48V Mild Hybrid Systems
Market Needs and Technical Solutions
Ulf Stenzel
AVL Engineering and Technology
Content
48V Market Situation & Needs
48V Powertrain Technologies and Challenges
AVL’s Project Examples
AVL UK Expo 2014 / Ulf Stenzel
2
Content
48V Market Situation & Needs
48V Powertrain Technologies and Challenges
AVL’s Project Examples
AVL UK Expo 2014 / Ulf Stenzel
3
Mild Hybrids – Global Market Overview
Global xEV Production
Vehicle Production [units]
7,000,000
In 2020
(10-15)% of
global xEV production
are Mild Hybrids
6,000,000
5,000,000
4,000,000
3,000,000
2,000,000
1,000,000
0
2013
2014
2015
2016
2017
2018
2019
2020
Year of Production
Hybrid-Mild (incl. 48V)
Vehicle Production [units]
Mild Hybrids, per Region
Hybrid-Full (incl. PHEV)
EVs (incl. REEV)
800,000
700,000
Mild HEVs produced in NA in 2020
will most likely be dominated
by High Voltage Systems
600,000
500,000
400,000
300,000
In 2020 almost all Mild HEV’s
produced from European OEMs
are 48V Systems
200,000
100,000
0
2013
2014
2015
2016
2017
2018
2019
2020
Year of Production
South Asia
North America
Japan/Korea
AVL UK Expo 2014 / Ulf Stenzel
Greater China
Europe
Source: IHS Q3 2013
4
EU
Mild Hybrids – Market Overview Europe
Mild Hybrids produced
in Europe (of which
98% is 48V in 2020)
Vehicle Production [units]
300,000
E-Segment
D-Segment
250,000
200,000
150,000
C-Segment
B-Segment
100,000
50,000
Vehicle Production [units]
400,000
400,000
350,000
per Vehicle Brand
350,000
300,000
250,000
200,000
Luxury
Premium
Mid
Entry
150,000
100,000
50,000
2013 2014 2015 2016 2017 2018 2019 2020
No 48V applications in the A
segment (e.g. Ford Ka, Chevrolet
Spark) forecasted until 2020
Significant 48V shares in larger
vehicle classes and in the B
segment (e.g. VW Polo)
Early implementation in E segment
vehicles (e.g. BMW 7 series, MB
E-Class) (see 2018)
AVL UK Expo 2014 / Ulf Stenzel
400,000
350,000
300,000
250,000
200,000
150,000
100,000
50,000
Rolls-Royce
Nissan
Smart
Porsche
BMW
Ford
Peugeot
Citroen
Audi
Mercedes-Benz
Dacia
Renault
0
0
0
Vehicle Production [units]
Per Regional Sales
Price Class
per Segment
2013 2014 2015 2016 2017 2018 2019 2020
2013 2014 2015 2016 2017 2018 2019 2020
Large share of 48V applications in
the Mid (e.g. Renault Clio, Ford
Mondeo) and Premium (e.g. BMW
7 series, Smart Forfour) segment
High share of German premium
OEMs
Entry: e.g. Renault Duster, Dacia
Logan
No share from Fiat (and it’s sub
brands) forecasted until 2020
No share from Volkswagen
projected
Luxury: Porsche Macan, RollsRoyce Ghost
Source: IHS Q3 2013
5
German OEMs are pushing for 48V
The LV 148 standard defines a 48V
power supply system including its
functions and interfaces.
The standard describes all relevant
electrical requirements and test
procedures for the new 48V
components
It is defined by the big 5 German
automakers and shows a clear trend
out of Europe to push 48V technology
towards production.
These five OEMs have been involved:
Audi AG
BMW AG
Daimler AG
Porsche AG
Volkswagen AG
AVL UK Expo 2014 / Ulf Stenzel
6
EU
Past and Future Progress to meet the 2020 Target
Overall the required rate of progress to the
proposed 2020 targets is slightly greater
(4.1%pa) than the rate that has already been
achieved over the past five years (3.6%pa).
However, these figures do not include the effect
of flexibilities (i.e. supercredits) that effectively
provide free grams. Carmakers are therefore
even closer to achieving targets than the data
suggests.
The clear conclusion is that the 2020 target is
achievable for makers of all types and sizes of
cars with appropriate planning and introduction
of fuel consumption reduction measures.
Source: European Federation for Transport and Environment (T&E)
AVL UK Expo 2014 / Ulf Stenzel
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EU
Taxes and Incentives for Mild Hybrids in Europe
AVL UK Expo 2014 / Ulf Stenzel
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Definition of Hybrids according to Legislation by Region
From ECE R101: … means a vehicle,…. that, for the purpose of mechanical propulsion, draws
energy from both of the following on-vehicle sources of stored energy/power:
(a) a consumable fuel;
(b) a battery, capacitor, flywheel/generator or other electrical energy/power storage device
EU
USA
CHN
JPN
KOR
12V ST/ST SIN
12V ST/ST SIG
w/o TA
12V ST/ST SIG
with TA
(1)
(1)
(2)
(1)
(1)
(2)
48V Alternator
(aux. supply only)
48V Mild HEV
SIN…Start in Neutral
SIG…Start in Gear
TA… Torque Assistance
(1) Yes, if energy storage is rechargeable
(2) Yes, if rechargeable and kinetic energy converter
AVL UK Expo 2014 / Ulf Stenzel
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48V Main Drivers – Summary
Reduction of CO2 emission to meet future
emission legislation
Comfort enhancement and new functions
Production volume
Less integration effort, weight & cost,
compared to HV systems (safety, battery)
48V systems have the potential to fill
the gap between state-of-the-art 12V
Start/Stop systems and high voltage
hybrid powertrains.
Source: Bosch on „48V Power Supply“ Conference 2013
AVL UK Expo 2014 / Ulf Stenzel
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Content
48V Market Situation & Needs
48V Powertrain Technologies and Challenges
AVL’s Project Examples
AVL UK Expo 2014 / Ulf Stenzel
11
12V/48V Electrical Architecture
48V High-Power Consumer
EPS / EHPS
eBooster
… PTC Heater
Electric Pumps
El. AC Compressor ...
Roll Stabilization
48V Boardnet
48V
48V Starter/Generator
48V Battery System
Classic 12V Boardnet
DC/DC
12V
AVL UK Expo 2014 / Ulf Stenzel
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E-Machine Integration
The integration of the E-machine
defines the recuperation potential; the
engine drag torque reduces the
amount of recuperative energy (P2
versus P1/BSG)
Cost advantage high speed Emachine (BSG) versus high torque
(ISG); high torque density leads to
higher cost
Integration cost & effort; package
(ISG, P2), transmission modification
(P2)
Preferred system architectures,
functionalities and the resulting cost to
benefit ratios are depending on
vehicle class & vehicle application
AVL UK Expo 2014 / Ulf Stenzel
13
BSG Integration Challenges - Impact on Engine
FEAD Design
Belt Durability
Variable Belt Tensioner
Increase tension during cranking
and boost (machine to engine)
Increase tension during recuperation
(engine to machine)
Reduce tension during normal
driving to reduce friction loss
NVH
Belt chirp during cranking
Crankshaft Main Bearing
Durability
AVL UK Expo 2014 / Ulf Stenzel
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Powertrain Key Components - BSG System
Besides the main requirements
(EM power & torque) as well as
packaging constraints the
supplier selection also to take
care of cooling requirements
and NVH
48V BSG systems vary across
different supplier
As an independent partner AVL
can provide comparable and
consistent component
characterization
AVL UK Expo 2014 / Ulf Stenzel
15
48V Electrical Load Migration – Impact on eStorage
12V
DC
12V
48V
DC
DC
48V
DC
>10 Ah
6 Ah
SG
SG
CO2 reduction only
Electrical Load Migration
Start/Stop, Boost, Recuperation
Chassis Control, Climate
Comfort, Engine Components
Electrification, eBooster, etc…
AVL UK Expo 2014 / Ulf Stenzel
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Powertrain Key Components – eStorage System
12V
Conv.
Micro
48V
Mild
>>48V
Mild
200-800V
Full
PHEV
EV
Flooded Lead Acid
Enhanced
Flooded
Strong
effort
in the
Lead Acid
enhancement
of advanced
carbon
Carbonadded
addedVRLA to meet
48V
requirements
VRLA
Lead Acid + UCap could be an
interim
solution
Lead Acid
+ UCap
Migration from High Voltage to 48V
with Li-Ion
Ideally carry over modules from
high power Li-ion HV battery packs
Li-ion
NiMH
?
Source: Adapted from Dr. Menahem Anderman (2013)
Legend:
AVL UK Expo 2014 / Ulf Stenzel
Dominating
Potential
Candidate
17
48V Li-Ion Battery Technology Roadmap
Lithium Titanate (LTO)
The cell performance varies across cell
technologies
Lithium Iron Phosphate (LFP)
Lithium Nickel Manganese Oxide (NMC)
2013
2020
Specific Energy
100
90
80
70
60
Specific Power
50
Costs
Source: AVL internal benchmarking (averaged values)
40
30
20
10
0
Safety
Lifetime
Performance
AVL UK Expo 2014 / Ulf Stenzel
NMC
LFP
LTO
NMC & LFP cathode materials fulfil current
48V automotive requirements in terms of
performance and safety and will be the
dominating Lithium-ion technologies in 48V
applications
LTO (lithium titanate oxide) anodes show
excellent life, low temperature performance,
safety but lead to high system costs
18
Overview 48V Main Functions
AVL UK Expo 2014 / Ulf Stenzel
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ADV. 48V FUNCTIONALITIES IN LEGAL CYCLES – NEDC
Hybrid States
120
100
80
60
40
20
0
200
400
v [k m /h ]
0
600
t [s]
800
1000
50
40
30
20
10
0
0
AVL UK Expo 2014 / Ulf Stenzel
50
100
150
200
t [s]
20
ADV. 48V FUNCTIONALITIES IN LEGAL CYCLES – FTP
Hybrid States
60
40
20
0
0
500
1000
1500
2000
2500
t [s]
Hybrid States
90
80
70
60
v [km/h]
v [km/h]
80
50
40
30
20
10
0
2000
AVL UK Expo 2014 / Ulf Stenzel
2050
2100
2150
2200
2250
t [s]
2300
21
Content
48V Market Situation & Needs
48V Powertrain Technologies and Challenges
AVL’s Project Examples
AVL UK Expo 2014 / Ulf Stenzel
22
The “TWINS”: 12V and 48V LC Super Hybrid
NEDC CO2 Emission [g/km]
180
160
140
120
100
80
60
40
20
0
Acceleration 0 - 100 kph [s]
12
-12%
-18%
18 %
-24%
Potential
Similar
for further
Performance improvement
10
8
6
4
2
0
1,8-litre TSI
1,4-litre TSI with
Start/Stop
LC Super
Hybrid
AVL UK Expo 2014 / Ulf Stenzel
48V Mild HEV
Concept
1,8-litre TSI
1,4-litre TSI with LC Super Hybrid 48V Mild HEV
Start/Stop
Concept
23
48V Advanced Lead Carbon Battery Diesel Hybrid Prototype
Project Overview
Features:
48V mild hybrid with Belt Starter
Generator (BSG) & electric
supercharger (VES)
•
+20% Power
•
-15% CO2
Engine update for BSG
Controls / Operating Strategy
Demo Vehicle Built & Calibration
Engine &
Vehicle
AVL UK Expo 2014 / Ulf Stenzel
Belt Starter Generator
E-Booster
Lead Acid
Battery
24
AVL Engineering Project History since 2002
Concept Study
Concept Study „100mpg“
48V
Market evaluation
48V
Demo Vehicle
Start/Stop
12V
SRM BSG
Conti VW Touran
42V
Mild Hybrid
Testing
Comp. Dev.
Case Study „Affordable Hybrid“
<60V
JAC Refine
14+x
Micro/Mild Hybrid
Start / Stop
12V
Engine durability testing
„Beltless Engine“
42V
Mild Hybrid
Eco Target
42V
Mild Hybrid
Start/Stop
14V + X
BSG +AMT.
JAC Binyue
BSG Demo vehicle
Drive Benchmark
42V
Mild Hybrid
Start/Stop
12V
Start / Stop
BSG
12V
Battery performance testing
EV Demo
42V
SW Dev.
42V Mirco / Mild Hybrid
LC Super Hybrid
12V
BSG + eCharger
AT Start / Stop
48V
LC Super Hybrid
BSG+switched CS pulley
48V
BSG + eCharger
BISG SW dev.
48V
Start/Stop
ALABC Pack Dev.
14V + X
48V
Li-Ion Batt Pack Dev.
BSG + UCap
48V
48V Mirco / Mild Hybrid
12V BSG Micro Hybrid
Engine Start / Stop
2003
AVL UK Expo 2014 / Ulf Stenzel
2005
2007
2009
2013
25
Summary
In 2020 almost all Mild HEV’s produced from European OEMs are 48V
Systems. German OEMs are pushing towards 48V
Implementation of new 48V HEV functions into an existing platform requires a
systematic approach and an independent holistic view on the powertrain
architecture and components
Interdependencies between components need to be fully understood to avoid
undesirable impact on:
…Emissions and fuel consumption
…Performance
…Drivability / comfort
…Energy mgmt. / charge balance
AVL UK Expo 2014 / Ulf Stenzel
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Thank you
for your
Attention!
AVL UK Expo 2014 / Ulf Stenzel
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