1 ICAT - Istanbul 13.11.08 GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH 2008. All rights reserved,...

1

ICAT - Istanbul 13.11.08

GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Dr. Jan LichtermannDirectorHybrid SystemsGasoline Systems

The Electrification of

Powertrain

2



1 Introduction

2 Market

3 Systems

4 Components

3



Safe ResourcesClimate Protection

Non-renewable ResourcesCO2 Emissions

Worldwide Environmental Challenges

4



Development in Powertrain Technology (Examples)

1967 1967 20002000 20062006 2007200719861986

Start/Stop System

Electronic Diesel Injection

Electronic Gasoline Injection

20032003

3rd Gen. CR with Piezo Injectors

2008ff …2008ff …

Gasoline Direct Injection

GDI with Piezo Injectors

1976 1976

Lambda Sensor for three-way Catalytic Converter

Hybrid Drives

Hybrid Drives are the latest technology milestone for CO2 reduction

5



Ford-Escort, DC-Motor

35 years Experience in Hybrid Technology

1973

6



Hybrid Engineering Center in Tamm

Test Center

De

velo

pm

en

t T

ea

ms Electrical-Drive,

Hybrid Systems,Software,Braking Systems

Cu

sto

me

r T

ea

ms

EuropeKorea,Japan, China,USA

Ad

min

istr

ativ

e

Te

am

s

Management,Marketing,Controlling,Quality-Management,Purchasing,Administration

T o t a l S t a f f 320

7



1 Introduction

2 Market

3 Systems

4 Components

8



Drivers Powertrain Electrification

Country-Taxes

Base: progress in battery technology

CARB 35mpg

EU CO2-Legislations

CaliforniaZEV-credits

Oil reserves &Fuel prices

City restrictions:Paris, London,…

Convent. ICE: increasing penetration of 14 V Start/Stop Systems

HEV: Affirmation of trend

PHEV: increasing importance in US and Japan

EV: pushes EV technology e.g. battery

Green-Image Business models:Agassi, Think Global

Drivers

9



0

2.000

4.000

6.000

8.000

10.000

12.000

14.000

2008 2015

3.000

7.450

3.850

650

Electro vehicle,Plug-in hybrid

Liquefied gas(Liquefied Petroleum gas, LPG )

Natural gas(Compressed NaturalGas, CNG)

Hybrid

Flex-Fuel

volu

mes

(100

0) veh

icle

s

5.000

12.000

Market development alternative drives world-wide

2

350

10



1 Introduction

2 Market

3 Systems

4 Components

11



System strategy HEV, PHEV, EV

-+12V

HV1.3kWh

-+

Inverter20kW

12 V Gen HV-GEN S/S + 12 V Gen. HV-BSG

Inverter60kW

Charger

-+HV

12kWh

Inverter60kW

Charger

-+HV

12kWh

HEV PHEV 1 PHEV 2 w./ r.e.

EV Convent. ICE

-+HV

12kWh

Charger

Inverter85kW

12



Powertrain Electrification (Subcompact class)

20

10

1 – El. Mix 2006, 2 – ECE R(101), 3 - a <0,3g, vmax 130km/h, 4 – SoC Swing 20%, 5 – SoC Swing 70%, >20Ah/cell6 – Tax of el. Energy as today, Battery cost included in vehicle price

CO2 [g/km](Well to Wheel) 1

140 120 93 88

80 (EU)

El.Range [km] - 2 120 50 802

VehicleWeight [kg] 1100 1250 target

800 1453 target

1000Max. El. Power. [kW] - 20 603 603 853

Energy Batt. [kWh] - 1,34 125 125 125

Cons.. [€/km]

0,11 0,09 0,056 0,046 0,026

EV gets attractive, if: Battery available with sufficient energy density Lightweight design of vehicles realized Electric energy cost does not increase dramatically


EV Convent. ICE

13



Hybrid Architectures with Parallel Energy Flow P2 Parallel Hybrid

(AT w/ 2 clutches)AT with clutch as launch element

TS Torque Split Hybrid (eDCT)DCT w/ integrated electric drive

AS Axle Split (eAD)Conventional drive train pluselectric axle drive (eAD)

engine

imp. starter

12Vgen.

DCT

engine

imp. starter

12Vgen.

DCT

motordual clutch

engine

DCT

motordual clutch

engine

DCT

engine motor

clutch 1

AT

clutch 2IMG

SMG

EV Electric vehicleElectric axle drive

14



1 Introduction

2 Market

3 Systems

4 Components

15



Components for HEV, PHEV, EV


EV Convent. ICE

Inverter withDC/DC* Converter

Integrated E-Machine

incl. clutch

Separated E-Machine

Engine Management

Brake Systems

Transmission Control

Charger

Li-Ion Battery

Battery Management

16



Product Line IMG and SMG E- Machines

15kW

SMG 138

IMG 300

IMG 290

IMG 260

Nmax=6800rpm

SMG 180Nmax=14.000rpmNmax=18.000rpm

170Nm 200Nm

70Nm 100Nm

Le[mm]0 22 55 77 100 200150

Iron lengths scalable in steps of 11 (IMG) or 10 (SMG) mm

100

Do[mm]

150

250

300

200

300Nm

150Nm

Peak torque

Nmax: max. operational speedDo: Outer stator diameter (active parts)Mech. power 10-40kW, dep. on battery

Le

Le

IMG

SMG

17



Axle parallel system with e-drive disconnection clutch# gears

Advantages side mounted coaxial

1

low complexity Cost effective solution no gear switching

operation Compact, low weight

2

High torque for driveaway / acceleration.

Enhanced regeneration capabilities.

Optimization of efficiency.

Cooperation Bosch – Getrag in development of Electric Double Clutch Transmission and Electric Axle Drive for Parallel Hybrid Systems.

Cooperation Bosch – Getrag in development of Electric Double Clutch Transmission and Electric Axle Drive for Parallel Hybrid Systems.

18



UN=288 V =/~

300 Aeff

=/= 12V; 3kW (~200A)

PSM

HV-Battery InverterE-Machine300Nm/34kW

12V-Battery 12V-Powernet

DC/DC-Converter

control unit

HW & SW

power supplycontrol signals / vehicle functions

communicationlines (CAN, LIN, Flexray)

Functional overview – Power Electronics

19



Voltage range up to 400VDC DC/DC-converter (Integrated; bidirectional) Water cooling 85°C MED17-control technology Double inverter option

Gen2 - SoP 2010

Power Electronics

Gen 1

Cooler with DC capacitor and (DCDC-) inductances

Mounting fixture

DC/DC and bottom housing

Power module

Phase connections with current sensors

Pressing plate for power module

Housing cover with control board and gate drivers

20



Battery JV Bosch Samsung

OEM Customers

Scope of Business: Li-ion battery technology for automotive power-train and board-net

applications

SB LiMotive Co. Ltd. 50% 50%

21



Thank you for your attention

Conclusion and Questions

1 ICAT - Istanbul 13.11.08 GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH 2008. All rights reserved,...

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Transcript of 1 ICAT - Istanbul 13.11.08 GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH 2008. All rights reserved,...