future directions in powertrain light duty · pdf filefuture directions in powertrain –...

FUTURE DIRECTIONS IN POWERTRAIN –LIGHT DUTY PERSPECTIVE

Mike Harpster

Director, Propulsion Systems Research

General Motors

COMMON BASE ENGINE ARCHITECTURE

Top-Rated Truck

Best of the Best

Pickup Truck of the Year

North American

Car and Truck

of the Year

Automobile of the Year

Best of the Best

Performance Car of the Year

Best Resale

Value Top Ten

Hottest New Car of the Year

Car of the Year

10 Best

Fleet Truck

of the YearBest Resale

Value Award

Best Pickup

65

85

105

125

145

165

185

205

225

2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

CO

2 E

mis

sio

ns

on

MV

EG-B

dri

ve c

ycle

(gC

O2

/km

)

Industry Targets normalized to EU drive cycle with units convertedDashed lines indicate proposed (not yet final) regulation

*Canada standard follows U.S.

Mo

re S

trin

gen

t

U.S.*

India

Korea

EU

China

Mexico

10Feb15

Brasil

Saudi Arabia

ENVIRONMENT – GLOBAL FUEL ECONOMYCO2 OUTLOOK

Source:

GM Public Policy

Meeting MY2025 CO2

regulations while delivering vehicles that customers

want and can afford

THE REAL CHALLENGE

Significant US

gasoline price

volatility with a

recent 40% drop

Source: US DOE Energy Information Administration

<5% MY2014 vehicles

meet MY2025 CO2 and all

are advanced powertrains

Source: EPA US Light-Duty

Automotive Technology,

Carbon Dioxide Emissions

and Fuel Economy Trends:

1975 Through 2014

MY

2014 V

ehic

les M

eetin

g C

O2

Reg

Conventional

vehicles are closing

the gap to hybrids

Source: EPA US Light-Duty Automotive

Technology, Carbon Dioxide Emissions, and

Fuel Economy Trends: 1975 Through 2014

~24 mpg ~15 mpg

Source: US DOE Energy Information Administration

Annual Energy Outlook 2014

0

2

4

6

8

10

12

14

16

18

2011 2013 2015 2017 2019 2021 2023 2025

US New Vehicle Sales by Propulsion System Technology Type (millions)

FCEV

BEV

PHEV

LPG

CNG

TDI Diesel

HEV

Conv Gas

Conventional gasoline

vehicles forecasted to

dominate US sales

US New Vehicle Sales by Propulsion System Type (millions)

CONVENTIONAL VEHICLES WILL PLAY A ROLE

MEGATRENDS FOR FUTURE POWERTRAINS

ELECTRIFICATIONEFFICIENCY IMPROVEMENTS

SOURCE OF ENGINE CO2 REDUCTION

Engine Focus Minimize pumping losses (VVA , downsizing/AFM, dilute combustion)

Minimize parasitic losses (variable speed/displacement pumps)

Minimize friction losses (low friction piston/bore interface, downsizing)

Maximize work extraction (dilute combustion, waste heat recovery)

Improved Fuels

Vehicle/Powertrain Integration Focus Simultaneously solving the transmission, engine

and vehicle equation to minimize CO2

Maximizing engine-off operation

Active thermal management

Intelligent electrification

Connected and autonomous vehicles

Time

Op

po

rtu

nit

y

Powertrain System Focus Wider transmission ratio spreads with small or infinite

steps to enable efficient engine operation

Advanced dampers enabling down-sized boost engines

and cylinder deactivation

0%

100%

¶ GM is studying dilute combustion concepts to maximize efficiency

¶ The physics say air dilution offers greater benefits that EGR but the required lean aftertreatment has significant challenges (e.g. cost)

Stoichiometricw/o EGR

Stoichiometric w/ EGR

Lean w/ EGR

Isentropic

Indicated

13%3%

DILUTE COMBUSTION

FUELS – OPTIMIZED FOR SI COMBUSTIONIncreasing RON allows increased downsizing and/or

compression ratio and thus engine efficiency

FUELS – OPTIMIZED FOR LOW TEMPERATURE COMBUSTION

Octane Index (OI = RON – K*Sensitivity) is a good measure of fuel performance when

“K” is adjusted to the engine/combustion mode

Easy to Ignite

Hard to Ignite

0

2

4

6

8

10

12

14

16

18

20

72 74 76 78 80 82 84 86

CA

50 @

NV

O =

130

Octane Index with K = 2

RON = 100

Sensitivity = 13 RON = 90

Sensitivity = 3

Sensitivity = (RON-MON)

Data based on 7 full blend gasoline fuels






Improved Fuels







Time

Op

po

rtu

nit

y





0%

100%

WE NEED TO SELECT THE RIGHT TRANSMISSION FOR THE SPECIFIC APPLICATION

Example: 3-cylinder Turbo Study

Transmission Energy (kJ) Loss

(= Pump + Trans Spin + Gear Efficiency + Shift Efficiency + Shift Energy + Torque Converter)

Co

mp

os

ite

Fu

el

Co

ns

um

pti

on

gC

O2/m

ile)

CVT

Step Gear

Trans A

Trans B

CVTA

CVTB

Step gear transmissions are

mechanically efficient…

…but CVT has better CO2

performance due to ratio capability

For this application, CVT is the

preferred technology

ENGINES DRIVING TRANSMISSIONS EVOLUTION

1000 2000 3000 4000 5000 6000-50

0

50

100

150

200

250

300

240240

250250

250

260260

260

280 280280

300 300300

340 340340

400 400 400

500 500 500

700 700 7001000 1000

Engine Speed (RPM)

Bra

ke

To

rqu

e (

Nm

)

BSFC (g/kW-hr)

1000 2000 3000 4000 5000 6000-50

0

50

100

150

200

250

300

185

185

19

0

190

19

5

195

195

20

0

200

200

20

5

205

205

210

210

210

215

215

215

220

220

220230

230

230

240

240

240

250

250

250

260

260

260

280

280

280

300300

300

340340

340

400400

400

500 500500

700 700 7001000 1000 1000

Engine Speed (RPM)

Bra

ke

To

rqu

e (

Nm

)

BSFC (g/kW-hr)

Today’s Engine Maybe Tomorrow’s Engine

BSFC (g/kW-hr) BSFC (g/kW-hr)

Engine Speed (RPM) Engine Speed (RPM)

Bra

ke

To

rqu

e (

Nm

)

Bra

ke

To

rqu

e (

Nm

)

¶ The engines of tomorrow may look very different than today’s engines

¶ As the engine “transformer”, transmissions are likely impacted

¶ Need to optimize at the propulsion system level to maximize overall value






Improved Fuels (high RON, high sensitivity)







Time

Op

po

rtu

nit

y





0%

100%

POWERTRAIN/VEHICLE BANDWIDTH

Vehicle bandwidth for a given engine (TWC, RL, Grade, 0-60)

Be

tte

rC

O2

Pe

rfo

rma

nce

Biggest CO2 Impact

Sub-optimization

MEGATRENDS FOR FUTURE POWERTRAINS

ELECTRIFICATIONEFFICIENCY IMPROVEMENTS

ELECTRIFICATION SOLUTIONSREDUCE CONSUMPTION & DISPLACE PETROLEUM

CONSERVATION DISPLACEMENT

Petroleum and Biofuels(Conventional and Alternative Sources)

Increasingly Electrified Propulsion Systems

Electricity(Zero Emissions Energy Sources)

Light ElectrificationExtended-Range

ElectricBattery Electric

HEVPHEV

2016 Chevrolet Volt

50 miles of EV range

400 miles of total driving range

IMPACT OF ELECTRIFICATION ON POWERTRAINS

The Volt is a great example of the impact of electrification

Volt has to operate efficiently in two modes of operation:

EV Mode with energy coming from the battery and motors

Extended Range Mode with energy coming from the engine

Engine Speed (RPM)

En

gin

e T

orq

ue

(N

m)

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 100000

50

100

150

200

250

300

350

400

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0.36

0.35

0.30

Radically different capabilities drive significantly different transmissions Electric motor’s advantage over the engine:¶ ~60% More speed range¶ ~2.6x More torque and available down to near zero speed¶ Broad efficiency islands with up to 93% peak efficient (vs 37.5% for engine)

Engine Map(2016MY Volt)

Motor + Inverter Map(2015MY Volt)

EREV ENGINE VERSUS ELECTRIC MOTOR

VEHICLEINTELLIGENCE

Mechanical76%

Electronics13%

Other9%

Software2%

TECHNOLOGY INNOVATIONVALUE OF ELECTRONICS AND SOFTWARE

$400

20 ECUs

1M lines of code

$1,200

75 ECUs

100M lines of code

2000 Today

Mechanical55%

Electronics24%

Other8%

Software13%

CADILLACSUPER CRUISE

=+Sensor

Fusion

System

3 Short-Range Radars

1 Long-Range Radar

1 Front Camera

8-10 Ultrasonic

Sensors

1 Rear Camera

2 Short-Range Radars

HOW IT WORKS

LANE FOLLOWING: Using a combination of GPS

and optical cameras, Super Cruise watches the

road ahead and adjusts steering to keep the car in

the middle of its lane.

COLLISION AVOIDANCE: A long-distance radar

system detects vehicles more than 300 ft. ahead.

The vehicle will automatically accelerate or apply the

brakes to maintain a preset following distance.

ACTIVE SAFETY

AUTOMATEDSTEERING & LANE

FOLLOWING

CADILLAC TO INTRODUCE SUPER CRUISE IN A NEW 2017 MODEL

VEHICLECONNECTIVITY

9th International CTI Symposium North America 2015, Novi, Michigan

- Mike Harpster, GM Propulsion Systems Research -

VEHICLE CONNECTIVITY:GM SPEEDS UP WITH ONSTAR 4G LTE

Built-in Wi-Fi hotspot

Connect multiple mobile devices at once

Faster, more reliable connection

Connect to vehicle remotely

On more than 30 GM vehicle models



V2X TO DEBUT ON 2017 CADILLAC CTS

Technology allows cars to communicate with each other (V2V), the infrastructure (V2I), and pedestrians (V2P)



WHAT DOES THIS MEAN TO THE POWERTRAIN?

Information about surrounding vehicles and infrastructure

The ability to manipulate vehicle operation when the driver has transferred control

Route Information

Access to information and computational power outside of the vehicle



SUMMARYGlobal convergence of CO2 regulations will drive unprecedented scale opportunities for fuel economy enabling technologies

Conventional powertrain technologies still have a significant potential for fuel economy improvements

Engine innovation will be as part of a powertrain system solution and will be significantly impacted by:

– Engine evolution

– Powertrain electrification

– Greater on-vehicle access to information

– More automated driving

Must keep the customer at the “center”

– In the end, our customers will decide based on what they want and can afford

future directions in powertrain light duty · pdf filefuture directions in powertrain –...

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