The Tailored Engine & Powertrain for 48V · Dr. Helfried Sorger AVL List GmbH (Headquarters) Public...
Transcript of The Tailored Engine & Powertrain for 48V · Dr. Helfried Sorger AVL List GmbH (Headquarters) Public...
Dr. Helfried Sorger
AVL List GmbH (Headquarters)
Public
The Tailored Engine & Powertrain for 48V
Dr. Helfried Sorger
Future Powertrain Conference
Birmingham, 28.02.2018
Comprehensive Solutions for Optimum Efficiency and Cost
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 2Public
SOME HEADLINES
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 3Public
2025Global Engine ProductionAVL Prediction 12/2016
120
100
80
60
40
20
0
Glo
bal
En
gin
e P
ro
du
cti
on
–M
io/
Year
Conventional ICE:• Significantly higher effort for emission compliance
(RDE, China6, SULEV xx, …),
• “Zero Impact Emission Concepts”
Mild Hybrid: • 48 V in various configurations P0 – P4
• Power Increase 15 20 30 kW
• ICE utilizes synergies
Full Hybrid: Primarily with Japanese OEM´s
Plug In Hybrid: CAFE and city access as driver
BEV: Dependent on infrastructure, incentives and access restr.
Fuel Cell: limited to specific markets?
Technologies until 2025
2025 50% electrified - still 100 mio ICE´s – but high scatter of predictions
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 4Public
Fuel efficient GasolineSolutions for Lambda=1 at full load
Specific λ=1 Power ICE [kW/l]
50 60 70 80 90 100 110 120 140
TGDI standard (wastegate TC) T3 ≤950°
TGDI IEM T3 ≤980°
TGDI MILLER IEM T3 ≤980°
TGDI MILLER IEM SC* T3 ≤980°
TGDI MILLER IEM SC-VGT* T3 ≤950°
TGDI VCR-VVL (var. MILLER) IEM T3 ≤980°
TGDI VCR T3 ≤1000° λ1
TGDI VCR-VVL (var. MILLER) IEM SC* T3 ≤980°
235
235
220
215
215
235
210
<205
RON95, typical PC enginesfrom measurements
Min. BSFC in map [g/kWh]
1D simu check
By projective 1D-engine
simulations
λ ≤1 / actual
λ =1 / RDE
TGDI-HY (fix MILLER) IEM SC* T3 ≤950°<205
TGDI MILLER IEM VGT T3 ≤950°218
TGDI, WI T3 ≤1030°
Currently upto 170 kW/l
Refined combustion• Improved knock : higher CR, accept GPF gen2 (higher backpressure)
• Refined charge motion extended Miller / Atkinson, increased EGR tolerance
• Advanced charging extended efficiency / spec. performance trade off
• Reduced emission & PN especially with cold drive-off (RDE 2)
• Full stoichiometric operation
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 5Public
Fuel efficient GasolineSolutions for Lambda=1 at full load
Specific λ=1 Power ICE [kW/l]
50 60 70 80 90 100 110 120 140
TGDI standard (wastegate TC) T3 ≤950°
TGDI IEM T3 ≤980°
TGDI MILLER IEM T3 ≤980°
TGDI MILLER IEM SC T3 ≤980°
TGDI MILLER IEM SC-VGT T3 ≤950°
TGDI VCR-VVL (var. MILLER) IEM T3 ≤980°
TGDI VCR T3 ≤1000° λ1
TGDI VCR-VVL (var. MILLER) IEM SC T3 ≤980°
235
235
220
215
215
235
210
<205
RON95, typical PC enginesfrom measurements
Series Compressor
IEM: (c-head) Integrated Exhaust Manifold
VCR: Variable Compression Ratio
VVL: Variable Valve Lifts
By projective 1D-engine
simulations
λ ≤1 / actual
λ =1 / RDE
TGDI-HY (fix MILLER) IEM SC T3 ≤950°<205
TGDI MILLER IEM VGT T3 ≤950°218
VGT: Variable Geometry Turbine
TGDI, WI T3 ≤1030°
WI: Water Injection
Currently upto 170 kW/l
AVLDual Mode VCS
SC: Series Compressor (intercooled)
Min. BSFC in map [g/kWh]
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 6Public
Low Emission DieselExtended RDE emission compliance
1,44
2,00
0,981,11
0,710,63
0,48 0,49
-2,4
-0,7
-6,3
-10
-8
-6
-4
-2
0
0
0,5
1
1,5
2
2,5
Fu
el C
on
su
mp
tio
n[%
]
Co
mp
lian
ce
Fa
cto
r (C
F)
[-] CF 2017: 2.1
CF 2020: 1.5
DIESEL –Walk towards CF<<1
• HP-EGR• HP-/LP /-EGR• 48V with 4kW Ecat• 48V with 4kW Ecat and
10 kW P0 e-Motor Boost / Recuperation
Reduction of Fuel Consumption &Emissions.
Example: PC 2.0L Diesel, HP EGR, LNT + SDPF, CW 1700kg
Compliance Factor
Total
Compliance Factor
CityFuel Consumption
Electrificationm to support Emission stability & CO2
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 7Public
Technology Trends Combustion Engine
Gasoline (SI)
Miller,Atkinson
today
Extended Miller,advanced boostingRefined emission
VCR, HCCI,.....
tomorrow
Extended 48V systems (1520>30 kW)
as enabler for low emission & CO2
48V
Diesel (CI)
Lean NOx Trap + SCR
Advanced EAS & Temperature Management, adapted operating strategy
Electrification as enabler for next refinement level of ICE
EAS … Exhaust gas Aftertreatment SystemHCCI ….. Homogeneous Charge Compression IgnitionVCR … Variable Compression Ratio
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 8Public
48V Powertrain architectures
P1
P2
P0
P3
P4
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 9Public
Features and functions vs. architectures
Function P0 P1 P2 P3/+P0 P4/+P0
Advanced stop start
Charging at standstill
Charging at driving
Recuperation
Boost
Sailing
Coasting
eCreep
Electric drive
Engine shutdown assist
Engine stall protection
eAWD
1)1) 1) 1)
1) 1)
1) 1)
1) 1)
1) MT with eClutch2) P2 with SSM
2)
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 10Public
+ + ++ ++ ++
0 + ++ + +/0
0 0 0 0 0
+ + ++ ++ ++
+ + 0 + +
+ + + + +
0 0 0 0 0
0 0 0 0 +/- 1)
1) Baseline vehicle with mechanical AWD
1)
Attribute P0 P1 P2 P3/+P0 P4/+P0
Fuel Consumption
Performance
Emissions - Gasoline
Emissions - Diesel
NVH
Drivability
Ride Comfort
Handling
Vehicle attributes vs. architectures
Rating:
0 … similar to baseline vehicle+ … better than baseline vehicle- … worse than baseline vehicle
P2 configuration combines best attributes with lowest complexity
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 11Public
0
100
200
300
400
500
600
700
800
900
1000
2 4 6 8 10 12 14 16 18 20
Recu
perati
on
En
erg
y [
Wh
]
E-Machine Size [kW]
WLTC
NEDC
HIGHWAY
C SegmentB Segment E Segment SUV (Diesel)
Recuperation Energy vs. ArchitecturesNEDC, WLTC, Highway
Significantly increased importance of
electrification by the higher dynamics of the
cycle
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 12Public
0,00
100,00
200,00
300,00
400,00
500,00
600,00
700,00
800,00
900,00
1000,00
1100,00
0 5 10 15 20
Recupera
tion E
nerg
y [
Wh]
E-Motor Size [kW]
Recuperation Potential
WLTC B P0
WLTC C P0
WLTC C P2
WLTC C P4
WLTC SUV-D P0
WLTC SUV-D P4
WLTC E P0
WLTC E P2
WLTC E P4
P0,P1P0,P1
P0,P1
P0,P1
P2
P3,P4
C SegmentB Segment E Segment SUV (Diesel)
Recuperation Energy vs. ArchitecturesWLTC - 48V up to 20 kW
P3,P4
P2
P3,P4
20kW is sufficientwith the exception of the heavy vehicles
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 13Public
0,00
100,00
200,00
300,00
400,00
500,00
600,00
700,00
800,00
900,00
1000,00
1100,00
0 5 10 15 20 25 30
Recupera
tion E
nerg
y [
Wh]
E-Motor Size [kW]
Recuperation Potential
WLTC B P0
WLTC C P0
WLTC C P2
WLTC C P4
WLTC SUV-D P0
WLTC SUV-D P4
WLTC E P0
WLTC E P2
WLTC E P4
P0,P1P0,P1
P0,P1
P0,P1
P2
P3,P4
C SegmentB Segment E Segment SUV (Diesel)
Recuperation Energy vs. ArchitecturesWLTC - 48V up to 30kW
P3,P4
P2
P3,P4
25 - 30kW is useful for• Heavy vehicles• Extended electric
driving
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 14Public
P0 as basic electrificationEspecially for smaller, cost sensitive segments
P2 is appropriate before 2020depending on individual fleet demand
Architecture comparison
2025 and beyond mandatory to meet severe CO2 legislation with significant mild hybrid market share
2025 and beyond not sufficient to meet severe CO2 legislation with significant mild hybrid market share
How to realize a P2 architecture?
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 15Public
In line 4 Cyl TGDI Base engine
Displacement [l] 1,6 Intake system CAC
Rated speed [min-1] 4850 Water pump Fixed ratio
Rated Power [kW] 120 Oil pump Fixed sump pump
Max Torque [Nm] 251 FEADA/C, tensioner, idler, W/P, alternator, PS pump
Start / Stop Yes Piston cooling Pressure regulated
In line 4 Cyl Diesel Base engine
Displacement [l] 1,5 Intake system CAC
Rated speed [min-1] 4000 Water pump Fixed ratio
Rated Power [kW] 80 Oil pump Fixed sump pump
Max Torque [Nm] 250 FEADA/C, tensioner, idler, W/P, alternator, PS pump
Start / Stop Yes Piston cooling Pressure regulated
Gasoline & Diesel Base engine VariantsIntegration in C-Segment Vehicle
Both with 12V e-SC + Long Final Gear Ratio
Base engines - state of the art
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 16Public
Electrified Gasoline & Diesel engineIntegration in C-Segment Vehicle
Fuel Tank Volume 50 Liter
Total Length 4250 mm
Total Width 1800 mm
Total Height 1460 mm
Wheelbase 2640 mm
Curb Weight (=dry weight) 1130 kg
Gross Weight 1450 kg
C-SEGMENT BASE VEHICLE
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 17Public
What can be electrified tosimplify the base engine?
Function
Eff
ect
on
p
erfo
rm
an
ce
Eff
ect
on
FC
& e
ffic
ien
cy
Packag
e
Cu
sto
mer v
alu
e
Fu
ncti
on
al
ris
k
Co
mp
lexit
y
red
ucti
on
Co
mm
en
t
Generator/E-machine + + O + O + P2 architecture
E-Water pump O + + O O +E-Oil pump O + + O - +AC compressor O O + + O + Mechanical and e-driven
PS pump O + + O O + Needed for pure e-drive
Vacuum pump O + + O O + Needed for pure e-drive
E-cam phaser + + + + O OE-Charger + + O + O O Highest potential in FC
E-catalyst O + O O O O Heating strategy
Supporting measures
Grill Shutter O + O O O O Reduction Air-Drag
Thermal encapsulation O + O + O O Faster Warm Up and Restart
o Basis 12V w BSG+SS
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 18Public
The ideal base engine for 48 VoltsFeatures
Removal of 12V starter motor
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 19Public
48V 20kW E-machine
Gear drive 1:3
Separation clutch C0
The ideal base engine for 48 VoltsFeatures
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 20Public
Elimination of FEAD
The ideal base engine for 48 VoltsFeatures
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 21Public
Repositioning of AC compressor at transmission side
The ideal base engine for 48 VoltsFeatures
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 22Public
Electrification of A/C compressor
A/C driven by engine
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 23Public
Electrification of A/C compressor
A/C electrically driven
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 24Public
Electrification of A/C compressor
A/C driven by wheels
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 25Public
Elimination of chain driven oil pump
The ideal base engine for 48 VoltsFeatures
Repositioning of oil cooler and filter
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 26Public
Combined oil cooler/filter module with e-pump
The ideal base engine for 48 VoltsFeatures
Elimination of conventional coolant pump
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 27Public
Introduction of electrical coolant pump
The ideal base engine for 48 VoltsFeatures
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 28Public
The ideal base engine for 48 VoltsFeatures
Electrification of vacuum pump
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 29Public
No front cover needed
No front sealing required
The ideal base engine for 48 VoltsFeatures
Damping element instead of TVD
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 30Public
Electrical cam phasers
The ideal base engine for 48 VoltsFeatures
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 31Public
The ideal base engine for 48 VoltsFeatures
Electrification of vacuum pump
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 32Public
Implementation of turbo charger with recuperation
potential
The ideal base engine for 48 VoltsFeatures
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 33Public
Electrical Waste Gate actuation
The ideal base engine for 48 VoltsFeatures
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 34Public
Catalyst heating element
The ideal base engine for 48 VoltsFeatures
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 35Public
Catalyst heating element
Electrical coolant pump
Oil cooler/filter module with e-pump
48V 20kW e-Motor
Electric Supercharger
Electric Cam-phaser
The ideal base engine for 48 VoltsFeatures – Diesel engine
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 36Public
DCT 7 speed transmission
The ideal base engine for 48 VoltsIntegration
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 37Public
Engine selective systems encapsulation
The ideal base engine for 48 VoltsIntegration
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 38Public
Electric brake booster
The ideal base engine for 48 VoltsIntegration
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 39Public
Active grill shutters
The ideal base engine for 48 VoltsIntegration
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 40Public
48V battery
The ideal base engine for 48 VoltsIntegration
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 41Public
▪ 550Wh usable energy
▪ LN7 size with increased height
▪ Air or water cooled depending on the requirements
▪ 9kg
▪ Design to ensure cold cranking under extreme conditions
48 Volts battery
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 42Public
DC / DC converter
The ideal base engine for 48 VoltsIntegration
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 43Public
Power electronics
The ideal base engine for 48 VoltsIntegration
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 44Public
The ideal base engine for 48 VoltsPackage Envelope almost neutral
+/- 0mm+60 mm- 40mm
+ 20mm
Additional e-motor drive assembly
Removal of FEAD and oil pump drive
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 45Public
Ideal base engine for 48vMinimised overall weight increase
4,5 kg18 kg
Production engine&
48V electrification
Electrified base engine&
48V electrification
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 46Public
Architecture optimizationby means of global vehicle simulation
Change of operating point in 3 dimensions:BMEP, engine speed and temperature
Outcome
Real-life Cycles
on the Road
Contribution of each sub-system to the operating conditions
Fuel consumption
f(BMEP, speed, T)
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 47Public
Impact of electrified auxiliariesCoolant pump in WLTC
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0 200 400 600 800 1000 1200 1400 1600 1800
Ener
gy r
elat
ive
to e
ngi
ne
[%]
cum
late
d p
ow
er [
kWh
]
Time [s]
Coolant Pump
Basis Mechanical controlled Electrical controlled
Absolute Energy
Energy relative to engine
Fuel consumption reduction potential for the coolant pump
~0.4%
Energy Requirement reduced by 50% with switchable coolant
pump main benefit enhanced
warm-up (not considered here!)
Energy requirement of electrical driven pump - coolant flow
controlled on demand
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 48Public
0
1
2
3
4
5
6
7
8
9
10
0
0,02
0,04
0,06
0,08
0,1
0,12
0,14
0 200 400 600 800 1000 1200 1400 1600 1800
Au
xilia
ry e
nerg
y r
ela
tive t
o e
ng
ine [
%]
Au
xilia
ry c
um
late
d p
ow
er [
kW
h]
time [sec]
Cumulated mechanical power of auxiliariesduring WLTC
HT Coolant Pump Oil pump Steering pump
Vacuum pump Idlers Auxiliaries (sum of)
Sum relative to engine
Impact of electrified auxiliariesUp to 4% CO2 reduction in WLTC
Auxiliaries (sum of) relative to engine [%]
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 49Public
Impact of 48V hybridization on gasolineUp to 13% CO2 reduction in WLTC
Base engine thermal encapsulation not includedNot active vehicle grill shutters
Significant e-Drive capability and energy recuperation in WLTC
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 50Public
60
65
70
75
80
85
90
95
100
105
110
CO2 [g]
48V Diesel Engine 48V Gasoline Engine
CO2 optimzation potential comparison of 48V Diesel and Gasoline in WLTC
FEAD Additional VTMSOptimisedBaseline
48V Hybrid
12V D
iesel
12V G
as
𝚫 =17,5g CO2
-20,50%
-21,70%
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 51Public
Cost to benefit vs. architectures
C Segment Gasoline
B Segment E SegmentSUV
(Diesel)
Assumptions:>500.000 units p.a.Established supplier base for 48VBase engine modificationsconsidered
Cost / CO2 Range
<= 80 €/(gCO2/km)
<= 60 €/(gCO2/km)
<= 40 €/(gCO2/km)
<= 20 €/(gCO2/km)
C Segment Diesel
Attractive cost to benefit
ratio for P2
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 52Public
CO2 Reduction - WLTC [g/km]
Cost to benefit vs. features
Assumptions:>500.000 units p.a.Established supplier base for 48VBase engine modifications considered
Ad
d O
n B
OM
Cost
[€
]
AS
SP
<= 80 €/(gCO2/km)
Turbo with recuperation (TR)
<= 40 €/(gCO2/km)
48V Hybridization of powertrain 48VE-machine, 48V Battery, DC/DC Conv
Oil pump (OP)
<= 20 €/(gCO2/km)
Water pump (FMEP+control) (WP)
Active shutters (AS)
<= 10 €/(gCO2/km)
Steering pump (SP)
Vacuum pump (VP)
Engine encapsulation (EE)
OP
TR
VP
EE
WP
48V
Summary of all features
35€/g CO2 km
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 53Public
➢ 48V Mild Hybrids will achieve significant market share
➢ Overall CO2 Reduction from 20,5 up to 21,7% in WLTC
➢ Dedicated 48V Base Engine
➢ Powertrain Vehicle integration
➢ Energy Management
➢ Thermal Management
➢ Product Cost Improvement
Benefit from AVL’s system approach
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 54Public
Dedicated beltless engines for 48V introduced in 2017
M 264 – Der neue Mercedes-Benz 4-Zylinder Toptype-Ottomotor
mit 48V-Elektrifizierung
M 256 – the new Mercedes-Benz high-performance six-cylinder
in-line gasoline engine with intelligent 48V electrification
(SOURCE: DAIMLER AG, 38TH VIENNA ENGINE SYMPOSIUM 2017)
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 55Public
48V – AVL is ready
• The Ideal Base Engine for 48 Volts – Chances for Efficiency Improvement and Optimization of the Overall System Complexity (Aachener Kolloquium – Lecture Aachen & Beijing 2015)2015
• Engine Technology International – The optimized engine concept for 48 Volt (ETI 09/2016)
• Der Einfluss von 48 V auf Grundmotorreibungs- und Effizienzoptimierung –Ansatz zur Quantifizierung in zukünftigen Fahrzyklen (ATZ - Lecture 11/2016)
• Vehicle Integration of a new engine concept for 48 Volts – Opportunities for Efficiency improvement and optimization of the overall system complexity (Motorenkongress Baden-Baden –Lecture 02/2016)
2016
• The ideal Powertrain for 48V – Comprehensive Solutions to Efficiency and Cost Optimization (MTZ 05/2017)
• The tailored powertrain for 48V – Options for the Gasoline Engine –Chance for future Diesel Engines (HDT München - Lecture 04/2017)
• The tailored powertrain for 48V – Options for the Gasoline Engine –Chance for future Diesel Engines (Motorenkongress Baden-Baden - Lecture 02/2017)
• Elektrifizierung des Fahrzeugantriebs mit 48V Architektur (Essay SHW Geschäftsbericht 02/2017)
2017
Dr. Helfried Sorger | PTE - D2 | 26 Februar 2018 | 56Public
AVL - Rightsizing the electrification