Future Steel Vehicle – Advanced Powertrains
and the influence on Material Selection
Great Designs in Steel: May 13th 2009
Harry Singh
(EDAG FSV Program Manager)
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Overview
1.
Introduction:
EDAG – brief overview
WorldAutoSteel, Sponsoring Companies
2.
WorldAutoSteel – Future Steel Vehicle (FSV)
•
Advanced Power Train Systems HEV, PHEV, BEV, FCEV
•
Well to Wheels efficiencies
•
FSV Materials Portfolio
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EDAG - Overview
In USA since 1994, 350 employees
Product Development Engineering Services
Styling
Design & Engineering
Computer Simulation
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WorldAutoSteel Members
WorldAutoSteel, the automotive group of the World Steel Association, continually
explores steel innovation that demonstrates the value of steel to the automotive
industry.
WorldAutoSteel member companies from around the world pool global resources to
deliver vital research that is central to effective steel automobile applications.
ArcelorMittal - Luxembourg
POSCO - South Korea
Baoshan Iron & Steel Co. Ltd. - China
Severstal - Russia/USA
China Steel Corporation - Taiwan, China
Sumitomo Metal Industries, Ltd. - Japan
Hyundai-Steel Company - South Korea
Tata Steel & Corus - India, UK, Netherlands
JFE Steel Corporation - Japan
ThyssenKrupp Stahl AG - Germany
Kobe Steel, Ltd. - Japan
United States Steel Corporation - USA
Nippon Steel Corporation - Japan
Usinas Siderurgicas de Minas Gerais S.A. Brazil
Nucor Corporation - USA
Voestalpine Stahl GmbH - Austria
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Future Steel Vehicle
WorldAutoSteel continues to lead the materials revolution through
projects like the Ultra Light Steel Family of Research:
•
•
ULSAB, ULSAC, ULSAS (BIW, Closures & Suspensions)
ULSAB-AVC
AVC (Advanced Vehicle Concepts)
WorldAutoSteel’s newest program Future Steel Vehicle (FSV)
Part 1 – Engineering Study (2008 – July 2009)
Part 2 – Concept Design (July 2009 - 2010)
Part 3 – Demonstration Hardware (2010 - 2011)
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Future Steel Vehicle
FSV Objective:
Strengthen Steel’s Position as the Automotive Structural Material of Choice for the
Future Vehicles (2020) & identification of new applications for steel.
FSV Justification:
Global growth of vehicle fleet from 820,000,000 vehicles in
2008 to 1 billion by 2020.
Transportation at present is 96% dependence on petroleum.
Daily worldwide petroleum usage 85,000,000 barrels
Vehicle emissions standards: EU 130 CO2 g/km 2009 & 95
g/km 2020, Japan 145 g/km 2009, USA CAFE 35mpg 2015.
Increasing vehicle efficiencies to reduce petroleum
consumption & to reduce Green House Gas emissions:
are the key drivers for the implementation of Advanced
Powertrains with increased focus on Vehicle Mass Reduction.
Reduction
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CO2
FSV: Phase 1 – Engineering Study
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FSV - OEM Direction/Trends
The assessment of the announcements from automobile manufacturers show
progress on various technologies which include;
1.
Conventional internal combustion engine (ICE) based smaller more
efficient gasoline/diesel vehicles
2.
Higher efficiency Hybrid Electric Vehicle (HEV)
3.
Plug-in
in hybrids (PHEV) with limited range of miles driven in Electric Mode.
This option offer significant reduction in fossil based petroleum usage,
especially when the daily distances driven are close to the vehicle’s electric
range. The additional distance being driven using petroleum or Bio-fuels
Bio
4.
Battery Electric Vehicles (BEV) with driving range of approximately 200 km
5.
Fuel Cell Electric Vehicles (FCEV) using hydrogen gas as a fuel source
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FSV - OEM Announcements
A broad range of alternate propulsion vehicles have been announced by automakers
around the world. The following table shows the number of vehicles announced by
OEMs (Concept and Production)
Future Steel
Vehicles
Type
OEM Announcements
Electric only Plug-in Hybrid
Fuel Cell
BEV
18
-
-
PHEV
-
9
-
FCEV
-
-
4
Mitsubishi (2009)
Subaru (C)
Mercedes (2011)
Th!nk (2009)
BMW (2015)
Tesla (2009)
BMW (2009)
Nissan (2010)
NICE (2009)
Dodge (2010)
Toyota (2012)
REVA (C)
BYD(2011) TATA (2011)
Ford (2011)
Magna (C)
Honda (2009)
GM (C)
Hyundai (C)
Mercedes (C)
GM (2011)
GM (2010)
Fisker (2010)
Chrysler (2012)
Toyota (2010)
Mercedes (2012)
BYD (2009)
Volvo (C)
(XXXX) – Proposed year of production
(c) – Concept Vehicle
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F
Future
Advanced Powertrains
PHEV (Plug-in Hybrid Electric Vehicle)
Toyota – Prius PHEV
BEV (Battery Electric Vehicle)
Mitsubishi - I MiEV
EREV (Extended Range Electric Vehicle)
GM - VOLT
FCEV (Fuel Cell Electric Vehicle)
Fuel Compressed Hydrogen Gas
Honda - Clarity
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Small Cars can be affordable,
safe & fun, and HEV & BEV’s
TATA nano 3100mm – 4 Occupants
Daimler Smart for-two 2695 mm
Toyota IQ 2985mm – 3+ Occupants
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FSV – Fuel Cell Technology Assessment
70
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FSV – BEV Battery Technology Assessment
kWh/kg
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Petroleum to Li-ion
Li
Batteries?
Approx 110 Wh (90 Wh for small car) of energy required per km of driving
For small car 5 kWh battery driving range 32 km (year 2015 cost estimate $2,346)
For mid-size
size car 12 kWh battery driving range 64 km (year 2015 cost estimate $5,400)
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Vehicle Daily Distances Traveled
USA
Miles
PHEV40 – 70% daily miles driven in Electric mode
PHEV20 – 50% daily miles driven in Electric mode
Europe
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km
FSV: Vehicle Size & Power Trains
Worldwide over 70% market share between two vehicle sizes: Small car
(up to 4,000mm, A/B class) and Mid-Class
Mid
car (up to 4,900mm, C/D class)
PHEV20
FSV 1
BEV
Electric Range – 32km
Total Range – 500km
Total Range – 250km
Max Speed -150km/h
150km/h
Max Speed -150km/h
0-100 km/h 11-13
13 s
0-100 km/h 11-13 s
PHEV40
FSV 2
FCEV
Electric Range – 64km
Total Range – 500km
Total Range– 500km
Max Speed -161km/h
161km/h
Max Speed -161km/h
0-100 km/h 10-12
12 s
0-100 km/h 10-12 s
Range based on UDDS cycle
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FS
FSV1:
Occupants, Front & Rear Leg
Room and Luggage Targets
Occupants:
Front Row Seating – 2
Rear Row Seating – 2+
825 mm
250 Liters
1065 mm
Vehicle Class
Average Front Leg Average Rear Leg
Room
Room
Luggage
Liters
A
1055
760
170
B
1065
850
340
C
1070
877
370
D
1075
961
450
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FS
FSV2:
Occupants, Front & Rear Leg
Room and Luggage Targets
Occupants:
Front Row Seating – 2
Rear Row Seating – 3
920 mm
370 Liters
1065 mm
Vehicle Class
Average Front Leg Average Rear Leg
Room
Room
Luggage
Liters
A
1055
760
170
B
1065
850
340
C
1070
877
370
D
1075
961
450
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FSV:
V: Advanced Powertrains Concept Layouts
FSV: BEV
Battery Electric
Vehicle
FSV: FCEV
Fuel Cell Electric Vehicle
FSV: PHEV40
Plug-in Hybrid Electric Vehicle
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FSV: Total Life Cycle Assessment (LCA)
At present vehicle use
(Pump to Wheel) Fuel
consumption:
km/l or CO2 g/km or
mpg
LCA: For Vehicle life of 200,000 km
1. Green House Gas CO2:
2. Energy Efficiency:
3. Cost of Ownership:
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g/km
wh/km
$/km
FSV
SV: Efficiency of Fuels and Energy Sources
Well to Pump
Pump to Wheel
Gasoline
Production
80
Diesel
Production
84
Well to Wheel
Gasoline 20-35 % efficient
16
Diesel 25-40 % efficient
21
Ethanol 22-37 % efficient
8
Bio-Diesel 25-40 % efficient
8
Bio Fuel:
Ethanol
100
units of
energy
38
31
Diesel
Renewable
91.5
Internal
Combustion
Engine
Electric
Motor Drive
35
33
BEV
70
31
Electricity
Generation
US-Mix
38
FCEV
H2 - NG
9
27
Reformation
24
10
57
23
62
Greet 1.8b Argonne National Lab
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21
20
FSV1 - Pump to Wheel CO2 Emission g/km
110
7
Gasoline
Toyota Prius 2010
PHEV20 - CS6
34 mpg, 14.4 km/l,
7.0 l/100km
Pump to Wheel
100 kg Vehicle Mass Reduction
PHEV20 - 500km 5
95 g/km 2020 EU
PHEV20 - 150km4
PHEV20 - 65km3
130 g/km 2012 EU
PHEV20 32km CD2
0
BEV1
0
0.0
140 g/km 2009
JAMA (voluntary)
20.0
40.0
60.0
80.0
100.0
120.0
140.0
CO2 Emissions in g/km
CD – charge depleting – energy from battery
CS – charge sustaining – energy from petroleum, similar to HEV
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160.0
180.0
200.0
FSV: Electricity Production
USA - Electricity Production
Results also available for Europe, India, China, Japan, 100% coal, 100% Renewable
[Source: Greet 1.8b US-Mix]
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FSV1 - Well to Wheel CO2 Emissions g/km
Gasoline 7
138
Toyota Prius 2010
PHEV20 -
CS 6
Well to Pump (US Mix Electricity)
Pump to Wheel
100 kg Vehicle Mass Reduction
PHEV20 - 500km 5
PHEV20 - 150km 4
PHEV20 - 65km 3
PHEV20 - 32km CD 2
BEV
E50
J57
114
0
-10.0
Electricity 100% Coal
110
1
10.0
30.0
50.0
70.0
90.0
110.0
130.0
150.0
170.0
190.0
CO2 Emissions in g/km
E50
Electricity Mix Europe
J57
Electricity Mix Japan
CD – charge depleting – energy from battery
CS – charge sustaining – energy from petroleum, similar to HEV
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210.0
230.0
250.0
FSV2 - Pump to Wheel CO2 Emission g/km
Gasoline8
134
Ford Fusion HEV 2010
PHEV40 - CS7
Pump to Wheel
PHEV40-500km6
29 mpg, 12.5 km/l,
8.0 l/100km
100 kg Vehicle Mass Reduction
PHEV40-250km5
95 g/km 2020 EU
PHEV40-100km4
PHEV40 64km CD3
0
FCEV H2 - NG2
0
FCEV H2 - Elec1
0
0.0
130 g/km 2012 EU
140 g/km 2009
JAMA (voluntary)
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
180.0
CO2 Emissions in g/km
CD – charge depleting – energy from battery
CS – charge sustaining – energy from petroleum, similar to HEV
H2 NG – Hydrogen from Natural Gas
H2 Elec – Hydrogen from H2O Electrolysis
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200.0
FSV2 - Well to Wheel CO2 Emission g/km
168
Gasoline8
Ford Fusion HEV 2010
PHEV40 - CS7
Well to Pump (US Mix Electricity)
PHEV40-500km6
Pump to Wheel
100 kg Vehicle Mass Reduction
PHEV40-250km5
PHEV40-100km4
PHEV40 64km CD3
FCEV H2 - NG2
FCEV H2 - Elec1
-10.0
10.0
30.0
50.0
70.0
90.0
110.0
130.0
150.0
170.0
190.0
210.0
230.0
CO2 Emissions in g/km
CD – charge depleting – energy from battery
CS – charge sustaining – energy from petroleum, similar to HEV
H2 NG – Hydrogen from Natural Gas
H2 Elec – Hydrogen from H2O Electrolysis
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250.0
CO2 (g/km)
FS Pump to Wheel CO2 g/km comparison
FSV:
●
●
●
●
▲
▲
Gasoline AT
Gasoline CVT
Gasoline MT
Hybrid
Diesel
LPG
ICE
Hybrid
PHEV40, CS – Battery
Charge Sustaining
PHEV20, CS – Battery
Charge Sustaining
PHEV, CD – Battery Charge Depleting
BEV – Electric Vehicle
FCEV – Fuel Cell Vehicle
Vehicle Mass (kg) FSV – PHEV20 & PHEV40
70% Miles Driven in EV mode – Energy from
Electric Grid
30% Miles Driven in HEV mode – Energy from
Petroleum
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Future Steel Vehicle
Part 1 – Engineering Study (2008 – July 2009)
Part 2 – Concept Body Structure Design (July 2009 - 2010)
Part 3 – Demonstration Hardware (2010 - 2011)
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FSV: Phase 2 – Concept Design
•
Investigate the vehicles mass reduction potential with the use of
Advanced High Strength Steel (AHSS), advanced manufacturing
technologies and use of computer aided structural optimization.
•
Understand the loads imposed by advanced powertrains on the
vehicle structure and hence identify requirements for new grades of
steel for optimized low mass vehicle structural applications and
designs.
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FSV – Body Structure Mass Targets
BIW Wt. vs. GVW
450
400
BIW (Kg)
350
'01 - '03 Steel BIW
ULSAB-AVC
Aluminum BIW
'04 - '08 Steel BIW
Top 10 Steel BIW
EU Super Light Car
Linear ('01 - '03 Steel BIW)
300
250
Future Steel Vehicle
• Battery Electric
• Plug-in HEV
• Fuel Cell
200
150
1000
1500
2000
GVW (Kg)
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2500
3000
Steel Grades for ULSAB (2000)
Low Strength
Steels (<210MPa)
High Strength
Steels
Ultra High Strength
Steels (>550MPa)
70
60
Elongation (%)
50
40
Mild
30
BH
20
10
MART
0
0
300
600
900
1200
1600
Tensile Strength (MPa)
ULSAB Program: Achieved 25% reduction in BIW Mass
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Steel Grades for ULSAB – AVC (2004)
Low Strength
Steels (<210MPa)
High Strength
Steels
Ultra High Strength
Steels (>550MPa)
70
60
Elongation (%)
50
40
Mild
30
BH
20
10
MART
0
0
300
600
900
1200
1600
Tensile Strength (MPa)
ULSAB – ABC Program: Achieved
24% reduction in BIW Mass
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Steel
el Grades Availability for FSV (2020)
Low Strength
Steels (<210MPa)
High Strength
Steels
Ultra High Strength
Steels (>550MPa)
70
60
Elongation (%)
50
40
Mild
30
BH
20
10
MART
0
0
300
600
900
1200
Tensile Strength (MPa)
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1600
Steel
el Grades Availability for FSV (2020)
FSV
Choice of Steel
Grades
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Manu
nufacturing Processes ULSAB
Manufacturing Techniques considered for the WorlAutoSteel ULSAB &
ULSAB-AVC programs.
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M
Manufacturing
Processes FSV
Manufacturing Techniques available (existing and emerging) that are being
considered for the WorlAutoSteel FSV program.
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Summary
WorldAutoSteel – Future Steel Vehicle (FSV)
•
Advanced Power Train Systems PHEV20, PHEV40, BEV, FCEV
•
Well to Wheels efficiencies
•
FSV Materials portfolio
Part 1 – Engineering Study (2008 – July 2009)
Part 2 – Concept Body Structure Design (July 2009 - 2010)
Part 3 – Demonstration Hardware (2010 - 2011)
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FSV – Body Structure Mass Targets
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