international automotive congress 2008 from micro to full

© fka 2008 · All rights reserved#80530 · 8gn0810.ppt Slide No. 1 31.10.2008

International Automotive Congress 2008

From Micro to Full Hybrid -Two cars developed by fka and ika

Shenyang, 31st October 2008

Prof. Dr.-Ing. habil. Jan-Welm Biermann Dipl.-Ing. Bruno GnörichForschungsgesellschaft Kraftfahrwesen mbH Aachen (fka)Institut für Kraftfahrzeuge (ika), RWTH Aachen University


Santiago/Chile, 1 hour after rainfallSantiago/Chile, 30 hours after rainfall

Air pollution and climate change are major drivers for the development of new propulsion technologies


Noise emissions also play a major role:Mapping of traffic noise in mega-cities (e.g. London)


Drivers for new propulsion technologies

Drivers:

Development Targets:

further improvement of fuel economy

Rise inMobility

socio-economic

Rise inEnergy Costs

economic

Climate Change

environmental

30

35

40

45

50

55

60

65

70

75

2000 2010 2020 2030 2040 2050

Jahr

10

12 P

ers

on

en

kil

om

ete

r /

Ja

hr

15

25

35

45

55

65

75

2002 2003 2004 2005 2006 2007

Jahr

Ro

hö

lpre

is [

US

D / b

arr

el]


Technical aspects influencing fuel economy

d riv in g re s is ta n ce

c o n su m p tio n re le va n t in flu e n ce s

d rive tra in lo s se s e n g in e o p e ra tio n

drivin

gre

sis

tan

ce

po

we

r

v e lo c ity

Pa

Pc l

Pa ir

Pr

Pa

Pc l

Pa ir

Pr

P o te n tia l

- lo w re s is ta n ce tire s- in c re a se d tire p re ss u re

- lig h tw e ig h t c o m p o n e n ts- a e ro d yn . o p tim ise d b o d ie s- lo w e re d ch a ss is

- e n g in e d o w n s iz in g- th e rm a l m a n a g e m e n t

- lo w v isc o s ity o il- re g e n e ra tiv e b ra k in g

- s ta rt-s to p o p e ra tio n- o p tim ize d g e a rs h ift

- g e a rsh if t in d ica to r- o p tim ize d g e a r ra tio s

s pe e d [ r p m ]

torq

ue

[N

m]


Presentation overview

• Alternative drive activities at fka and ika

• Case Study: Micro Hybrid with a light-weight body and sophisticated

subsystems

• Case Study: Full Hybrid with foresighted energy management

• Case Study: Hybrid bus for commuter transport

• Summary





subsystems



• Summary


fka and ika’s activities in terms of hybrid, electric and FC vehicles

• national and international public projects funded by

European Commission, BMWi, BMBF etc.

• confidential bilateral industrial projects

fka and ika are cooperating as R&D partner in numerous:

with OEMs and suppliers like:


fka and ika’s competence in development of alternative drives

• simulation

• concept design of drive components

• operational strategy / energy management

• controller hard- / software

• prototype vehicles

• testing (test benches and road tests)


Time line hybrid vehicles developed by fka and ika since 1970

19751980

1985

1990

1995

2000

2005

1970

2010

19751980

1985

1990

1995

2000

2005

1970

2010

2008

ika- Hybrid III

Ford EHV

1993

Ika-Hybrid I

1973

Ford e-Ka

2001

Hybrid Bus

1980

Ika-Hybrid II

1992

SUVA Hybrid

2003

INMOVE

2000




• Case Study: Micro Hybrid with a light-weight body and

sophisticated subsystems



• Summary


Public project to develop a vehicle with low CO2 emissions

Funded by:

Federal German Environmental

Agency (UBA)

Objective:

Reduction of fuel consumption without

compromising drive performance

VW Golf GT

1.4l TSI

Engine:

Fuel Super plus

max. power [kW] 125

@ [rpm] 6000

max. torque [Nm] 240

@ [rpm] 1750

Performance:

Top speed [km/h] 220

0 - 100 km/h [s] 7.9

Fuel consumption

Inner urban [l/100km] 9.6

Extra urban [l/100km] 5.8

Total [l/100km] 7.2

CO2-Emission [g/km] 173

VW Golf GT

1.4l TSI

Engine:

Fuel Super plus

max. power [kW] 125

@ [rpm] 6000

max. torque [Nm] 240

@ [rpm] 1750

Performance:

Top speed [km/h] 220

0 - 100 km/h [s] 7.9

Fuel consumption

Inner urban [l/100km] 9.6

Extra urban [l/100km] 5.8

Total [l/100km] 7.2

CO2-Emission [g/km] 173

Duration:

2004 until 2008


Consumption reduction in the ika test vehicle consumption saving technologies

Transmission with

long gear ratios

Start-Stop +

regen. braking

Lightweight seats

Carbon hatch

Battery

VW downsizing

engine

(1.4l / 125 kW)

Low resistance tyres with high

pressure

Mirror substitute systemHeat reservoir

Gear shift

indicatorCarbon

engine hood

Low viscosity oils

ReducedTankvolume


Consumption savings in the NEDC:

appx. 0,2 l/100km

Aimed weight savings ≈ 100 kg

Component Saving [kg]

Tank volume reduction appx. 20

205R16 tyres 14.4

Carbon Bonnet 8.9

Lightweight construction seats 8.6

Carbon Hatch 7.6

Ceramic brake discs (rear) 6.5

Blei-Vlies-Batterie 4.6

Optimised transmission 1.4

Rear wiper removed 1.0

Total 73.0

Driving resistanceweight reduction in ika test vehicle


Summary potentials of every single measure

engin

e o

pera

tion

drive

trai n

losses

drivi

ng r

esis

tance

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Low Resistance Tyres

Substitution of

Outside Mirrors

Weight Reduction

Low Viscosity Engine

and Transmission Oil

Coolant Heat Storage

Regenerative Braking

Transmission with

long Gear Ratio

Gear Shift Indicator

Start-Stop Automatic

Fuel Consumption reduction in NEDC [l/100km]


SummaryCO2-Emissions for the same engine power in NEDC

* Source: VW

0

20

40

60

80

100

120

140

160

180

200

220

Otto-

Saugmotor *

TSI TDI * TSI

(ika-Golf)

CO

2-E

mis

sio

ne

n [

g/k

m]

213

173156

131

-19%

-39%

-27%

-24%

CO

2-E

mis

sio

ns

[g

/km

]

Gasoline

engine





subsystems



• Summary


Public project to develop a hybrid vehicle with prediction ability

Funded by:

Project Duration: 2004 - 2008

Federal ministry of Economy and Technology

Objective:

Reduction of fuel consumption by

hybridisation and by prediction technology

Project contents:

• Build-up of subcompact-class vehicle with

hybrid components of the newest

generation

• On-line availability of prediction data by a

digital map, which contents compared to

up-to-date maps additional information

about speed limits, elevation and curve

radius

• Build-up of a vehicle layout that allows a

predictive operational strategy

ika Hybrid 3 demonstrator


Demonstratorika Hybrid III (Parallel Hybrid) based on Opel Corsa C 1.0 Easytronic

Li-Ion battery

288 V7,5 Ah

Automated 5-gear transmission (MTA)

Chain drive

Combustion engine 44 kW89 Nm1.0 l 3-cylinder gasoline

E-motor37 kW223 Nm

GPS

Low resistancetires

Active brake booster

Lidar sensor

ConverterDCDC Inverter

HMI


Source: Bosch

Available prediction technology

• Ego-Vehicle (velocity, acceleration, yaw rate)

• State of traffic(free driving, stop and go) *

• Traffic situation(city, rural, highway)

• Vehicle in front(distance, velocity) *

• Routing / navigation information(speed limits, elevation, curve radius) *

5050

7070

7070

* Technology chosen for the ika Hybrid 3


80

5050

6060

7070

100100

60605050

5050

3030

3030

5050

8080

Staugebiet: Feierabendverkehr

80

8080

5050

6060

7070

100100

60605050

5050

3030

3030

5050

80808080

Staugebiet: Feierabendverkehr

8080

Digital map / model of environment Aachen cycle

120.00

130.00

140.00

150.00

160.00

170.00

180.00

190.00

200.00

210.00

220.00

0 5000 10000 15000 20000 25000 [m]

[m]

Altitude profile

120.00

130.00

140.00

150.00

160.00

170.00

180.00

190.00

200.00

210.00

220.00

0 5000 10000 15000 20000 25000 [m]

[m]

Altitude profile

39%Share urban

10,0 kmTrack length urban

61%Share extra-urban

15,6 kmTrack length extra-urban

Traffic jams at rush hour

Aachen City


ResultsDriving tests

Road works on highway with a deceleration from 120 to60 km/h

with AACC

without AACC

50

60

70

80

90

100

110

120

130

220 240 260 280 300 320 340 360 380

Zeit [s]

Ge

sc

hw

ind

igk

eit

[k

m/h

]

time [s]

velo

cit

y[k

m/h

]

AACC has improved the energy efficiency by 6.5 % in average while braking





subsystems



• Summary


City bus „Evobus Citaro Hybrid“

Hybrid bus benefits

• High portion of start stop operation Energy recuperation

• Hybrid structure Higher engine efficiency

• Possible ZEV operation Great in urban environment

• Acoustic behaviour (interior/exterior) Lower noise emissions

• High acceptance by fleet operators Higher system costs amortisated in 3-5 years


Serial Diesel Hybrid• „Downsizing“ ICE: 12 l (240 kW) -> 5 l (160 kW)

• Generator capacity: 140 kW

• 4 wheel hub motors (320 kW drive power)

• Energy: Li-Ion Battery (17,4 kWh; 180 kW, 520 to 750 V)

• Prototype status (currently first fleet tests in Stuttgart, Germany)

• (Small) Series production planned for 2009• Fuel Consumption Benefit: 24 - 35 %

Diesel ICE OM 924 LA

Li-Ion Battery

Auxiliaries

Air Conditioning

Inverters

Air Conditioning

Inverters

Diesel tank AdBlue tank

Wheel Hub MotorsGenerator

City bus „Evobus Citaro Hybrid“


City bus „Evobus Citaro Hybrid“Noise, vibrations and harshness (NVH)

• Challenging vehicle concept with regard to noise and vibrations (Pedestrians at bus stops must still hear an approaching bus)

• Engine speed independent from vehicle speed

• Unusual noise pattern for passengers and pedestrians (bus stop)

• Adapted NVH optimisation measures for ICE/motor/generator unit as well

as for wheel hub motors

Noise source

Airborne noise transfer

Emission

Body vibrations

Structure-borne noise transfer

Motor - Generator - Verbund

Bremse

Ansauganlage

UmrichterDachkühlanlage

Tyre / road

Wind noise

Exhaust system

ICE/Motor/Generator unit

brakes

Air Intake

Auxiliaries (roof)

Inverters

Wheel hub motors

Air Conditioning





subsystems



• Summary


Summary

• Fka and ika have a long tradition in R&D of alternative drivetrains

• Hybrid vehicles have been developed, built and tested by fka and ika since the early 1970s

• „Conventional“ technologies still offer significant potential for improved

fuel consumption, as shown in the „UBA“ VW Golf

• Advanced control systems such as prediction of traffic conditions and digital maps offer additional efficiency in full hybrid vehicles, as shown in

the Opel Corsa prototype, as well as in combustion engine powered cars

• Hybrid commuter buses are good examples of economic benefits of hybrid vs. non-hybrid systems: Higher system costs are compensated

after 3-5 years of service

• Besides the CO2 and toxic emissions, the noise radiation of vehicles is a major R&D topic for the future


Contact

Prof. Dr.-Ing. habil. Jan-Welm Biermann

Forschungsgesellschaft Kraftfahrwesen mbH AachenSteinbachstr. 752074 Aachen Germany

Phone +49 / 241 80 25 606Fax +49 / 241 80 22 147E-Mail [email protected] www.fka.de

international automotive congress 2008 from micro to full

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