Technologien zur Erreichung der CO2-Ziele. Technologien zur Erreichung der CO2 Grenzwerte bei Pkw

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1 Technologien zur Erreichung der CO2-Ziele Technologien zur Erreichung der CO2 Grenzwerte bei Pkw Technologies to achieve the CO2-targets for passenger cars Martin Rauscher 1

2 Agenda Market drivers for future vehicle developments CO2 emissions legislation Status CO2 emissions of vehicles sold in Europe Technology trends Potentials of powertrain measures Engine measures Start stop coasting E-mobility Combinations of different measures Summary 2

3 Major market drivers for powertrain improvement Fuel Economy / CO 2 CO 2 fleet targets W-EU: 130/95g CO 2 /km US CAFE: 34,1 mpg in 2016 Fuel availability ( Peak Oil ) Driving comfort Noise, vibration, harshness Shift- & launch quality Easy driving Emissions & Diagnosis EU6 (PM/PN, ext. EOBD) LEV III (SULEV20, PM) Worldwide Driving Cycle Real Driving Emissions Variants Globalization Powertrain & vehicle diversification Fuel differences Image & Emotions Fuel Economy Labeling Willingness to pay for green image and emotions Fun to Drive Power and low end torque Response time (dynamics) Quality and Safety Reliability, Robustness ISO26262 City Restrictions Ban on driving Specific traffic lane, parking Costs Affordable mobility (price, TCO) OEM entry efforts (invest, E&A) Incentives and taxation 3

4 Development CO 2 Fleet Targets l/100 km 8,6 7,5 6,4 5,7 4,3 3,8 mpg 22,3 24,9 36,5 41,6 54,8 62,3 CO g/km CAFE PC CAFE LT/MDV 217 EU PC EU LCV proposed / ,1 1, gasoline (diesel) 50 EU US CAFÉ Japan China Korea CAFE = Corporate Average Fuel Economy PC = Pass. Cars LT / LDT = Light Trucks (pick-ups, vans, SUVs) MD(P)V = Medium Duty (Pass.) Vehicles LCV Light Commercial Vehicles 4

5 Overview GS engine measures for efficiency edz CDA LB OC FR Extreme Downsizing (downsizing to 1.1L) Cylinder Deactivation half engine operation w/ switching Lean Burn (lambda >1 combustion, EGR) Optimized Combustion (charge motion, ) ICE Friction Reduction (electric auxiliaries & extr. mech. friction) Dethrottling Best Efficiency Operation ICE PT Efficiency ICE Operation points Energy Recuperation DoSp S/S SSC ReCu Downspeeding (gear ratios, shifting, n_max) Start/Stop (no idle operation in stand-still) Start/Stop Coasting Electric Recuperation (for example w/ 48V BRS) 5

6 Europe: Overview Vehicle CO 2 emissions CO 2 emission [g/km] Diesel SI Hybrid Best in Class SI Curb weight [kg] 130 gco 2 /km 95 gco 2 /km Quelle: DAT CO 2 Leitfaden 6

7 Europe: Cars with low CO 2 emissions CO 2 emission [g/km] SI Best in Class SI Curb weight [kg] Technologies: Start/Stop 12 of 12 Controlled Auxiliary 12 of 12 Friction reduction 12 of 12 Downsizing / TC 11 of 12 VVT 11 of 12 Downspeeding 10 of 12 Direct Injection 9 of 12 VVL 3 of 12 Best in Class 1.4l DI T/C, 90 KW, 120 gco 2 /km with Cylinder Deactivation 1.0l DI T/C, 74 KW, 109 gco 2 /km with extreme Downsizing Quelle: DAT CO 2 Leitfaden DS/MKS R2 7

8 FE for Compact Class vehicle * CO2 g/km I4, 1.4 l, DI / TC, 100 kw edz I3, 1.1 l, DI / TC, 100 kw DoSp OC LB FR WLTC NEDC ASSUMPTIONS 1: Further Downspeeding: DoSp adaption of final drive (20%) improved boosting system 2: Optimized Combustion: OC reduction of unburned fuel +2 units (const. knock) 3: Red. of throttling losses LB red. by 70%: stratified and/or lean burn, ideal exhaust after-treatment FR 4: Engine friction reduction 60 Base Downspeeding Optimized combustion De-throttling lean-burn friction reduction *) 1400 kg, MT 8

9 Innovation line Technologies to achieve the CO2-targets for PC Evolution of Start/Stop Start/Stop & Start/Stop Eco 2 0 x / min ~0 km/h 6 Start A Stop km/h 0 Advanced Start/Stop, Stop-in-Gear km/h Start A Stop x 1000 / min km/h Time line Start/Stop Coasting ~120 km/h CO 2 targets 2012 CO 2 targets 2015ff CO 2 targets beyond 2015ff x 1000 / min 6 Start A Stop Coasting km/h

10 Start/Stop Coasting (SSC): Overview Start/Stop Coasting drivetrain open & engine off effect: reduced drag torque veh. speed engine fuel cut off rolling distance transmission increased increased rolling rolling distance distance Coasting system system requirements requirements starter system power net G VVC transmission steering S starter cycles, CoM ability, start time, NVH pinion starter & clutch start OR advanced starter systems/brs (up to 600k starts) cyclic load & redundancy (~37% engine-off time in comparison to ~10% with Start/Stop) two energy sources (e.g. 2 batt.-pn) DCT - dry, AMT none AT, CVT, DCT - wet advanced hydr. system, el. oil pump, electrification: el./el.-hydr. power steering base in most vehicles 10

11 CO 2 benefit official test cycles TODAY New New legisla legisla -tion -tion official test cycle real-life cycle (Stuttgart cycle) Coasting Start/ Stop NEDC no Coasting base: 6.18 l / 100km SSC IDC ~0% ~0% 5% FTP75 20% SSC share base: 6.21 l / 100km SSC up to 9% 7% IDC ~2% 4% WLTC (V4) 21% SSC share base: 6.36 l / 100km SSC up to 8% 6% IDC t.b.d. 2% normal 27% SSC share base: 6.62 l / 100km SSC up to 10% IDC ~3% up to 8% (heavy traffic) 4% max. eco. 47% SSC share SSC up to ~22% IDC up to 8% (heavy traffic) 4% up to ~9% base: Compact Class, 1.4L DI-TC gasoline, 7-gear DCT (dry, el-hydr), w/o St/St, w/ intelligent generator control, Power net: P el =300W 11

12 Powertrain Electrification Mechanical Coupled, e.g.: engine fan water pump steering pump Start / Stop Start / Stop Coasting Electrified, e.g.: switched fan elec. water pump elec. steering Advanced Recuperation Electrical Torque Assist Mild Hybrid Strong Hybrid Plugin Hybrid Electrification of Auxillaries Sophisticated Control, e.g.: PWM fan thermal management generator control EV with REX Pure EV Electrification of Propulsion Overall energy efficient vehicle, e.g.: X by Wire C2X Smart HMI 12

13 e-drive System Performance (kw) Hybrid Systems Electr. Vehicle Systems Bosch Electric Powertrain Mild HEV ~10% Strong HEV 70% Plug-in HEV 20% Market shares 2015 City EV 40% Compact EV 40% Performance EV 20% e-machine as Separate Motor Generator e-machine as Integrated Motor Generator Power Electronic Inverter with Integrated Converter 13

14 CO2-benefit vs. cost for CC vehicle base 2020 CO2 [g/km] NEDC G vehicle size reduction ICE power reduction Gx G1 HEV G0 20km G1 10km PHEV 40 kw SC Gx G1 30km OEM add-on system cost G1 G PHEV km Real-life CO2 depends on driving range patterns. Higher driving performance due to electric add-on torque. Min e-range required to satisfy consumer expectations of e-motion Gx Base I4, 1.4 l, DI / TC, 100 kw SI-ICE Highest CO2/cost-benefit w/ cost efficient measures. 95g for gasoline w/ ICE measures possible SC Gx w/ BRS and mass+cw A reduction (SC class) 14

15 Summary The CO2 limit of 130 g/km can be achieved with todays technologies for SI engines in compact class This was achieved by a summary of detail optimizations Downsizing and Gasoline direct injection are mainstream measures Coasting allows further reduction of more than 10% Additional improvements are only achievable with hybridisation Willingness to pay for electrified powertrains depends on tangible end consumer benefits 15