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A3PS-Workshop, Wien 25. Mai 2016

Theodor Sams

AVL List GmbH

Forschungsfelder bei Fahrzeugantrieben –

potentielle Synergien

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Fuel / Energy

Infrastructure

Legislation

TRENDS PASSENGER CAR POWERTRAIN

TECHNOLOGY DRIVERS

RDE: From reproducible

test cycle towards

Real World Driving

• Availability /

Sustainability

• Distribution /

Storage

• Cost

Diversified and quickly changing boundaries, Legislation & energy infrastructure decisive

CO2: 2020+ limits below

potential of conven-

tional powertrain

Guidance:

• Incentives / taxes

• Access / registration

restrictions

Customer

Demands

• Total cost of

ownership

• Vehicle

preference

• Driving

experience

3

Electrification

TRENDS PASSENGER CAR POWERTRAINWORLDWIDE CO2 / FUEL ECONOMY LEGISLATION

CO

2E

mis

sio

n –

g/k

m n

orm

aliz

ed

toN

ED

C T

est

Source: ICCT, November 2012, Global

Transportation Energy and Climate

Roadmap , AVL EU 2021-22: 50

for Supercredits

EP proposalEU 2012-20: 50

for Supercredits EU 2025:

68-78* EP

1000

US 2025: 91

Year

Future CO2 / FE legislations require significantly increased powertrain electrification

1100 1200 1300 1400 1500 1600 1700 1800 1900

Vehicle weight - kg

4

ElectrficationTransmission Vehicle

• Future CO2 targets cannot be met by ICE only

• The optimum balance of powertrain and vehicle measures is most decisive for cost effectiveness

Engine

GLOBAL TECHNOLOGY DEMAND

COST EFFECTIVE FUEL ECONOMY /CO2

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COST EFFECTIVE FUEL ECONOMY /CO2

ALLOCATION OF FUNCTIONALITIES

Incre

asin

gE

lec

trif

icati

on

Tra

ns

mis

sio

n F

un

cti

on

alt

yMT 5 MT 7

AT 5 AT 9+

CVTstd CVTadv

Start/Stop std

Start/Stop adv

DCT 6DCT 9+

MT AMTBSG / ISG

E-Charger

MHEV

48 V 1220kW

HEV

PHEV

BEV + REX

From “FULLY FLEXIBLE ICE”

towards “FULLY FLEXIBLE POWERTRAIN”

Allocation of flexibilities not only at the ICE, but where most cost effective within the whole powertrain

Transmission

Variabilty ICE

ElectrificationCombustion Engine

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GLOBAL PRODUCTION FORCAST

TOTAL PASSENGER CAR ENGINES

On a global scale, the ICE remains the dominating power source even beyond 2025

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AVL FUEL EFFICIENCY ROAD MAPHEAVY DUTY TRUCKS

MY 2014

HD Engine

5045(LHV: 42.8 MJ/kg)

+5% BTE

Advanced Turbocharging Concepts

Increased Compression Ratio, Adv. Timing

Variable Valve Timing

Insulation of Exhaust/Ports

Waste Heat Recovery

Base Engine Friction Reduction

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CONNECTED POWERTRAIN

Auxiliaries

EngineP&E

Shifting

Hybrid

EnergyMgmt.SystemControl

Electric System

Driveline

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COMMERCIAL VEHICLE PREDICTIVE ENERGY MANAGEMENT

VEHICLE ENERGY COORDINATOR

BATTERY

CONTROL

SOC control

SOH control

SOF control

thermal

management

control

etc.

TRANSMISSION

CONTROL

clutch control

gear shift control

oil pump control

retarder control

etc.

COMBUSTION ENGINE

CONTROL

• real time capable vehicle / powertrain model (AVL CRUISE embedded)

• power split: comb. engine - e-motor – battery

• scenario calculator (cost calculator / optimizer)

E-MOTOR

CONTROL

torque control

speed control

thermal manage-

ment

safety monitoring

etc.

HUMAN MACHINE INTERFACE DATA TRANSLATOR

VEHICLE / POWERTRAIN / HYBRID CONTROL

GPS, v2v, i2v, …

Real time P&E control

Adaptive emissions control

Smart Auxiliaries

Vehicle thermal management

WHR control

Engine brake control

OBD

etc.

kW_demand_current

kW_demand_predictedcost / kW

Tasks:

• predictive cruise control

• hybrid system control

• vehicle cooling syst. control

• e-power steering control

• interface to trailer (trailer energy management)

• etc.

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EMBEDDED CONTROLS

Auxilliaries

Emissions

Shifting

Hybrid

EnergyMgmt.SystemControl

Electric System

Driveline

EmbeddedEnergyMgmt.SystemControl

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CONNECTED VEHICLE FEATURES

Connected vehicle features enhance the functionality and create content by combiningseperate functions. Fuel economy target improvement by using traffic light recognition, speedsign recognition, navigation maps and local information.

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ENHANCED OPPORTUNITY SPACE INDUSTRY 4.0

Industry 4.0: Gather information along the entire lifecycle and generate knowledge out of the raw data to improve the production w.r.t. costs and product quality and to increase flexibility (incl. safety, durability, reliability)

SERVICEIN-USEPRODUCEVALIDATEDEVELOPCONCEPT

SERVICEIN-USEPRODUCEVALIDATEDEVELOPCONCEPT

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AVL’S SEAMLESS FRONTLOADED DEVELOPMENT PROCESS

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Delivering support to a major automotive vehicle manufacturer based in Germany. The delivery is to all of the OEM’s engines for the foreseeable future. The delivery includes three main packages. Calibration, function development and testing (vehicle and chassis dyno).

Systems and application knowledge from concept to SOP delivery for Automated feaures.

The scope of this delivery includes:

Calibration drivability cruise control, adaptive cruise control, limiter and trailer tow assist

Calibration of automatic park assistant, predictive efficiency assistant

Lead technical interface to all internal OEM/Supplier contacts for the existing features

Ownership of functional safety and quality management

Ownership of feature integration including development and quality improvement

Lead interface to customers (vehicle owners, manufacturing and service) including owner manuals/training materials/user awareness information and support during build/vehicle launch.

Creator/owner of all feature sign off specifications and sign off authority for all test cases

Support for issue resolution and warranty investigation.

In addition for lead applications we support testing, bug fixing, senior management approval for feature usage and operation.

Full sign off testing of concept, preproduction and production level for features.

ADAS Test Solutions

AVL Cube “Vision” HIL to Roadvia “DrivingCube”

Connectivity

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Seamless simulation toolchain supports

connected development.

Model & test case reuse from Office PC, to

HiL, to Powertrain Testbed.

Reproducible real-world traffic &

environmental conditions during

development.

RoadTestbedLabOffice

Reuse models, test cases

SEAMLESS MIGRATION OF ADAS FROM PURE OFFICE SIMULATION TO TESTBED

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DEVELOPMENT OF THE CONNECTED POWERTRAIN™HOLISTIC AVL APPROACH

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SUMMARY

• CO2 and fuel economy regulations beyond 2020 cannot be met byconventional powertrains and fuels

• Increasing diversification of powertrain technologies and energycarriers

• “RIGHTSIZING” becomes the key approach both for InternalCombustion Engines but also for Electrification

• Connected Powertrain will be a key technology to improve fuelconsumption, comfort and safety

• Advanced Driver Assistance Systems are also a key technology tolower fuel consumption, improve safety and increase comfort

• Comprehensive methodology and tool environment has to bedeveloped

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Thank You for Your Attention!