Mild Hybrid cOst effective solutions for a fast Market penetratiONGA number 724037

Grant Agreement number 724037

Mild Hybrid cOst effective solutions for a fast Market penetration

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 2

Thomson overall objectives

GOAL : demonstrate the sustainability of cost efficient 48V systems toincrease vehicle fuel economy and to reduce pollutant emissions,supporting a faster penetration of electrified powertrains on the market.

APPROACH : two different applications – Diesel and CNG – with twoarchitectural approaches – P1f (BSG) and P2 – highlighting the potential ofthe mild hybrid as enabler of some useful complementary functionalities(e.g. e-boosting, e-heated catalyst) thanks to the system energy recoverycapabilities.

TARGET :• Cost reduction at system level w.r.t. non-hybrid vehicle• Fuel Consumption / CO2 reduction – more than 20% including, engine

downsizing, electrification, e-boosting and e-auxiliaries• Emissions reduction - Vehicle demonstration of real driving emissions

with a 1.5 compliance factor.

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 3

Project Partnership

12 Partners4 EU countries represented

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 4

Project structure and timing

WP3 - 48V

P1F architecture

1.6 DIESEL engine

CRF

BOSCH

FAURECIA

POLI MI

WP4 - 48V

P2 architecture

1.0 TC CNG engine

FORD

CONTINENTAL

SCHAEFFLER

UNIV of BERLIN

WP1 – Advanced cost effective boosting systems –

University of Bath / Borg WarnerDevelopment of advanced e-booster / simulation models

WP2 – Thermal, Emissions and Energy management –

Ricardo / Schaeffler / Emitec

Vehicle energy modelling, thermal management and e-heated

catalyst development

WP5 – Project technologies assessment –

CRF / FORD / Ricardo / Continental

Performance, emissions and cost analysis

WP

6 –

Pro

ject

man

ag

em

en

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CR

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Project start : 1 October 2016Project end : 30 September 2019 (3 years duration)Coordination : CRF- Stefania Zandiri (Stefania.zandiri@crf.it)

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 5

Project Interactions among the WPs

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037

• Aim to provide:– New boosting hardware and simulations for

engines (WP3/4) and

– Validated component models for integration in system simulation and optimization tool (WP2)

• Key Project Deliverables– Boosting hardware for 1.6L Diesel (WP 3)

– Air path layout for 1.6L Diesel (WP3)

– Support air path layout for 1.0L

• Research Outcomes– Engine independent boosting system performance metric

– Transient boosting system experimental evaluation methodology

– Simplified Boosting Component Models improving upon map based approaches (incl. heat transfers and thermal states)

– Methodology for transient matching

6

WP1 – Advanced Cost Effective Boosting systemsObjectives

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037

• Key Objectives– System and component level air path

simulations for both Diesel and CNG engine (WP3 and 4)

– New component modelling approaches for air-path components and validation of these models

– Engine independent, transient evaluation of air path performance

• Activities– 1D simulation for optimizing engine/boosting

system matching for electrified air-path– Construction of dynamic air path testing

facility– Provision of novel boosting hardware (e-

booster, advanced turbocharger– New, physically based models of air-path for

inclusion in optimization framework (WP2)– 3D Optimization of intake air path

configuration

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WP1 – Advanced Cost Effective Boosting systemsProgress & Main Achievements so far

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 8

WP2 – Thermal, Emissions and Energy ManagementObjectives

1. Improve the benefit / cost ratio for hybrid 48V mild hybrid vehicles by enhanced management of all energy flow (and storage) in the vehicle

2. Evaluate the cost and stored value of different energy forms and thus define an optimising strategy for the energy management

3. Define a strategy that will, by situation-dependent optimisation of the total internal energy flow inside the vehicle, achieve a fuel consumption reduction (related to CO2 emission) whilst complying with all emission limits and allowing purely electric driving over an improved range

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037

The initial results from the THOMSON toolchain shows potential for a 2-4% CO2

reduction at no additional on-cost

9

WP2 – Thermal, Emissions and Energy Management Main Achievements (1/2)

• State-of-the-Art toolchains enable optimisation of hybrid and aftertreatment calibration, but typically assume fixed engine calibration

• The THOMSON toolchain is able to consider impacts of engine calibration simultaneously with all other optimisation parameters

FC (/100km)

Tailp

ipe

NO

x (

mg

/km

)

WLTC Cycle Optimisation Results Re-optimised EGR Map

2%

Conventional toolchain

THOMSON toolchainConventional toolchain

THOMSON toolchain

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037

• The THOMSON toolchain leads to greater usage of the BSG in motoring mode through the cycle – both calibrations are SOC neutral

10

The energy management strategy and system calibration are significantly different between the two approaches

Conventional toolchain

THOMSON toolchain

motoring

generating

motoring

generating

State-of-the-Art toolchain

WP2 – Thermal, Emissions and Energy Management Main Achievements (2/2)

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 11

WP3 – Diesel cost effective hybridization technologiesMain objectives

• Assessment of diesel mild electrification(48V) to improve powertrain efficiencyand performance minimizing the CO2 onhomologation cycle as well as on real lifeensuring the lowest noxious emissionimpact.

• Realization of a 1,6L demo vehicleintegrating BSG, e-Booster, electricallyHeated Catalyst and optimized SCRaftertreatment solution, with the maingoals to achieve:

• 16% CO2 reduction on WLTP cycle andcomparable performances w.r.t. 2,0L140Hp engine

• Eu6d Final emissions compliance

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 12

WP3 – Diesel cost effective hybridization technologiesMain achievements

e-BoosterFocus on performance

Advanced ATSFocus on emissions

BSGFocus on CO2

Main demo vehicle contents :• 48V architecture with BSG (Bosch)• e-Booster (BorgWarner) to recover

low-end torque and improvetransient operations

• e-HC (48v Conti-Emitec) with close-coupled DOC+SCRF Canning(Faurecia)

• Dedicated control system for BSG,e-Booster and e-HC (Bosch – CRF)

Demo Vehicle : Fiat 500X 1,6L MT FWDBase engine: 1,6L 120 HP 4cyl. Eu6

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 13

WP3 – Diesel cost effective hybridization technologiesMain achievements - Advanced aftertreatment system

LP EGR

Electric Heated Catalyst

eHC allows a fast increment of gastemperature during the first part ofthe cycle. Electrical managementneeds to be optimized in order tominimize impact on CO2.

ASDS NH3 dosing system

ASDS assessment was completed atthe test bench in terms of NOxconversion efficiency.A NOx reduction efficiency in therange of 30%-45% has beenmeasured under 180°C @ inletSCRF where AdBlue dosing is notpossible.

Improved SCRF solution

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 14

Engine on the dyno equipped with new BorgWarner turbocharger and 48V e-Booster

e-Booster

By-pass valve

1.6l Eu6 NP Engine

Target for Thomson

1.6l with new turbocharger

1.6l with new turbocharger + e-Booster

WP3 – Diesel cost effective hybridization technologiesMain achievements - Advanced boosting

• Good performance in terms of low-end torque and transient response• Maximum power is below the target mostly due to the new ATS that heavily impact on exhaust backpressure• New turbocharger definition is ongoing to recover the lack of power

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 15

WP3 – Diesel cost effective hybridization technologiesMain achievements - Experimental activity status

To better understand the value of eachtechnology it has been decided to activatetechnologies with a step by step approach.

Steps:• BSG with 48v architecture (activity on

going)• eHC (48v)• eBooster (48v)

Activity on demo vehicle is ongoing at roller test bench.

Base engine calibration and the preliminary calibration of eHC and eBoost carried outat engine dyno.

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 16

WP4 – 1.0L TC CNG engineObjectives

• Aim to provide:– a solution of a cost-optimized hybrid

powertrain, comprising of an affordable 48V Mild Hybrid system and a 1.0 l GTDI CNG engine

• Key Project Deliverables– Build demonstrator vehicle with

lower/equal CO2 emissions than similar Diesel powertrain and with driveability of the next-up gasoline powertrain in same vehicle platform.

• Research Outcomes– Feasible and customer focused powertrain

solution for methane based ICE in combination with an affordable level of powertrain electrification.

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037

• Core Workpackage

– Simplified, feasible derivative based on GasOn engine derived for THOMSON to support cost objectives.

– Engine, air-path, clutch and P2-off axis modules defined, designed and powertrains build.

– Vehicle build ongoing.

– Simulation tool chain developed to establish up-front analysis of attribute vs CO2 trade-off.

– Smart-testing approach established, powertrain on transient dyno ongoing to support up-front vehicle controls development & refinement.

– Solution for an integrated 12V/48V battery system developed including vehicle feasible package solution.

– Engine mapping on dynomameter ongoing

• Interaction with WP1

– Optimization of air-ducting to minimize energy consumption using CFD based techniques

– Feasibility of vehicle emission testing according to EU6d temp under investigation at UoB

• Interaction with WP2

– First level of optimization

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WP4 – 1.0L TC CNG engineMain Achievements

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037

• Powertrain and CNG-Di system developed, hardware available and functional tests successfully finished.

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WP4 – 1.0L TC CNG engineMain Achievements

• mHEV topology was identified to support both, CO2 reduction and driveability attributes.

• 48V P2-off-axis mHEV system selected, designed, build, tested and verified.

• Combined 12V-48V battery packaged.

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037

• Tool chain developed to conduct up-front analysis of CO2 vs. driveability trade-off.

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WP4 – 1.0L TC CNG engineMain Achievements

• First level of energy management system available to support 2-pedal approach (removal clutch pedal).

• Powertrain build and ready for testing on transient test-bed to assess smart-testing approach.

• Vehicle build in progress, commissioning phase (controls) scheduled for October’18.

Thomson : Mild Hybrid cOst effective solutions for a fast Market penetrationGrant Agreement number 724037 20

THANKS !!

Coordination : CRF - Stefania Zandiri stefania.zandiri@crf.it