Electrified Commercial Vehicles and Lubricants Adam Banks – Senior Marketing Manager – eMobility David Thompson – CTS Manager – Driveline David Ellis – OEM Director AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. AFTON Afton Chemical: we keep things moving • • • • A global, independent and focused company supplying lubricant and fuel additive solutions A key player in the industry for 100 years $2.9bn revenue with ~1900 employees Committed to delivering solutions for evolving industries and their applications Afton serves all types of fluids and fuels applications for Commercial Vehicles – On and Off Road Afton Heavy Duty Engine Oil additives are used in factory fill and genuine oil fluids by leading OEMs across the world Afton is the volume leader in Electric Vehicle Transmission Fluids (Passenger Car and Commercial Vehicle) Afton additives are used in some of the highestprofile electric Heavy Duty trucks AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Summary of Part 1 Emissions legislation is compelling OEMs to electrify as part of their fleet mix. This will accelerate in 2025, and deepen greatly in 2030 AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Summary of Part 1 Various power sources will compete and each will find a niche AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Summary of Part 1 The destination is a uniform and low carbon system, but our route includes the ‘messy middle’ AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Summary of Part 1 Industry change won’t be rapid but… …lubricants can help greatly in both improving the efficiency of existing designs, and enabling new hardware AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Summary of Part 1 Electrified Commercial Vehicle fluid needs will be more advanced from the start than those in Passenger Car AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. How could vehicles and lubricants change in the future? 1 Options for eCV Layouts 2 3 eCV transmission lubricant requirements Detail on eFluids for electrified drivetrains AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Electrified truck / bus layouts Greater variety / complexity than Passenger Car (PC) eAxle Axle ICE Conventional P4 Variant P4 eAxle P3 EV Layout 1 EV Layout 3 eMotor reducer Reducer differential ICE P0 Parallel hybrids Series Hybrid Hybrid Wheel hub motors ICE Generator Wheel hub motors P2 P1 eMotor reducer EV Layout 4 AMT eMotor PS Powersplit integration eMotor ICE AMT AMT eMotor / reducer Reducer differential Axle AMT Axle Other independent factors to be overlaid: Direct / indirect eMotor cooling Combinations of sumps / fluids EV Layout 2 EV Layout 5 Electric / Fuel Cell AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Electrified truck / bus layouts Greater variety / complexity than Passenger Car (PC) eAxle Axle Axle AMT ICE ICE AMT Conventional P4 Variant Axle PS AMT eAxle P3 P2 P1 Generator ICE ICE Powersplit P4 P0 Parallel hybrids Series Hybrid Other independent factors to be overlaid: Direct / indirect eMotor cooling Combinations of sumps / fluids P4 Variant and Series Hybrid can be implemented with a variety of EV systems - see EV layouts 3-5 (previous slide) Parallel hybrids depend on eMotor position. P2 and P3 (input or output to the transmission) are most interesting for combining and may see new lubricant needs Penetration of hybrids will be small (max 10%) so unlikely to see greatest investment by OEMs Hybrid AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Electrified truck / bus layouts Central Drive systems fit into existing design architecture and supply chains A transition technology Central drive requires a 90° turn in power, needing greater electrical property protection Central Drive Transverse Reducer differential eMotor / reducer integration eMotor Greater variety / complexity than Passenger Car (PC) EV Layout 1 EV Layout 3 eMotor reducer Reducer differential Ultimate destination Wheel hub motors Direct cooled electric motors expected for transverse systems Wheel hub motors EV Layout 4 AMT eMotor Transverse layouts are more efficient eMotor reducer EV Layout 2 EV Layout 5 Electric / Fuel Cell AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. How could vehicles and lubricants change in the future? 1 Options for eCV Layouts 2 3 eCV transmission lubricant requirements Detail on eFluids for electrified drivetrains AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Fluid needs for Commercial Vehicles (CVs) Theoretical Heavy Duty BEV Coolant for fast charger station Grease for eMotor Coolant for battery Coolant for power electronics ETF eMotor Coolant Battery Coolant 15L 2L 30L Match long-drain axle (500k km)? Per eAxle fluid ? (1m KM) BEV and FCEV 60% by 2040 ? 60% by 2040 Sump Size ODI eDrive Oil for eMotor and gearbox Adoption Depending on configuration, could include… Axle oil (unchanged) Hybrid HDEO Hybrid-MTF H2 combustion EO Fuel cell coolant Source: Afton Chemical AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Direct and indirect effects of electrification on fluid needs Direct: Lubricant directly applied to electrified systems – eMotors, power electronics, batteries Indirect: Traditional sub-systems, but used in a different way: engines, reduction gears, wheel bearings AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Direct eMotor cooling benefit to OEMs Joint work between Afton Chemical and Ricardo PLC delivered the following assessment of different eAxle hardware in passenger cars, enabled by advanced Electric Transmission Fluids (ETF) Direct cooling (wet vs dry) Improved vehicle efficiency - 1.2% in WLTP - 2-3% anticipated in real-world extremes Lower temperatures - ~25°C reduction in maximum winding temp - Significantly lower rotor magnet temp, enabling use of lower grade magnets - Improved component life Better performance - 25% gain in eMachine continuous performance Smaller and lighter - Potential for reduction in packaging size and mass – thinner stator housing and consolidation of cooling systems The results presented are based on analysis assumptions and input data, and therefore are provided to describe indicative benefits, rather than precise predictions AftonChemical.com Source: Afton Chemical and Ricardo PLC 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Why are new fluids needed? eMotor example Electric coil as stator Much more copper in a critical role New materials (coatings etc) Magnetic rotor Loses magnetism at high temperature Cooling is critical for safe function Oil may be applied directly to cool these sensitive, electrical parts AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Direct battery cooling offers OEM benefits Joint work between Afton Chemical and Ricardo PLC delivered the following assessment of different battery hardware, enabled by direct coolants Direct battery cooling Longer battery life - 5-10% longer life with a 4.5C charger cycle - Further battery life benefit from lower cell-to-cell temperature, which in turn would lead to lower voltage variation, thereby reducing the cell balancing requirements. This may also provide an efficiency benefit. Lower temperatures and gradients - With immersion cooling cold plate module the following reductions were seen: - 13°C lower max cell core temperature (60°C vs 73°C) - 23°C lower max cell case temperature (40°C vs 63°C) Faster charge time - 20-25% shorter time to 80% State of Charge Further benefits not assessed by this work may include: improved fire safety, power output for high performance vehicles, and efficiency. The results presented are based on analysis assumptions and input data, and therefore are provided to describe indicative benefits, rather than precise predictions AftonChemical.com Source: Afton Chemical and Ricardo PLC 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Direct power electronics cooling Cooling of power electronics is prioritised by many OEMs First in the cooling circuit of many designs made public Direct cooling with a dielectric fluid provides better cooling than indirect with water/glycol Comparison of calculated heat transfer coefficients of direct oil spray cooling and water / glycol (50/50) tube cooling as a function of volume flow. Source: “New Measurement Method for Direct Cooled Power Electronic with Transmission Fluids”, JECTC, March 2021 AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Additive technology options Axle Additives MTF Additives ETF Additives Hypoid gear protection Spiral bevel gear protection Cleanliness Synchroniser performance eMotor cooling - Direct eMotor cooling - Indirect Mechatronics compatibility AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Example layout – lubricant considerations EV layout 2 - separate eMotor coolant EV layout 3 – single integrated ETF sump eMotor / reducer reducer differential integration eMotor AMT EV Layout 3 EV Layout 2 Direct eMotor coolant • Dielectric fluid MTF • Additional needs Axle fluid • Additional needs Electric Drive Unit Fluids (ETF) Requirements to serve: • eMotor • Power electronics • Reduction gears and differential • Shifting system AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Commercial Vehicle (CV) vs Passenger Car (PC) differences Relative importance and speed of adoption Low / Not Prioritised Important / High Multi-speed - Direct-cooled eMotor Specific Gear Loads - Required for greater vehicle mass Assumed in many heavy CV projects - Friction system or dog-clutch? - PV and CV trending towards this - Prioritised earlier in CV for efficiency - - Due to greater vehicle mass More difference between OEMs than PC vs CV eMotor Speed - eMotor speeds up to 10k rpm (up to 30k in PC) - But CV OEM feedback shows concern on the effects of this; wear, aeration and seals Efficiency - Larger battery and cost - Therefore larger value in efficiency - But viscosity change is much bigger for CV Voltage - Larger battery and power output means higher voltage (and to enable fast charging) - This promotes direct battery cooling Life / ODI - Much longer ODI and full lifetime in CV - Fluid durability emphasised in CV AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. How could vehicles and lubricants change in the future? 1 Options for eCV Layouts 2 3 eCV transmission lubricant requirements Detail on eFluids for electrified drivetrains AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. eCoolant key parameters Cooling Capability Foam Control Oxidation Resistance eCoolants Material Compatibility Mechanical Protection Electrical Properties Fire Safety AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Integrated eDrive systems Require Additional Performance Electric Transmission Fluids (ETF) ETF performance is a balance EP v. Compatibility EP and Wear vs. Electrical Properties Cost vs. Cooling Performance Materials Compatibility Elastomers Engineering Plastics Electrical Properties Friction Single/multi-speed Clutch Synchro Performance Copper Electrical conductivity Aged electrical conductivity Dielectric breakdown voltage Mechanical Protection Cooling Performance Sustainability Extreme Pressure Life Cycle Analysis Pitting Cradle to Gate Wear (Gear and Bearing) Thermal conductivity Specific heat capacity Oxidation Efficiency Foam and Aeration Range extension through: Surface tension Thermal Properties Aeration Friction Viscometrics AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Electric Transmission Fluid (ETF) product landscape Compatibility (metals, plastics, sealants) Fluid styles (gears, bearings) Mechanical Highest compatibility Protection Bearing and gear protection Balanced Difference by Other factors important Application Region OEM Efficiency Friction Fluid durability CV OEMs likely to prefer mechanical durability AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Efficiency – High Value for Range Extension Built on a solid foundation of additives AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Afton’s approach for copper (Cu) corrosion assessment Fluid Phase I Interface (dissolved and fluid components) Gas Phase Failure mechanism and phase dependent consideration In-house tests e.g. CBT - In-house tests e.g. CBT Mod D130 Lab tests - D130 Mod D130 Lab tests Conductive layer | Cu Leaching -> el. short | -> el. interruption AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Afton’s multi-phase copper (Cu) corrosion test Fluid Phase I Interface (dissolved and fluid components) Gas Phase Test set-up CBT Lab test - - CBT D130 Lab tests Conductive layer | Cu Leaching -> el. short | -> el. interruption Source: Afton Chemical AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Materials Testing Afton Test Development Magnet wire Plastic and insulation Connector and sensor Magnet PCB Bare copper Magnet wire test example Source: Afton Chemical AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Electrical Properties Conductivity is the ability of charged particles to move Breakdown voltage measures potential difference before arcing How many? Are they free to move? Resistivity is the inverse From industrial testing AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Electrical Properties Fresh and aged fluid. Bearing ESD. Control of electrical conductivity before and after ageing Conductivity nS/m 2500.0 2000.0 1500.0 1000.0 500.0 0.0 20 40 60 80 100 120 Temp (oC) 140 160 180 High resistivity in fresh and aged fluid can be achieved Electrostatic discharge (ESD) in bearings can be addressed by lubricant AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Traditional lubricants – issues Indirect effects of electrification Vapour phase corrosion Adjacent compartments, controls and sensors at risk Seals and aeration Faster rotational speed from eMotor output shaft Wear (gear and bearing) Usage, RPM and shift pattern all different Bearing electrical discharge Charge can transfer between sections of hardware or lubricants Lower viscosity for efficiency Huge value in electrification (higher range /smaller battery) SAE 75W-80? AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Summary AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Future powertrains for commercial vehicles Summary Numerous eCV layouts are possible High complexity OEMs continue to develop their pathway – unclear needs Direct cooling of eSystems benefits the OEM Enhanced efficiency and performance Multiple fluid types may be needed to serve CV OEMs eCoolants Electric Transmission Fluids (ETF) Traditional oils with enhanced performance Testing and test development is important to measure performance Efficiency, materials, copper, electrical AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Next Mobex webinars: Future Powertrains for Commercial Vehicles: Part 3 Part 3: Navigating the Messy Middle; Lubricant Needs for Alternative Fuels When: Thursday 14 December, 2pm GMT Alternative fuels under consideration Lubricant challenges with alternative fuels Fuel agnostic or dedicated lubricants Did you miss Part 1? Available on-demand from Mobex Part 1: Future Powertrains for Commercial Vehicles AftonChemical.com Drivers for change and subsequent OEM response Hardware and technology mix by energy source Lubricant requirements for future combustion engines and hybrid and electric systems AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. Q&A Adam Banks, Senior Marketing Manager, eMobility: adam.banks@aftonchemical.com David Thompson, CTS Manager, Driveline: David.Thompson@aftonchemical.com David Ellis, OEM Director: David.Ellis@aftonchemical.com AftonChemical.com 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation. 2023 © Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation.
