eMobility –

Passing the baton from fossils to electrons

Octavio Vargas, PhD

Program Manager, eMobility

Historical perspective – late 19th century

FOSSIL FUELS ELECTRIC

1) High energy density

2) Cost

3) No air pollution concerns

1 Octavio Vargas

1885 1899

Schaeffler Symposium 2014

Society Technology

Biosphere Economy

2

Megatrends in mobility

"Mobility for Tomorrow"

Octavio Vargas Schaeffler Symposium 2014

Powertrain electrification driven by CO2 legislations

CO2 legislation worldwide

60

80

100

120

140

160

180

200

220

240

260

2000 2005 2010 2015 2020 2025

China: 117 g

in 2020

EU: 95 g

in 2020

Japan: 105 g

in 2020

USA: 107 g

in 2025

EU: 68-78 g

in 2025

Source: icct 2013

Light vehicles

in g CO2

Proposed target

Enacted target

USA: incl. light duty vehicles

Light vehicle production

2013 2020 2030

Powertrain concepts

98%

80%

56%

2%

19%

35%

1%

9%

Hybrids Electric

Source: : IHS 2013; University of Duisburg-Essen 2012

Combustion engines

3 Octavio Vargas Schaeffler Symposium 2014

Powertrain electrification driven by CO2 legislations

Powertrain concepts

Hybrids Electric

Light vehicle production

Source: : IHS 2013; University of Duisburg-Essen 2012

2013 2020 2030

Combustion engines

98%

2%

80%

19%

1%

56%

35%

9%

44%

4 Octavio Vargas Schaeffler Symposium 2014

Powertrain electrification – Schaeffler's roadmap

Powertrain concepts

Hybrids Electric

Light vehicle production

Source: : IHS 2013; University of Duisburg-Essen 2012

Combustion engines

2013

98%

2%

2020

80%

19%

1%

2030

56%

35%

9%

5 Octavio Vargas Schaeffler Symposium 2014

6

P2 – hybrid module

Hybrid Module 2nd Gen with dry clutch

+ -

Between engine and transmission

Hybrid module 2nd gen with integrated

electronics

P2-hybrid module 1st generation

Octavio Vargas Schaeffler Symposium 2014

7

Reduced axial space by 17 mm

Electrical sailing up to 100 miles/hr

Applicable to all types of transmissions

P2 – hybrid module 2nd generation

Octavio Vargas Schaeffler Symposium 2014

8

Hybrid electric drivetrain architectures

Parallel

Power split

Serial Widest range of applications

Based on known drivetrain technologies

Only one E-Motor is needed

* *

Micro Micro Mild Full electric Plug-in Range extender

Octavio Vargas Schaeffler Symposium 2014

9

Hybrid modules

Micro Mild Full Plug-in Range extender Hybrid

Hybrid – modules

Modular solutions for all levels of hybridization!

Parallel

Octavio Vargas Schaeffler Symposium 2014

Powertrain electrification – Schaeffler's roadmap

Hybrids Electric Combustion engines

2013

98%

2%

2020

80%

19%

1%

2030

56%

35%

9%

10 Octavio Vargas Schaeffler Symposium 2014

Product portfolio electric axle systems

Low power

electric axle

Degree of electrification Regeneration

Mini hybrid vehicles (48V)

CO

2 p

ote

ntia

l / f

un

ctio

nalit

y

Mechanical torque

vectoring

2-speed

electric drive

2-speed electric

drive (parallel axis)

48V HV

11 Octavio Vargas Schaeffler Symposium 2014

12

48V axles – why 48volts?

12V

48V

HV

Higher power output

Smaller cable cross-

sections -> lower

current losses

~10-12% less fuel consumption

and CO2 emissions

Low implementation costs

New CO2 regulations

Up to 12 kW of traction power

AFFORDABLE POWERTRAIN

ELECTRIFICATION

Reduced safety

requirements

Low cost system

Octavio Vargas Schaeffler Symposium 2014

CO

2 R

eduction [

%]

- 5.6

- 8.6

- 9.8

12V Functions

- 5

Start/Stop

- 3

+Smart

Alternator

48V axles – CO2 reduction potentials (e-segment car)

+eSailing

(ICE idle)

+eSailing

(ICE off)

Load point

shift

(Delta between 12 V

and 48 V) = up to 7%

with additional

functionalities

-14.8%

- 8%

- 2.7

1-speed

48 V Functions

+eCreeping

(10 mph)

2-speed

Schaeffler Symposium 2014

All

rights

reserv

ed t

o S

chaeffle

r T

echnolo

gie

s A

G &

Co.

KG

, in

part

icula

r in

case o

f gra

nt

of

an IP

rig

ht.

Front wheel drive Rear wheel drive eAWD All wheel drive

48V axles – vehicle architectures

P3 P2 P4 elect. P0 – P3

14 Octavio Vargas

Schaeffler Symposium 2014

Product portfolio electric axle systems

Low power

electric axle Degree of electrification

Hybrid vehicles

(HEV, PHEV)

Electric vehicles

(BEV)

Regeneration Electric driving Plug-in

charging

Zero emission

mobility

New vehicle

concepts

Mini hybrid vehicles (48V)

CO

2 p

ote

ntia

l / f

un

ctio

nalit

y

Mechanical torque

vectoring Mechanical TV

2-speed

electric drive

2-speed electric

drive (parallel axis)

48V HV

15 Octavio Vargas Schaeffler Symposium 2014

Weight ca. 60 kg

Power output 65 kW

Dimensions 230 x 423

Maximum torque 2000 Nm

Maximum speed of vehicle > 260 km/h

Customer benefits

o Compact coaxial electric transaxle

o Modular system 1- or 2-speed

o Suitable for HEVs and BEVs as well

o Good scalability of power level

o Customer tailored scope of delivery

Technical Data Traction

motor 2 speed

transmission

Spur gear

differential

Electric axle drive gen III – HV system

16 Octavio Vargas Schaeffler Symposium 2014

Traction Motor

Transmission Differential

Traction Unit

60 kW

Traction

6kW

TV-Transmission

TV-Motor

TV-Unit

Torque Vectoring +

Torque vectoring – basic configuration

17 Octavio Vargas Schaeffler Symposium 2014

2000 Nm -2000 Nm

2000 Nm

-2000 Nm

70kW 70kW

60kW 6kW

Traction [Nm]

TV [Nm]

33kW 33kW

Torque vectoring system

18 Octavio Vargas Schaeffler Symposium 2014

AD

Improved traction

AD

Dynamics & safety

AD

Steering support

AD

High comfort

Torque vectoring – benefits

19 Octavio Vargas Schaeffler Symposium 2014

TV power electronics

TV electric

motor

Traction electric

motor

Gear shifting

actuator

Actuator control unit

Electric axle drive gen III with torque vectoring

20 Octavio Vargas Schaeffler Symposium 2014

65 kW

65 kW

85 kW

Electric motor (scalable)

1 Planetary gear set

2 Planetary gear set

Spur gear differential

Transmission actuator with ECU

Torque vectoring unit

Other components

2 speed, TV

2 speed, N 1 speed, N 1 speed

2 speed, N 1 speed, N 1 speed

eAxle – modular concept

21 Octavio Vargas Schaeffler Symposium 2014

Powertrain electrification – Schaeffler's roadmap

Powertrain concepts

Hybrids Electric

Light vehicle production

Source: : IHS 2013; University of Duisburg-Essen 2012

Combustion engines

2013

98%

2%

2020

80%

19%

1%

2030

56%

35%

9%

22 Octavio Vargas Schaeffler Symposium 2014

Maneuverability Extended steering angle

Usable space In-wheel drive train

Safety High control quality

Customer benefits

23 Octavio Vargas Schaeffler Symposium 2014

Power electronics

Friction brake

Motor

Liquid cooling system

eWheel 2nd generation: prototype cross section

24 Octavio Vargas Schaeffler Symposium 2014

25

eWheel – exploded view

Octavio Vargas Schaeffler Symposium 2014

Powertrain electrification

Schaeffler's solutions

2020 2030

Hybrids Electric Combustion engines

2013

98%

2%

80%

19%

1%

56%

35%

9%

HYBRID MODULE:

• Modular Concept

• 15-30% FE

• P2 configuration

eAXLE:

• 48V or HV variants w or w/o TV

• Coaxial / in-parallel design

•1-speed / 2-speed configuration

eWHEEL:

• Innovative product

• Integral compact design

• New vehicle configurations

26 Octavio Vargas Schaeffler Symposium 2014

It is not the strongest or the most

intelligent who will survive but those who can best manage change.

” ‟

Charles Darwin

1809 - 1882