Electric Power Fuel Considerations

Veículos Elétricos e Híbridos Dr. Wanderlei Marinho da Silva BNDES – 12 Maio de 2010 Rio de Janeiro

Overview

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What is a Hybrid? … something (as a power plant, vehicle, or electronic circuit) that has two different types of components performing essentially the same function. (Your dictionary, 2001)

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Where we can find Hybrid Philosophy?

And locomotives etc... 4

Urban and Highways drive cycles

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Automotive Megatrends Going Green Vehicle Stability System

Infotainment Telematics/eCall

FlexRay™

Safety

Hybrid Engine Control Radar

The Affordable Vehicle

Night Vision

Connectivity/ Infotainment

Intelligent Distributed Control

Camera-based Collision Avoidance

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Today’s Automotive Electrical-Electronics Issues Electric Power Personal Considerations: •Interior lighting •Fans •Audio equipment •Rear entertainment displays •Navigation systems •Heated seats •Heated steering wheel •Active suspension •High-end sound •Computers, business machines, Cost and Technology navigation, communication, Drivers games… Electric Power Fuel Considerations: •Improved starting •Fuel processing systems •Power steering •Electric air conditioning •Electromagnetic valves •Electric drive engine (loads)

Electric Power Safety Considerations: •Exterior lighting •Electric power steering •Electric de-mist / de-frost •Anti-lock braking •Electric-hydraulic braking •Traction / stability control •Adaptive cruise control •Night vision •Collision avoidance systems •Ignition cut-off

Emission Considerations: •Stop/start/idle •Electric start assistance •Electromagnetic valves •Electrically heated catalysts 9

Automotive Component Lifecycle

10 Source: Integrated Vehicle Control System Technology — Steering, Braking, Suspension, and Powertrain Systems, Aloysius J. (Alois) Seewald, TRW Automotive Chassis

VHE – Development Levels of abstraction requirements specification architecture component design system integration 11

EVs and HEVs

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Vehicle Systems and their Architectures

Vehicle Electrical Architecture

Has a

Made of Distributed Software Architecture

Communication Architecture

Control Algorithm Architecture

Physical Electrical Architecture

Harness Architecture

Vehicle Electrical System Made of

Has a Devices

Harnesses

are Has a ECU Hardware Architecture

power actuators sensors gnd, fuses

ECU Made of comm

I/O

Made of wires

datalinks

Has a rom

CPU

ram

ECU Software Architecture

is

Made of software

hardware

Systems Engineering manages • capacities • properties 13

Hybrid variants Architecture approaches

Micro hybrid

Mild hybrid

Medium hybrid

Full hybrid

Boosting

passive

active

yes

yes

Recuperation

limited / overload

yes

yes

yes

Electric driving

no

no

limited

yes

Start / stop

yes

yes

yes

yes

12 V

12 - 50 V

12 - 100...400 V

12 - 200...500 V

≤ 5 kW

≤ 10 kW

≤ 15 kW

≥ 15 kW

Functionality

Vehicle elec. sys. Voltage level(s) Elec. machines

Power rating

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The New Transportation Era:

A Portfolio of Technology Options for Personal Transportation Vehicle drive trains become simpler as reliance on internal combustion engines decreases: High

Level of Complexity

Low

PHEV

EREV

BEV

(Plug-in Hybrid Electric Vehicle)

(Extended Range Electric Vehicle)

(Battery Electric Vehicle)

Utility infrastructure and charging infrastructure needs increase as “electric miles” increase: High

Level of Complexity

Low

PHEV

EREV

BEV

(Plug-in Hybrid Electric Vehicle)

(Extended Range Electric Vehicle)

(Battery Electric Vehicle)

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Vehicles in the Pipeline Toyota Prius

Chevy Volt Ford Escape

Volvo Recharge

Mitsubishi Miev Saturn Vue

Daimler Sprinter

BMW Mini Daimler Smart Nissan Cube

Declared Production Programs From GM, Nissan, Ford 2010- 2012

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Electric Vehicles in Pipeline 2008

A/B A/B

Think City

2009

Subaru R1E

Mitsubishi i-MiEV

2010

Tata Indica Vista

Nissan EV-02 Tata Nano

2011

Smart ED

VW Twin Drive

Mercedes A-class?

2012

Toyota IQ?

VW UP?

segment segment

C/D C/D

Kewet Buddy

Nice Cars Zero

BYD F3DM

Miles XS500

Fiat Doblo (Micro-Vett)

ZAP X

Bolloré Bluecar

BYD F6DM

Toyota Prius PHEV

BYD F3E

segment, segment, SUV SUV

G G segment segment

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Tesla Roadster

Heuliez/Orange/ Michelin Will

GM Volt Opel Ampera

Saturn Vue PHEV

BYD F6E

Tesla Model S

Mini E

Fisker Karma

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PHEV Development Timeline

2008

Annual New Plug-In Vehicle Sales

16,000

12,000 2,500 10,000 2,000 8,000 1,500 6,000 1,000

4,000

500

2,000

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11 20 12 20 13 20 14 20 15 20 16 20 17 20 18 20 19 20 20 20 21 20 22 20 23 20 24 20 25 20 26 20 27 20 28 20 29 20 30

20

09

0 20

20

2010

18,000

14,000

3,000

0

Production Ramp Up

Other OEM PHEVs, EVs Enter Market

2006

Annual Sales (thousands) Cumulative Sales (thousands)

3,500

Cumulative Plug-In Vehicle Sales

4,000

First Announcements of Production-Intent PHEV Programs 1st PHEV Introduction

2012

Begin SAE Standards Efforts

Launch of 1st Gen 2 Programs

2014

2016

Production Implementation of Smart Charging and AMI Integration Efficient Building Systems

Utility Communications

2003

Internet

Begin Utility-Auto Collaborations

Consumer Portal & Building EMS

Finalize Finalize Connector Communications (J1772) (J2836)

Dynamic Systems Control

Distribution Operations

Advanced Metering

Plug-In Hybrids

Data Management

Distributed Generation & Storage

Renewables PV

Control Interface

18 Smart End-Use Devices

http://www.greencarcongress.com/2010/01/hybsales-20100107.html

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Electric Vehicles Are Coming

3,000

18,000 16,000 14,000 12,000

2,500 10,000 2,000 8,000 1,500 6,000 1,000 500 0

4,000

Cumulative Plug-In Vehicle Sales

3,500

Annual Sales (thousands) Cumulative Sales (thousands)

2,000 0

20 09 20 10 20 11 20 12 20 13 20 14 20 15 20 16 20 17 20 18 20 19 20 20 20 21 20 22 20 23 20 24 20 25 20 26 20 27 20 28 20 29 20 30

Annual New Plug-In Vehicle Sales

4,000

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Electric Vehicle Power System Power system components

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Vehicle Design considerations for Vehicle based Mobile Electric Power Application

Electric Vehicle Power System

Vehicle Design considerations for Vehicle based Mobile Electric Power Application 26

Electrical vehicles with varying drive concepts, requirements and applications Electric motor drive

Electricity grid / solar

Comb. engine / elec. motor drive (hybrid) Fuel

Elec. equip.

Charger

3 AC

Battery

Comb. engine drive / elec. loads

Fuel

Generator

Elec. grid

Comb. engine

Energy store Generator

Inverter Generator

Vehicle elec. sys. Comb. engine Elec. motor

Elec. motor

Transf ormer

Vehicle elec. system Electrical loads

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Series HEV Configuration

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Parallel HEV Configuration

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Electric Vehicle Technology Competences • • • • •

Energy converters Energy storages Power electronic converters Control Auxiliary systems

• • • • •

Transmission Weight issues Packaging Laboratories Research and Development R&D

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Typical Power Electronics Applications

Automotive Power Electronics – opportunities and chalenges Ecostar Electric Drive Systems Company

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Electric Machines and Power Electronics cost evaluation

Handbook of automotive power electronics and electric drives

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Insulation faults in electric/hybrid vehicles: Example of possible

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Overview of standards Germany

International

DIN VDE 0122:1986-08 Elektrische Ausrüstung von Straßenfahrzeugen (Electric equipment of electrical road vehicles)

-

DIN EN 61851-1 (VDE 0122 T1):2001-11 Konduktive Ladesysteme für Elektrofahrzeuge - Teil 1: Allgemeine Anforderungen

IEC 61851-1:2001-01 Electric vehicle conductive charging system – Part 1: General requirements

DIN EN 61851-21 (VDE 0122 T 2-1):2002-10 Konduktive Ladesysteme für Elektrofahrzeuge – AC/DC-Versorgung

IEC 61851-21:2001-05 Electric vehicle conductive charging system – Part 21: EV requirements for conductive connection to an ac/dc supply

DIN EN 61851-22 (VDE 0122 Teil 2-2):2002-10 – Konduktive Ladesysteme für Elektrofahrzeuge – AC-Ladestation

IEC 61851-22:2001-05 Electric vehicle conductive charging system – Part 22: AC electric vehicle charging station

DIN EN 1175-1 (VDE 0117 T1):1998-11 Sicherheit von Flurförderfahrzeugen – Elektrische Anforderungen

EN 1175-1:1998-01 Safety of industrial trucks – Electrical requirements Part 1: General requirements for batt. powered trucks

DIN EN 1987-3:2000-07 Elektrisch angetriebene Straßenfahrzeuge - Besondere Festlegungen für die Sicherheit Teil 3: Schutz der Benutzer gegen elektrische Gefahren

EN 1987-3:1998 Electrically propelled road vehicles – Specific requirements for safety – Part 3: Protection of users against electrical hazards UL 2231-1:2002-04 Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits: General requirements UL 2231-2 – Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits: Particular Requirements for Protection Devices for Use in Charging systems

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Automotive Power Electronics

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Electromagnetic Compatibility Concerns

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EMC and EMI - Case

Electromagnetic Compatibility Concerns

λ=c/f [m] C= velocidade da luz ~300.000 km/s f=freqüência do sinal 38

Automotive Emission Testing

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How do I keep my equipment from emitting? • Chassis Material - Highly conductive • Chassis Joints - Tight and conductive

• Signal and power lines - Proper filtering • I/O Cables - Shield with proper terminations

• Quiet Noisy Circuits - Minimize spikes

• Magnetics - Magnetic and electric shielding

Noisy Circuit

Receiver

Equipment Chassis

Minimize EMI generated and contain in the chassis 40

How do I keep my equipment from emitting?

• Chassis Material - Highly conductive chassis or line plastic chassis with metal

All Quiet!

Receiver

• Chassis Seams and Lids - Provide tight, corrosion resistant Metal-to-Metal interfaces, use conductive gaskets or spring fingers, keep fastener spacing small or use lip seals • Quiet Noisy Circuits - Minimize ringing and reflections, provide local decoupling capacitors for high frequency circuits, use laminated buss bars and snubbers with power switches to eliminate ringing and overshoot

Noisy Circuit

Equipment Chassis

• I/O Cables - Use common mode and differential mode power line filters, feedthrough filter pins on I/O signals if needed, overbraid signals that are noisy by design (i.e. serial data buses) • Magnetics - Transformer gap radiation, use belly band or encase in steel can. Faraday shield can help with common mode noise.

Don’t make much noise and keep the noise you make

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How do I avoid susceptibility? • Chassis Material - Highly conductive • Chassis Joints - Tight and conductive • Signal and power lines - Proper filtering

• Sensitive circuits - Bypass and in-line filtering • I/O Cables - Shield with proper terminations • Power distribution - Power and ground planes

Sensitive Circuit Transmitter

Equipment Chassis

Good design practice and experience leads to EMC 42

Component Level Tests Conducted Emissions Radiated Emissions

Radiated Susceptibility

Conducted Susceptibility

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Models – What for ? Equipment designers want to predict EMC before fabrication

© Siemens Automotive Toulouse

• Most of the time, EMC measurements are performed once the equipment is built. • No improvements can be done at conception phase. • Predict EMC performances IC, board, equipment optimizations • However, need of non-confidential IC models (black box models) 44

Automated Chamber supported Units

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How to interconect all?

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In-Vehicle Networking complexity Immobilizer Motors Motors Motors Motors Motors Motors Motors Motors

RKE and TPMS Rx Seat Modules

Instrument Cluster

Nav

Display

Chassis Management

Sunroof

Door Module Rear Lighting

Temp

Cooling Fan

Occupant Classification

Fuel Pump

Driver Seat Belt Pretensioner

Blower

Lighting R

Glow Plug

NOX

Rain Sensor

Door Module

Video

Airbag

Steering Column

HVAC

Video Video

Engine Management

Alarm

Lighting L Motors Motors Motors Motors Motors Motors Motors Motors

Radio

Body Controller / Gateway

Rear Module Flaps Flaps Flaps Flaps Flaps Flaps

Amplifier

SJB 4x4

Pass. Seat Belt Pretensioner

Blind Spot Detection

Sensor Cluster

Wipers Battery Management

1996 Typical Vehicle: 6 ECUs 2008 High-End Vehicle: > 70 ECUs

Power Steering

Transmission Active Steering

Suspension Suspension Suspension Suspension

Anti-lock Braking

Park Assist Adaptive Cruise Control

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modern automobile’s networks Buses

Speed

Origin

D2B (5Mbit/s, electrical or optical mainly for digital audio)

High

Auto

MOST (22.5Mbit/s, audio, video,control)

High

Auto

FlexRay (10Mbit/s, x-by-wire, safety-critical control)

High

Auto

Byteflight (10Mbit/s, constant latencies, airbag, sear-belt)

High

Auto

TTP (5~25Mbit/s, real-time distributed/fault-tolerant apps)

High

Auto

Bluetooth (10Mbits/s, wireless for infotainment equipments)

High

Consume r

CAN (50-1000kbit/s control only)

Low

Auto

J1850 (10.4kbit/s and 41.6kbit/s, control)

Low

Auto

LIN (20kbps, control)

Low

Auto

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Roadmap of in-vehicle networks optics bus

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Layered Software Architecture Application Layer

Boot Loader

ECU Moding

Distributable Distributable Distributable unit unit unit (supervisory) (feature) (feature)

Library Routine

Middleware Layer

Feature Activation Services

Information Exchange Services

System Services Layer

Real Time Services

Local I/O Filter & Data Translation

COMM Handler

RTOS Timers & Task Scheduling

Memory Driver

Local I/O Device Drivers (HWIO)

COMM Datalink Device Driver

Processor

Memory

Hardware Services Layer Board Support Package Physical Hardware

Processor

Memory

C O N F I G U R A T I O N

Sensors & Actuators Serial Bus Controller

Sensors & Actuators

Serial Bus Controller

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Software Vehicle Value Chain Customer

Revenue Market Share

Dealer

Satisfaction Aftermarket Sales

Manufacturing & Service

Efficiency Purchasing

Speed Flexibility Economy

Vehicle Engineering 51

Unimpaired

Legend:

Entry

Mid-Level Impaired Deviation

Remedy

Service

Result

Failed

System

Degraded

Faulty

Low-Level Impaired

Information

Malfunctioning

Logic

Erroneous

Component

Ideal

Level →

Defective

Multilevel Model of Dependable Computing

High-Level Impaired Tolerance 52

Developing Trends of Automotive Electronic Systems • Rise of importance of software in the Car

53 Refer to:B. Hardung, T. Kolzow, and A. Kruger, “Reuse of Software in Distributed Embedded Automotive Systems”

EV Infraestructure Developments across the world

54

Future Overview Imaginary fueling station of the future

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Infrastructure Working Council A Stakeholder Organization for Collaboration on Standards Infrastructure Working Council - Utility-funded stakeholder group - Identify and address needs for codes and standards - Not a standards body

SAE

IEC

Society of Automotive Engineers - J1772 (Connector) - J2836 (Communications)

IEEE

Intl Electrotechnical Comm - TC69 (Charge Infrastructure) - SC23 (Connectors)

NEC National Electric Code - NEC625 (EV Charging Systems)

EPRI IWC

Inst of Elec and Elect Engineers - 1547 (Interconnecting DR)

Others

ANSI, UL, etc.

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Smart Grid: Enabling PHEV and Other Distributed Resources

http://www.fastcompany.com/1633874/what-will-an-electric-vehicleready-smart-grid-infrastructure-look-like

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Components of the V2G system

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Wireless Charging for Electric Vehicles ‘on-the-move’ within 2-3 years

http://electric-vehicles-cars-bikes.blogspot.com/2009/10/inductive-road-wireless59 charging-for.html

Wireless Charging for Electric Vehicles ‘on-the-move’ within 2-3 OLEV (online electric vehicle) project years

http://electric-vehicles-cars-bikes.blogspot.com/search/label/Wireless%20Power 60 Korea advanced institute of science and technology (KAIST)

Wireless Charging for Electric Vehicles ‘on-the-move’ within 2-3 OLEV (online electric vehicle) project years

http://electric-vehicles-cars-bikes.blogspot.com/search/label/Wireless%20Power 61

Nissan wireless battery charging

Wireless Charging for Electric Vehicles ‘on-the-move’ within 2-3 years Wintricity project

http://electric-vehicles-cars-bikes.blogspot.com/search/label/Wireless%20Power 62

Nissan wireless battery charging

Accountability Not Simple Wall Outlets Intelligent, Wireless Networked Workstations with the Ability to Generate Reports and Manage the Distribution of Electricity.

http://www.coulombtech.com/subscribers/

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Bollard

Pole Mount

Wall Mount

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Roadmap Today

Future

Tomorrow

Gasoline & Diesel

Syntetic Fuels & Bio-Fuels Hydrogen

Combustion Engines Hybrids

Fuel Cells

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A caminho do futuro... Século XVIII Século XIX

Século XX Século XXI

Século XXII 71

And in a future of future perhaps a Laser Propulsion system Then we will travel at Light speed…. 300.000 km per second… Wanderlei Marinho 72