AVL Powertrain Engineering Inc.

POWERTRAIN STRATEGIES FOR THE 21ST CENTURY

July 22, 2015

Paul Whitaker

2

Expertise

PowertrainEngineering

IntegratedPowertrain Solutions

AdvancedSimulation

Technologies

Instrumentation&

Test Systems

Three Divisions … One Globally Unique Company

AVL“Anstalt FuerVerbrennungskraftmaschinenList” (Institute For Combustion Engines)

3

AVL POWERTRAIN ENGINEERING AT A GLANCE

3750

7500

4

• CVT • DCT• 8/9/10 Speed• …

• ECU Complexity • TCU Complexity•…

Increased Powertrain Diversity:The Five Basic Elements of the Future Powertrain

Battery

IC Engine

Electric Motor

Control System

Transmission

• Gasoline/diesel • Valvetrain• PFI/GDI• NA/Boosted• …

• Storage capacity • Energy density• Recharge time• ...

• Torque output• Voltage requirements• Efficiency• …

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• ECU Complexity• TCU Complexity•…

• Torque output• Voltage requirements• Efficiency• …

• Storage capacity• Energy density• Recharge time• ...

Battery

IC Engine

Electric Motor

Control System

Transmission

Increased Powertrain Diversity:The Five Basic Elements of the Future Powertrain

• CVT • DCT• 8/9/10 Speed• …

• Gasoline/diesel • Valvetrain• PFI/GDI• NA/Boosted• …

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Transmission

NA PFI Engine with9 Speed Automatic Transmission

Battery

IC Engine

Electric Motor

Control System

Increased Powertrain Diversity:The Five Basic Elements of the Future Powertrain

7

Trac

tion

Forc

e -N

NA PFI6 speed AT

Fuel Economy Improvement By Transmission Measures

Energy consumed (WLTC)

BSFC < 240 g/kWh

7

8

Trac

tion

Forc

e -N

NA PFI6 speed AT

NA PFI9 speed AT

BSFC < 240 g/kWh

Increased no. of gears

Fuel Economy Improvement By Transmission Measures

Energy consumed(WLTC)

BSFC < 240 g/kWh

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9

Turbo GDI Engine with 6 Speed Automatic Transmission

Battery

Transmission

Electric Motor

Control System

IC Engine

Increased Powertrain Diversity:The Five Basic Elements of the Future Powertrain

10

Regional Market Share of Turbocharged Gasoline Engines

Share of Charged Engines - %

Japan

Europe

China North America

Source: IHS Q2/2013

Korea

• Share of boosted Gasoline engines will dramatically increase especially in Europe

• China higher share than US

• Various GDTI launches also in Japan

Downsizing / down-speeding based on boosted engines is already the main-stream technology for FE improve-ment

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Regional Market Share of GDI Engines

Share of GDI Engines - %

• Share of GDI will significantly increase in most major markets

• In Europe and US GDI will becomedominating

• China, Korea andJapan expected togain app. 40% by2020

Japan

Europe

China

North America

Korea

Source: IHS Q2/2013

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Fuel Economy Improvement With GasolineEngines - Turbocharging

BMEP

BSF

C

BMEP limit of

NA

Schematic

State-of-artCharged

CHARGING

NA

Turbocharged Engines

Extending area of low BSFC by Boosting and Downsizing

13

Trac

tion

Forc

e -N

NA PFI 6 speed AT

Gen 2 TGDI6 speed AT

BSFC < 240 g/kWh

CHARGING

Fuel Economy Improvement With GasolineEngines - Turbocharging

Energy consumed(WLTC)

BSFC < 240 g/kWh

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Transmission

NA PFI Engine with VCT+ 9 Speed Automatic Transmission

Battery

IC Engine

Electric Motor

Control System

Turbo GDI Engine+ 6 Speed Automatic Transmission

Battery

Transmission

Electric Motor

Control System

IC Engine

Increased Powertrain Diversity:The Five Basic Elements of the Future Powertrain

Advanced Turbo GDI Engine+ 9/10 Speed Automatic Transmission + BSG with start/stop

Battery

Transmission

Electric Motor

Control System

IC Engine

2015 2020 and beyond

15

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500N [1/min]

BM

EP

4 c

yl [k

Pa]

0

2

4

6

8

10

12

14

16

18

20

22

24

240

250

260

260

270

270

270

270

300

300

300

330

330

360400

500700 1000

24

68

10

15

20

25

30

35 40

45 50 55 60 65 70 75 80

BSFC < 240 g/kWh

Evolution Of Turbocharged GDI

BSFC [g/kWh]

BMEP

BSF

C

Gen 2 TGDI

Miller CycleSchematic

Next generations of TGDI signifi-cantly extend sweet spot area

Engine Speed

BM

EPGen 3 TGDI

16

1,6l TGDI; 104 kW/4500 rpm

Cooled Exhaust Manifold

Increased Compression Ratio

Miller Cycle

Cooled Forced EGR (HP)

Engine min. BSFC <210 g/kWh

90 g/km CO2 in NEDC Air mass flow meter

High Pressure EGR

Lambda sond

Throttle body

Turbo-charger

Boost pressure sensorElectric Supercharger

EGR / Air Rail

Non return valve

EGR valve

EGR cooler

AVL Patent Application

EGR / air rail

EGR / airfeed pipe Throttle

body flange

Miller TGDI DemocarGolf 7 HiEff

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Energy consumed(WLTC)

Miller TGDI6 speed AT

BSFC < 240 g/kWh

Gen 2 TGDI6 speed AT

BSFC < 240 g/kWh

refined enginetechnology

Evolution Of Turbocharged GDI

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Fuel Economy Improvement - Hybridization

Hybridization allows electric driving at low power requirements where the ICE would otherwise operate inefficiently

Recharging

+

19

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

2007 2008 2009 2010 2011 2012 2013 2014 2015

Spe

c. P

ow

er

[kW

/l]

GASOLINE Turbo DI – Global Engine Production vs. Specific Power

Development Trends TGDISpecific Power vs. Production Volumes

Units produced1 Mio

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Development Directions Gasoline Engines

Gasoline Engine

Mainstream 2013BSFCmin 235*)g/kWh

P = 60 - 90 kW /lBMEP = 17 - 25 bar

“Image / Top Performance“

ConceptsBSFCmin >230*)

g/kWh P = 110 - 180 kW /lBMEP = 28 - 30 bar

*) … 2l displacement

FE-ConceptsMiller+High CR+ext.EGRBSFCmin 200*)g/kWh

P = 65 - 80 kW /lBMEP = 17 - 20 bar

either - or

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100

150

200

250

300

350

400

450

4

6

8

10

12

14

16

18

20

22

24

26

28

30

32

1000 2000 3000 4000 5000 6000 7000

Po

we

r -

HP

BM

EP -

bar

Engine Speed - rpm

BMEP AMG

BMEP FPT E-Boost

BMEP FPT LowPower

AMG

FPT E-Boost

FPT Low Power

AVL 2013 High Performance TGDI R&D200 hp/l Alfa Giulietta

1.75l GDI TC Fam B engine reinforced

Longer exhaust camshaft

K16 Monoscroll TC

Valeo Electric Supercharger (12V)

Flap Exhaust System

350 HP / 6500 rpm (148 kW/l)

410 Nm / 3500 rpm

Boostpressure

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AVL 2015 High Performance TGDI R&D200KW/L

1.75l GDI TC Fam B engine

Reinforced crankshaft, conrods, pistons

Revised valvetrain

Biturbo charging with dual compressor

Electric Supercharger (48V)

Flap Exhaust System

474 HP / 8000 rpm (200 kW/l)

416 Nm / 8000 rpm

PK

150

200

250

300

350

400

450

500

4

6

8

10

12

14

16

18

20

22

24

26

28

30

32

1000 2000 3000 4000 5000 6000 7000 8000

Po

we

r -

HP

BM

EP -

bar

Engine Speed - rpm

BMEP

Power

Bi-turbo-1 stage expansion FG-turbine-2 stage compressors-Interstage cooling (LT-circ.)

e-m

Boost on demand (trans.)

-eSC (pre TC)

Catalyst „RDE-safe“-Small section / cat heating, low load-Big section / high power & speedsFlap controlled

BlowBy / PCV -Constant crankcasepressure control valve

AVL patent

Main CAC

interstageCAC

EX-line „controlled flow“-Acoustics vs. backpressure

CAC aftercooling-Air, water, iCAC: tbd with package

AVL patent

23

Variable Compression Ratio – Switchable Con Rod

AVL patent application

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Light-Duty DieselU.S. application will only become tougher due to more stringent emissions!

• Diesel has always been the benchmark for efficiency

• Tier 3/LEV 3 emissions will make diesel even more difficult to implement in the US− Costs will increase− Efficiency may reduceLEV III Fleet Average NMOG+NOx Standards

CooledEGR

DOC

T

pT

NOx

T NOx

SCR

Urea solution UREA

NH3

2000+ barFIE VGT

DPF

Fuel injection

NH3Cat

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Gasoline Powersplit Hybrid

Battery

IC Engine

Transmission

Electric Motor

Control System

Range Extended Electric Vehicle

Battery

IC Engine

Transmission

Electric Motor

Control System

Increased Powertrain Diversity:The Five Basic Elements of the Future Powertrain

Electric Vehicle

Battery

IC Engine

Transmission

Electric Motor

Control System

26

CO2 Reduction – Sedan in WLTP

Base Engine: 1.4L, 4-cyl, TGDI, Start/stop, smart alternator control

116

CO

2 –

g/km

12011511010510095908580757065

88

75

1.4 TGDI State of Art

200 g/kWh 170 g/kWh

Engine needs tobe operated asclose as possibleto BSFC min

BSFC min needsto be improved

Additional measures required on the vehicle side

Significant technical challenges lie ahead

EU 2025**

**proposed upper limit

US 2025*

*passenger car

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Thank You for Your Attention

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www.avl.com