4AT060 Powertrains (ED)

5AT010 Electrical Components

Introduction

Dr. Steven Wilkins

 Lecture Content

• Introduction and Context

• Market and Technology Trends
• General introduction to Electrified
Powertrains
• Powertrains: What’s it all about?

Further Reading:

Chapter 1 (‘Introduction’), Electric Vehicle Technology Explained, Second Edition, James Larminie, John Lowry

Chapter 8 (‘Electric Vehicle Modelling’), Electric Vehicle Technology Explained, Second Edition, James Larminie, John Lowry

Chapter 2 (‘Fundamentals of Vehicle Propulsion and Brake’), Modern Electric, Hybrid and Fuel Cell Vehicles, Fundamentals, Theory, Design, Second Edition, Mehrdad Ehsani, Yimin Gao, Ali Emadi
We face many challenges… 2

This is a decisive decade for our world

– Biden, UN General Assembly, 21st September 2021
 Your Challenge towards 2050

The EU has set itself a long-term goal of

reducing all greenhouse gas emissions by
80-95%, when compared to 1990 levels, by
2050.

The challenge:
• Transport includes rail, shipping, aviation, road, etc.
• Road transport is set to increase, even if CO2 from transport
~50%
• The actual CO2 (/km) improvement needs to be ~80-95%
• New energy vehicles selling at volume by 2035-2050
• Technology ready by 2025-2030
Source: Data viewer on greenhouse gas emissions and removals, sent by countries to UNFCCC and the EU Greenhouse Gas
• Accelerated R&D 2020-2025! Monitoring Mechanism (EU Member States). https://www.eea.europa.eu/data-and-maps/data/data-viewers/greenhouse-gases-
viewer
https://ec.europa.eu/clima/sites/clima/files/strategies/2050/images/targets.png
Src: https://ec.europa.eu/energy/en/topics/energy-strategy-and-energy-union/2050-energy-strategy
 The challenges for heavy duty:
Short-term targets, slow deployment
• Heavy Duty sector expected to increase
towards 2050
Innovation Growth Maturity
100%

90%
90%
Die Hards

Percentage Adoption
80%
Laggards

70%
Late
60% Majority

50%
50%
Early
40%
Majority
• Legislation introduced May 2018, first
30%
declaration year 2019:
− 15% reduction CO2 by 2025 20%

Influentials
− 30% reduction CO2 by 2030 10% Opinion
• Typical vehicle development cycle can be ~5-7 years Leaders 10%

• Adoption curve can be more gradual 0%

• The next 30 years to 2050 potentially requires more Time Adapted from Dent Research

dramatic changes than the last 30 (i.e. since 1990)

How (collectively) are we going to achieve this?

City of the Future

Geofenced Area

Emission Zone

Zero Emission

Transport Corridors

• Zero-emission zones supported through charging infrastructure

• Inter-zone require mixed functionality
• Various vehicle configurations, but key is on modularity and standardisation
 Zero Emission – What do we mean by it?

• Zero emission vehicles commonly interpreted as BEV or FCEV,

which is the case for light duty vehicles
• Under the Green Vehicles Directive DIRECTIVE (EU) 2019/1161,
a zero emission heavy duty vehicle is one emitting <1g
CO2/km, but allow current levels of pollutants
− Several OEMs1,2 view that hydrogen combustion vehicles would
therefore qualify as zero emission as a bridging technology

BUT…
• National governments and city policy focus bans on pollutant
emissions (i.e. zero tailpipe emissions), potentially to include all
combustion engines (main focus on cars, but also including HD)
− Zero emission means ‘zero tailpipe emission’ (i.e. no pollutants)
• For heavy-duty, some solutions exist around potential geofencing
technologies; such as via PHEV, which can operate in Zero
Emission mode whilst in cities
• In-Service Conformity still has some artefacts relating to PHEVs
• One potential scenario is a PHEV fleet gradually replaced with
FCEVs or BEVs as fuel cell / battery technology improves further
− Flexible solution with deployment of future charging/fuelling infra
− More moderate technology step from combustion engines
[1]https://www.volkswagenag.com/en/news/2020/10/MAN-presents-Zero-Emission-Roadmap.html
[2]https://www.daf.com/en/about-daf/sustainability/alternative-fuels-and-drivelines/hydrogen https://theicct.org/sites/default/files/publications/Combustion-engine-phase-out-briefing-may11.2020.pdf
 Death of the Internal Combustion Engine? (not yet…)

“General Motors believes in an all-electric future,” Reuss

(chief of global product development) said. “Although that
future won’t happen overnight, GM is committed to driving
increased usage and acceptance of electric vehicles.”

BMW has already said it will electrify its entire range, as

has Volvo. Volkswagen introduced 20 new all-electric cars
by 2020, with a manufacturing plan capable of building “2
to 3 million all-electric cars a year by 2025”.

Battery costs are plummeting, and Bloomberg

Netherlands (and other countries) have declared New Energy Finance predict that electric
intentions to ban emissions-producing trucks by 2040, vehicles (EVs) will be cheaper than petrol
with passenger cars earlier at 2035. ACEA has already cars by 2022. A Nissan Leaf can already
planned to phase out fossil fuel vehicles by 2040 receive a 80% charge in 30 minutes, and that
will only improve.
Volvo Trucks targets 50% sales of e-trucks by 2030
Dieselgate did not help….
 Key Leading Automotive Trends
Market undergoing two major transitions:
Automation and Electrification
Advanced control including automation:
• Need for tools/facilities to develop/assess control
• Increasingly sophisticated ECUs / sensors
• Levels of optimisation beyond single vehicle
• Challenges on verification / robustness
• Value of predictive control based on application
• Electrification and hybridisation:
• Primarily centred around CO2 reduction (incl. fuels)
• Battery technology, models, ageing
• Thermal and charge management
• Challenges on cost / scale-up / deployment
• Large transitions in battery cost / technology
Electric Vehicle Range is Expanding
Example Predictions for Sales
Example Predictions for Sales 11
Are Electric Vehicles Really Better for CO2?
Requires Life Cycle
Assessment (LCA)

Complex analysis; depends

on battery production,
lifetime, efficiency, and
energy production (country
dependent)
 Netherlands Perspective
Highlights:

• 2025 all zero emission buses

• Currently a push for electric trucks

• 2025 no new ICE-only sales, zero

emission by 2030

• VDL, Heliox, Connexxion, DAF,

GINAF, EBUSCO, EMOSS
• Prodrive, Punch Powertrain, etc.

https://www.greencarreports.com/news/1113295_all-cars-with-engines-to-be-off-dutch-
roads-by-2030-following-2025-sales-ban

What will be your impact?

What about Electric Long Haul Trucks?
• Urban + Regional easier (e.g. <350km/day)
• Longer distances are very challenging…

?
Battery Chemistry Advances
Wide range of battery types Transients in terms of costs

Wide selection range of cell types, configuration,

thermal and charge management options => complex
decision process
Important to understand
More in Lecture 3…
 Future Powertrain Research
• Example for HD applications:
− Combination of ICE and Powertrain
improvements
− Metrics for improvement are different

http://www.ertrac.org/uploads/documentsearch/id42/2016-06-
09_Future%20ICE_Powertrain_Technologies_final.pdf

Courtesy of Stef Cornelis, T&E, Future of Transportation, 2017

A quick word about Synesthetic Fuels (e-Fuels)…
• The link to energy

ERTRAC Annual Conference 2017

http://www.ertrac.org/uploads/images/2.%20Futu
Renewable grids have a supply-demand challenge re%20energy%20mix%20and%20mobility_ERT
 Convert energy to chemical fuels? RAC2017.pdf

 Power to gas
Scalable capacity (other options are possible)
 Power to liquid
Synesthetic Fuels (e-Fuels), Bio Fuels
• The link to energy

ERTRAC Annual Conference 2017

http://www.ertrac.org/uploads/images/2.%20Futu
re%20energy%20mix%20and%20mobility_ERT
RAC2017.pdf
Synesthetic Fuels (e-Fuels), Bio Fuels
• ‘Carbon Neutral’ fuels
− Often complex debate
− How do we use land?
− What’s the WTW efficiency?
(see right)
− What are the emissions?
(regulated / unregulated)
− How to ensure fuel quality?

Courtesy of Stef Cornelis, T&E, Future of Transportation, 2017

Which fuel will dominate?

 Enabling
Technologies

20
Advances in batteries
MORE ENERGY, MORE POWER
Increasing energy and power density

Transition to solid-state batteries will

significantly increase charger power (c.f.
Toyota 2021, 500km, 10min charge)

Heavy-duty vehicles are approximately 10x in

terms of energy and power levels

Ongoing research into prolonged life, thermal

management, ageing modelling, cobalt-free
batteries

Application of solid-state batteries to

commercial vehicles would yield large benefits

Intense area of technology advancement;

ubiquitous usage within vehicles/vessels
Medium/Heavy duty: from 2020 to 2030
SRC: BATTERIES EUROPE
Transitions of power electronics in automotive
WIDE BAND GAP POWER ELECTRONICS
Automotive is strongly focusing on the adoption of WBG
power electronics

TU/e is involved in projects such as HIPERFORM, and

HIEFFICIENT developing technologies around the application
of SiC/GaAs IGBT/MOSFET switches; including integrated
two-phase cooling technologies, state estimation, as well as
functionalities around fast charging.
Tesla Model 3
State-based charging will advance beyond CCCV regimes SiC Inverter

Improved onboard and offboard charger technologies enables

more functionality – offboard is always DC and high power

3rd generation native EVs involve cleansheet designs

 HD E-Axle Transmission Systems

Electric Axles
• Covering both electric and hybrid vehicles
• Novel and integrated transmission systems; LD Daimler/Renault
• 4x LD motors alternative option (c.f. Tesla)
• Volvo VERA example of integrated example
• AxleTech / Thor trucks recent examples [1]

[1] http://www.greencarcongress.com/2018/10/20181017-axletech.html

Tesla (@150-200kW each) Model 3 LD

24
Fast charging for long haul electric trucks

Definition/classification fast charging for commercial vehicles

Charging mode Power C-Rate Charging Rate SoC
Standard ≤150 kW ≤1C ≤3 km/min up to 90 % SOC
charging
Fast charging ≤350 kW ≤3C ≤6 km/minute up to 80% SOC
Ultrafast 700kW-1.2MW >3C ≤20km/minute up to 70% SOC
charging
Electrical Loss Time (ELT) as a function of the mean battery
Example: efficiency expressed in percentage © Bosch
Distance between stops =
80*4.5 = 360km used
70%@20km/min*30min =
~420km/stop charged

Charge Management,
Preconditioning and Thermal
management becomes key
consideration; innovations on
vehicle and grid-side
Adapted from the Informal Working Group IWG7 is a subgroup of Working Group
WG5 Application and Integration – Mobile of BatteRies Europe, the European
Technology and Innovation Platform (ETIP) for Batteries

Á. W. Imre, "Towards High-Performance Powertrain Solutions," in Advanced Automotive & Industrial Battery Conference, Mainz, 1/31/2018
V. Döge and Á. W. Imre, “Charge Transport in Energy Storage and Conversion Devices”, Diffusion Foundations, 2018, Vol. 19, pp 1-17
Heavy duty Energy, Charging power
THE DEMANDS OF LONG HAUL FREIGHT, 2030
0.1kWh/km, <50km trips
120kWh, 350kW charge
1-1.5kWh/km, 300-1000km trips, 1MWh, 1-2MW charge
Charge

Heavy duty debate:

• Fully electric is accepted for urban and some regional distribution applications
• For long-haul, heavily electrified vehicles will all contain batteries
• Charging will need to coincide with logistics patterns placing high power requirements
on remote areas. Hydrogen attractive for fuel cell and/or ICE

=> Freight corridors (TEN-T) present challenges for deployed infrastructure

https://www.electrive.com/2019/07/11/charin-is-working-on-truck-charging-with-up-to-3-mw
About Powertrains
Powertrains: What is it all about?
• Many interlinked functions and variables:
− Reduction in direct or indirect CO2 (g/km or kWh)
− Energy efficiency (kWh/km)
− Pollutant emissions (PM, NOx, HCs, g/km)
− Noise (dB)
− Comfort (torque interruption)
− Safety/stability (road handling, torque vectoring, brake blending)
− Sport (acceleration, top speed)
− Commercial applications
− …

− Extremely important subsystem of the vehicle! What is optimal?

− Purpose of the rest of this lecture: Basic background for working in the field of electric
powertrains
 Powertrain Development Process

Multi-D simulation System simulation

Power vs. Torque
Powertrains: What is it all about?

• What plays an important role in the design or operation of the optimal powertrain?
• Why is energy efficiency important for electric vehicles?

Nissan Leaf Chassis

Powertrains: What is it all about?

• How can components be combined, and how can the powertrain be simplified? What is the trade-off between
complexity and functionality?

Tesla Model S Chassis

Summary

• Broad overview of context

• General Powertrains themes
• Enabling technologies
• About Powertrains
 35

Questions