12V / 48V Hybrid Vehicle Technology - Steven Kowalec www.continental-corporation.com
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12V / 48V Hybrid Vehicle Technology Steven Kowalec www.continental-corporation.com Powertrain Division
Powertrain Electrification Technology
Mi
Micro-hybrids
h b id to
t BEVs
BEV
Fuel
ue saving
sa g with
t low
o voltage
o tage Fuel saving
ue sa gaand electric
de ect c 100
00 % eelectric
ect c
ystem Costs
technology driving driving
CO2 Reduction Potenttial
Sy
Degree of Electrification
APEC 2017
PUBLIC Steven Kowalec © Continental AG 2
Electrification Tailored-to-Fit
Mild H
Hybrids
b id - True
T Fit With Every
E Segment
S t
Electric 60 -150 kW 100%
Vehicle
Plug-in 60 -120
120 kW 50 - 75% High Voltage
Hybrid Axle Drive
High Voltage
Full 20 - 40 kW 20 - 30% Power Electronics
Hybrid
y
48 V Belt
48V Mild 5 - 15 kW 13 % Starter
Hybrid 48 V DC/DC Generator
Converter
12V Micro < 5 kW 3-4 % Voltage Stabilization
Hybrid System
A B C D E CO2 Saving
E-Motor
Potential in
Power Vehicle Segment
NEDC
Indicates segments in which the technology is most often applied.
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PUBLIC Steven Kowalec © Continental AG 3
Micro-hybrid Technology
Voltage
V lt Stabilization
St bili ti System
S t (VSS) and
d
Dual Battery Manager (DBM)
VSS
DBM
(example)
Secondary
energy storage
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PUBLIC Steven Kowalec © Continental AG 4
Powertrain Outlook 2030
P kC
Peak Combustion
b ti E Expected
t d iin 2025 - 2027
Global PV/LV Production* Global PV/LV Production*
Propulsion Split Electrification View
[mn. vehicles]
Vehicle Electrification is
making a decisive step
120 forward
Peak
100 › Cost optimized 48V
solutions will be found in
80 each Mid class car in mature
markets.
60
› Long term…pure EV will win
40 the race against hybrid
solutions
20
0
2015 2020 2025 2030 2015 2020 2025 2030
EV 48V Gasoline EV PHEV FHEV 48V
PHEV CNG/LPG
M/FHEV Diesel * Source: IHS, own estimates
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PUBLIC Steven Kowalec © Continental AG 5
Powertrain Outlook
Gl b l PV/LV Engine
Global E i Production
P d ti (2015-2030)
(2015 2030)
World – Combined View
[mio-units]
120 0
120,0
11%
PHEV+EV 4%
3% 3%
3% 5%
100,0 4% 7%
1% 4% EV
2% 1% 13%
1%
2%
48V PHEV
22%
80,0 18% M/FHEV
20%
14%
48V
10% 2%
9% 6% CNG/LPG
60,0 12%
14%
Diesel
4% GDI
29%
4% 30%
40,0 GDI (TC)
22% PFI (TC)
4%
2% PFI
20,0 49% 1%
27% 17%
21%
0,0
2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030
Source: Continental
Continental, IHS Rounding may cause percentages not to sum up exactly to100%
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48V Technology – More than a Mild Hybrid
St t i Over
Strategies O and
d Above
Ab CO2 Reduction
R d ti
› 48V electrification is primary driven by
CO2 reduction
› Future powertrain topologies with 48V
enable even higher CO2 savings
› Regenerated energy can be utilized for
safety, comfort and efficiency functions
› Allocation of electric components to the 12V
and 48V board net must be considered
› Maximum benefit can be achieved with a
predictive driving strategy via
connected energy management
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PUBLIC Steven Kowalec © Continental AG 7
48V Hybrid Vehicle Technology
12V 48V Ad
Adaptation
t ti
› Conventional 12V boardnet › 12V with additional 48V boardnet
› P0 implementation shown
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48V Topology
BMS DCDC C
BMS, Converter,
t IInverter,
t M Motor/Generator
t /G t
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48V Technology
48V Battery
B tt M
Managementt S
System
t (BMS)
› Protect the energy storage system against
over-current, over-discharge, over-load
› 14 Cell measurements and balancingg
› Battery pack and 48V DC link measurements
› Current and thermal measurements
› Contactor(s) and Fan control circuitry
› State-of-Charge (SOC)
› State-of-Health (SOH) 48V BMS
› State-of-Function (SOF)
500Wh battery used in Conti 48V
demonstration vehicles
APEC 2017
PUBLIC Steven Kowalec © Continental AG 1048V DC/DC Scalability
M d l Concept
Modular C t
48V/12V DC/DC 800W to 3.2kW
800W 1600W 2400W 3200W
1 Phase 2 Phases 3 Phases 4 Phases
› Bi-directional operation (voltage/current controlled)
› Precharge functionality for 48V DC link
APEC 2017
PUBLIC Steven Kowalec © Continental AG 1148V Technology
B lt St
Belt Starter
t G Generator
t (BSG)
Motor 1 Motor 2
Parameter
60mm 40mm
Maximum Start Torque
~50Nm ~30Nm
Typ. & (@-25°C, 0.5s)
M
Max. peak
k power ~13
13 kW mot ~13
13 kW mot
~14 kW gen ~14 kW gen
Cont. Power ~6 kW mot ~6 kW mot
~7 kW gen ~7 kW gen
C li Fluid
Cooling Fl id
-40°C…+115°C -40°C…+115°C
Temperature
Communication
CAN, LIN, FlexRay
Interfaces
Weight ~13kg ~10kg
Integrated
Length: Inverter
Length:48V Technology
B lt St
Belt Starter
t G Generator
t (BSG)
General Functions:
› Combustion engine start (standard cold
and warm start)
› Boost (electrical assistance)
› Recuperation (regenerative braking)
› Generator
› IC Engine Shaft positioning
› IC E
Engine
i Operating
O i point
i shift
hif Integrated
Inverter
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PUBLIC Steven Kowalec © Continental AG 1348V Technology
B lt St
Belt Starter
t G Generator
t (BSG) Configurations
C fi ti
P0 P2
› CO2 potential: -13% › CO2 potential: -22%
› 48 volt introduction › Maximum recuperation capability
› Integration in existing belt drive architecture › Electrified auxiliaries, eParking, eCreeping,..
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PUBLIC Steven Kowalec © Continental AG 1448V System
BSG Operating
O ti StStates
t
* eLaunch * Charge * Boost * Sailing * Coasting * Recuperation
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PUBLIC Steven Kowalec © Continental AG 15Connected Energy Management (cEM)
Di
Driver Guiding
G idi Functions
F ti
Static eH
Connected eHorizon Backend
Dynamic eHorizon
Topology ADAS HD Map and Dynamic
Localization Data
› Deceleration Assist
› Traffic Light
g Assist
› Slope Assist
› Curve Assist
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PUBLIC Steven Kowalec © Continental AG 1648V In the Real World
C
Coasting
ti as significant
i ifi t fuel-savings
f l i strategy
t t
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PUBLIC Steven Kowalec © Continental AG 1748V Technology
Additi
Additional
l fuel-saving
f l i strategies
t t i
› Due to the limitations on the existing 12V
boardnet
b d t strategies,
t t i the
th market
k t may soon
decide that adoption of 48V consumers is
necessary to provide customers with
features desired.
Component Peak Power [W]
PTC H
Heater
t ≤ 4 kW
AC Compressor ≤ 3.5 kW
Electronic Roll Control (ERC) ≤ 3 kW
Smart Cooling Pump ≤ 400 W
Fluid Pumps ~ 200 W
Front Windshield Heating ≤ 700 W
EH Brake System
EH-Brake ≤ 900 W
E-Compressor 3 kW - 7kW
E-Steering ≤ 2 kW
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PUBLIC Steven Kowalec © Continental AG 1848V Hybridization and Electrification
Summary
› 48 volt technology is entering the mass market
› 48V P0 architecture offers significant efficiency improvements with acceptable
cost and integration effort
› Additional efficiency improvement and electric launch capability with 48V P2
architecture
› Much better efficiency potential in urban driving comparison to FTP and WLTC
› Advanced functions available like boosting,
g sailing,
g coasting,
g electrical p
parking
g
› Electric torque assist for significant improvement of acceleration
› Optimization
Optimi ation of Electrical Architect
Architecture
re 12 V vs.
s 48 V
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PUBLIC Steven Kowalec © Continental AG 19Thank you!
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PUBLIC Steven Kowalec © Continental AG 20You can also read
