electrification trends in awd · 2019-12-18 · significant share of phev/ev required in 2025+,...

Electrification & All-Wheel Drive Congress, GrazMay 9, 2019

Electrification Trends in AWD

Dr. Stefan Demmerle

President & General Manager – Power Drive Systems

© BorgWarner Inc. 2

Trends impacting the Propulsion Technology

Evolution of Propulsion System Architectures

Resulting trends for AWD Systems

BorgWarner’s Answer for e-AWD

Outlook

Agenda


Photo Credit: Mascarinas, Erwin M. Photo Credit: HyundaiPhoto Credit: Prokhorova, Maya

Unique Propulsion Systems around the World


Trends Impacting Propulsion Technology

Regulatory compliance

continues to drive technology

roadmaps until 2025

Key markets US, EU, China

require different technology

solutions

autonomous

driving

shared cars

and rideshare

connected

cars

efficiency/CO2

emissions

autonomous

driving

shared cars

and rideshare

connected

cars

efficiency/CO2

emissions


A B

C, H, E

POINT A POINT B

The BorgWarner Alphabet


70

80

90

100

110

120

130

140

150

2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030

Ave

rage

d F

leet

CO

2 E

mis

sio

ns

[gC

O2

/km

]

Model Year

Historical Fleet Average

linear reduction 2007 - 2021 (NEDC)

2021 NEDC Target

linear reduction 2021 - 2025 (WLTP)

2025 WLTP Target (-15%)

linear reduction 2025 - 2030 WLTP Target (-37.5%)

2030 WLTP Target (-37.5%)

Conversion factor

NEDC – WLTC of 1.2

is considered

2021 WLTC value

according to NEDC

target is new base

Super credits for

vehicles with

< 50 gCO2/km

2020-2022

95% of the fleet have to

fulfil the 95 gCO2/km target

2x

EU CO2 Targets for Pass Cars


Type A

ppro

val C

O2

Em

issio

ns (

fleet

avera

ge)

[g/k

m,

NE

DC

]

Average Vehicle Mass [kg]Source: ICCT

1200 1300 1400 1500 1600

150

100

50

0

SUV TrendDiesel Decline

PHEV

HEV

MHEV

EV

Super-credits 2020-

2023

Impact for Representative EU Fleet


C-Segment, 1300kg

e.g. VW Golf

SUV, 1900kg,

e.g. Audi Q5

92g CO2 /km(NEDC)*

102g CO2 /km(NEDC)*

94g CO2 /km(WLTP)* 69g CO2 /km(WLTP)*


115g CO2 /km(WLTP)* 85g CO2 /km(WLTP)*112g CO2 /km(NEDC)*

*Target CO2 number based on vehicle mass (conversion factor between NEDC and WLTC is considered to be 1.2)

E-Segment, 1600kg,

e.g. VW Passat

DIESEL

MHEV

GAS

HEV

PHEV

BEV

Compliant

Not

compliant

150g 0g 150g 0g 150g 0g

Propulsion System Compliance in the EU

2021 2025 2030


C-Segment, 1300kg

e.g. VW Golf

SUV, 1900kg,

e.g. Audi Q5

92g CO2 /km(NEDC)*

102g CO2 /km(NEDC)*



115g CO2 /km(WLTP)* 85g CO2 /km(WLTP)*112g CO2 /km(NEDC)*

E-Segment, 1600kg,

e.g. VW Passat

DIESEL

MHEV

GAS

HEV

PHEV

BEV

Compliant

Not

compliant

150g 0g 150g 0g 150g 0g

2021 2025 2030

MHEV

HEVHEV

PHEV

EV

PHEV

EV

PHEV

EV

PHEV

EV

PHEV

EVHEV

HEV

Propulsion System Compliance in the EU

*Target CO2 number based on vehicle mass (conversion factor between NEDC and WLTC is considered to be 1.2)


Significant share of PHEV/EV required in 2025+, higher EV share shrinks the total ICE market

2025 (-15% vs, 2021, WLTP) 2030 (-37.5% vs, 2021, WLTP)

Scenario I

40% Plug In

Vehicles

4%

19%21%

lower CO2

7%

74

CO2g/km

49%Scenario I

20% Plug In

Vehicles

DIESEL

MHEV

GAS

HEV

PHEV BEV

13% 13% 9%

lower CO2

23%

101

CO2g/km

38%

3%

Scenario II (EV):

High EV enables

more MHEV and

less PHEV 5%

15%

101

CO2g/km

22%

45%

10% 3%

Scenario II (EV)

High EV

penetration

limits HV HEV/

PHEV4%

5%

30%

lower CO2

11%

74

CO2g/km

50%

lower CO2lower CO2

Market Scenarios for 2025 and 2030


0

5

10

15

20

25

30

2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030

Units (M)

LV Propulsion Outlook – Europe

2017: Peak in Combustion

engine volumes

Source: BW Apr. 2019 LV Market Outlook & IHS Markit


0

20

40

60

80

100

120

2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030

Units (M)

Combustion HEV Electric

LV Propulsion Outlook – Global

2017: Peak in Combustion

engine volumes

Will traditional AWD systems

also peak in the near future?



AWD Market Share for LV

13,3%

14,7%15,3%14,8%15,6%

16,5%

14,5%

16,1%

19,2%

20,3%

21,1%

0,0%

5,0%

10,0%

15,0%

20,0%

25,0%2

000

2002

2004

2006

2008

2010

2012

2014

2016

2018

2020

2022

AWD Share of Global LV

Includes: T-Cases, Couplings, eAxles & Integrated Transmissions

Da

ta fro

m C

ha

rlie

Estu

pia

n

20

30


50%

60%

70%

80%

90%

100%

2019 2024 2029

AWD Market Split

Traditional AWD P4/eAWD

P4/eAWD

Traditional AWD


CO2 WLTC [g/km]

0 -

100 k

m/h

Tim

e [

s]

10kW

48V

25kW

48V

PN raw

emissions

lower

2.0L Miller engine

140 kW, 320 Nm

220 g/ kWh best BSFC

Baseline

110kW

HV

2.0L

Performance

target

SUV

1900kg

1.5L

110kW

HV DHT

Impact of Electrical Power on Performance & CO2


<15kW 15-30kW >30kW

En

ha

nce

d H

an

dlin

g

EV

Dri

ve

CO

2S

ala

ble

Fe

atu

re

48V HV

Performance testing at

multiple Power/Torque

levels

Da

ta fro

m L

K T

ea

m

Performance Levels of Electrified AWD


48V P4 Module High Voltage Integrated Drive Module

48V and High Voltage P4 Offerings


o Secondary electric drive axle capable of regeneration/boost and limited AWD (P4 HEV)

o Leverage lower cost 48V infrastructure

o 1 or 2-Speed function for enhanced AWD and regen

o Deliver improved FE/CO2 improvement

o 7% FE gain in addition to 48V BAS equipped vehicle (simulated)

o Cost neutral to conventional mechanical AWD

o Launch assist (engine downsizing enabler) and creep capable for extended S/S

o Highway sailing sustained torque of 340 Nm

48V eAWD (P4)

D E S C R I P T I O N

B E N E F I T S

48V eAWD

Continuous Power 8 kW

Peak Power 12.5 kW

Continuous Output Torque 875 N-m

Peak Output Torque 1,450 N-m

Status POC

eAWD – P4


Fully Integrated Drive Module

D E S C R I P T I O N

B E N E F I T S

Wheel Output iDM 90 iDM 120 iDM 160

Continuous Power 45 kW 65 kW 85 kW

Peak Power 90 kW 120 kW 160 kW

Continuous Torque 1,400 Nm 1,800 Nm 2,000 Nm

Peak Torque 2,500 Nm 3,000 Nm 3,800 Nm

Status, SOP 2022 Q4 2021 2022

Samples Available 2020 Q4 2019 2020

o Drive Module with fully integrated Electrical

Machine and Power Electronics

o Operating Voltage: 250-450 VDC

o Easy Vehicle Integration

o Scalable and Modular Architecture

o Optimized System Efficiency World Class

Battery Energy Consumption

o State of the art Torque and Power Density

o High Speed Electrical Machine

oWater Cooled

o Optional e-Park Lock System

Integrated Drive Module iDM


AWD will continue to grow

Increase in electrified AWD solutions but the peak for traditional

AWD system is yet to come

BorgWarner will continue to be a Leader in AWD Solutions

for traditional AWD as well as e-AWD systems

Outlook


Thank you!

electrification trends in awd · 2019-12-18 · significant share of phev/ev required in 2025+,...

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