Map
Conclusion
Driver for hybridization : CO2 regulationsMain issue of hybrid / electric: COST!
China 2020(cars only):106
Flins 15 Décembre 2016 3Property of Valeo – Duplication Prohibited
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
Flins 15 Décembre 2016 4Property of Valeo – Duplication Prohibited
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
Flins 15 Décembre 2016 5Property of Valeo – Duplication Prohibited
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 ● ● ● ●
Flins 15 Décembre 2016 6Property of Valeo – Duplication Prohibited
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
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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
Flins 15 Décembre 2016 10Property of Valeo – Duplication Prohibited
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
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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
Flins 15 Décembre 2016 12Property of Valeo – Duplication Prohibited
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
Flins 15 Décembre 2016 13Property of Valeo – Duplication Prohibited
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
12V “clean” network12V “regen” network
Reversible Machine Starter + Alternator 12V 12V NON
Flins 15 Décembre 2016 14Property of Valeo – Duplication Prohibited
12V + 48VStarter
Reversible Machine 48V
DCDC48-12 V
eSC
12V “clean” network48V “regen” network
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
Flins 15 Décembre 2016 15Property of Valeo – Duplication Prohibited
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
Flins 15 Décembre 2016 16Property of Valeo – Duplication Prohibited
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
Systems CO2 gains / cost position
48V mild hybrid : more power and more energy availa ble
First and easier step : belt e-machine.
Flins 15 Décembre 2016 17Property of Valeo – Duplication Prohibited
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
Systems CO2 gains / cost position
Flins 15 Décembre 2016 18Property of Valeo – Duplication Prohibited
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
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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
Flins 15 Décembre 2016 20Property of Valeo – Duplication Prohibited
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
12V “clean” network48V “regen” network
48V Battery
12V Battery
48V NON Sensitive
Loads
12V Non Sensitive
Loads
12V Sensitive
Loads
48V 12V
StarterEfficiencyWeight
Flins 15 Décembre 2016 21Property of Valeo – Duplication Prohibited
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
Flins 15 Décembre 2016 22Property of Valeo – Duplication Prohibited
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
Flins 15 Décembre 2016 23Property of Valeo – Duplication Prohibited
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
Flins 15 Décembre 2016 24Property of Valeo – Duplication Prohibited
Thank you for your attention