Global Powertrain – The GM Case - Didattica

Transcription

Global Powertrain – The GM Case - Didattica
1° Colloquium at PhD’s course of Politecnico di Torino
Torino, Wednesday 20 May 2009
Ingegneria dell’Autoveicolo - Aula Magna Lingotto
Future Trends
in the
Transportation Systems
Giovanni Cipolla
Director Advanced Engineering & Site Manager Italy
General Motors Powertrain Europe
Torino, Italy
SHORT CURRICULUM VITAE
Giovanni CIPOLLA
Advanced Engineering Director
GM Powertrain Europe
 December 1947
born in Torino-Italy
 December 1971
graduated in Mechanical and Automotive Engineering at Politecnico di Torino
 June 1972
 April 1994
 July 1998
 January 2004
 May 2005
 June 2006
 June 2006
joined FIAT Research Center in Orbassano (Turin), where he was involved in
several engine R&D programs and finally managed the Racing Engines Research Center
joined Elasis in Pomigliano (Naples), as Powertrain Director of the R&D Center
joined Ferrari in Maranello (Modena), as Powertrain Director of the GT Division
joined FIAT-GM Powertrain joint venture (Turin), as Advanced Engineering Director
joined GM Powertrain Europe (new born DEC in Turin), as Diesel Engines Director
in GM Powertrain Europe as Diesel Advanced Engineering & Hybrids Director
in GM Powertrain Europe as Advanced Engineering Director & Site Manager AE Italy
 January 1996
January 2008
vicepresident of ATA (Associazione Tecnica dell’Automobile)
co-founder of SAE Torino (Society of Automotive Engineering, SAE International)
 July 2003
nominated Honorary Professor at Zwickau University (Germany) for
Advanced Powertrain Concepts
Future Trends in the Transportation Systems
Agenda

Introduction

Transportation Systems future scenario

Energy sources & carriers issues

Powertrain evolution implications & evolution

New competences development needs

Q&A
Future Trends in the Transportation Systems
Agenda

Introduction

Transportation Systems future scenario

Energy sources & carriers issues

Powertrain evolution implications & evolution

New competences development needs

Q&A
Mobility: a basic human need
Automotive environmental challenges
Crude oil price
(last 30 years)
2nd
Gulf
war
Kippur
war
O3
1st Gulf
war
Pakistan
crisis
CO2
CO
Earth
warming
NOx
SOx
HC
PM
Antropogenic
pollution
US evolution of emissions
(Tailpipe Emissions for Gasoline Duty Vehicle)
Europe evolution of emissions
(Tailpipe Emissions for Diesel Passenger Cars)
Source: VDA
GHG from Road Transport Worldwide
13% of Antropogenic
CO2-Emissions are due
to Transport
4% of CO2Emissions are
Man-made
Source: TU Wien
Source: IPPC, 2007
Global Regulatory approach for CO2 reduction
the Worldwide approach …
… & the EU plan
European Regulatory approach for CO2 reduction
10
Germany (KBA)
200
9
8
8
7
150
Europa (ACEA)
Diesel Engines (KBA)
6
5
100
ACEA Commitment
4
EU target
50
0
1980
Prognosis
3
2
1990
2000
Year
2010
6
5
4
3
2
1
1
0
2020
0
Fuel Consumption [l/100 km]
Diesel equivalent
CO2 Emission [g/km]
7
Gasoline equivalent
Gasoline Engines (KBA)
source: ACEA, EU, Kraftfahrt-Bundesamt (KBA)
Vehicle primary requirements : vision (1/2)
 Environmental preservation

w/o moving the problem elsewhere!

2015 Euro 6 emissions & CO2 << 120 gr/km
 “automatic” active safety

Correction of driver mistakes

By 2015 requirements by law for reduction of 50% of accidents

Technologies could prevent & reduce accidents
 Usable automobile

Easy city driving & parking, but w/ fun-to-drive & accessibility features

Low weight, low polar inertia, front/rear axles balancing, not longer than 4 m
[source: P. Massai “ATA Sardegna conference 2008”]
Vehicle primary requirements : vision (2/2)
 Substainable cost per mileage

Fuel consumption reduction (energy cost will increase)

Improved aerodynamic (Cx = 0,29; frontal area < 2 m2)

weight reduction (< 800 kg; < 3,5m.; weight/length = approx 320 kg/m)

Powertrain efficiency improvement

Tyres w/ low rolling resistance
 Acceptable price
car
class
Engine
type
Power
(CV)
Weight
(kg)
Weight/
power
(kg/CV)
Weight/
length
(kg/m)
Max
speed
(km/h)
Acceleration
0-100km/h
(s)
Max
BMEP
(bar)
CO2
(g/km)
Unit price
/weight
(€/kg)
/velocity
(€/km/h)
/power
(€/CV)
utitilty
Diesel
175
1365
7.8
335
220
7.1
18.9
171
17
104
132
sport
Gas
355
1597
4.5
372
288
4.8
13.1
285
61
352
286
flag
Gas
620
1798
2.9
383
330
3.7
12.7
490
128
694
370
[source: P. Massai “ATA Sardegna conference 2008”]
Technology Development Scenario
Technology development strongly dependent on several industrial
constraints :

technology maturity

cost & quality trade-off

time to market

manufactory footprints & KH

supplier chain & new technologies components availability

infrastructure for refuelling and service
As a consequence the “steady evolution”
is a more sustainable approach than the “breakthrough revolution”
Future Trends in the Transportation Systems
Agenda

Introduction

Transportation Systems future scenario

Energy sources & carriers issues

Powertrain evolution implications & evolution

New competences development needs

Q&A
Personal Mobility “MUST ’s” for Sustainability
• New York – Dedicated Bicycle Lanes
Singapore – Road Pricing
Bogota – BRT
Paris – Bike Sharing
Urban vehicle is a broader category than city car
Car
variants
Mitsubishi MIEV
MIT CityCar
Smart
Smart
Motorcycle
variants
Electric bike
BMW C1
Segway
Aptera
Novel
concepts
VentureOne
Volvo Tandem
Tango
Japan Minicars at 2007 Tokyo Motor Show
Honda PUYO
Nissan Pivo2
Toyota i-unit
Toyota i-Real
Suzuki SSC + PIXY
Reinventing Urban Personal Transportation
the MIT “city car” concept
 If you combine:
 the economy of car sharing with the
environmental friendliness of an electric vehicle
 and then add a design that allows the car to fold
 and stack like supermarket shopping carts at
convenient locations
 you have the innovative City Car, now being
developed at the MIT Media Lab.
Reinventing Urban Personal Transportation
the GM - Segway PUMA concept
Innovative Mobility Concepts
the Toyota I-Real
[ source: Toyota ]
Intelligent Driver Support
GM’s “Boss program”
Vehicles
who drive
themselves
The“360° vision”
Vehicle
“Low Fuel Consumption” concept cars
VW “1-litre Car” (2002)
H2PoliTo “Idra08”(2008)
Toyota “Sport Hybrid Car“ (2009)
Future Trends in the Transportation Systems
Agenda

Introduction

Transportation Systems future scenario

Energy sources & carriers issues

Powertrain evolution implications & evolution

New competences development needs

Q&A
A forecast of possible automotive fuel supply
Hydrogen
Energy
Demand
(x1018 J )
Gaseous
Fuels
Gas
300
Electricity
250
Synthetic Fuels
and biofuels
200
150
Liquid
Fuels
100
50
Diesel / Gasoline
Heavy Oil
0
2000
2020
2040
2060
2080
2100
Energy Resources: the propulsion options
Petroleum Fuels
1st & 2nd Gen. Biofuels
Energy
Carrier
Liquid
Fuels
Oil (Non-Conventional)
Synthetic fuels (XTL)
Syngas
CO, H2
Propulsion System
MECHANICAL DRIVE
Conventional ICE:
Gasoline/Diesel
Regional Niche ICE
Regional Niche
Gaseous Fuels
(e.g. CNG)
Biomass
ICE Hybrid
Natural Gas
Plug-In Hybrid ICE
Coal
Electricity
Renewables
Battery Electric
(Solar, Wind, Hydro)
Nuclear
Range-Extended EV:
IC Engine/Fuel-Cell
Hydrogen
Fuel-Cell Electric
ELECTRIC DRIVE
Electrification
Oil (Conventional)
Conversion
Battery
Energy
Resource
Italian Energy sources (2007)
nucleare (import)
carbone
[source: G. Di Napoli, A. Senatore “La questione energetica e le relazioni Russia – UE”]
Mix of Energy sources for Electricity
production in Italy (2006)
[source: G. Di Napoli, A. Senatore “La questione energetica e le relazioni Russia – UE”]
Italian dependency from Energy sources scenario
(from 2005 to 2025)
[source: G. Di Napoli, A. Senatore “La questione energetica e le relazioni Russia – UE”]
Well-to-Wheels (W2W) Analysis
il
G
/B
io
/S
ga
ho
s
LC
rt
G
R
H2
ot
at
/N
io
n
at
ur
Di
al
es
G
el
as
/C
ru
de
O
il
BT
L
/S
RM
ho
E
LC
rt
G
Ro
H2
ta
tio
/N
CG
n
at
H2
ur
al
/S
G
ho
as
rt
Ro
CG
ta
CG
tio
H2
n
H2
/E
/W
U
El
in
ec
d
tri
cit
y
M
ix
an
ol
CN
200
CM
G
O
0,80
Et
h
ru
de
0,00
[g CO2 equivalent/km]
0,20
/C
il
0,40
e
O
CN
ru
de
0,60
G
as
ol
in
CM
G
/C
G
/B
io
/S
ga
ho
LC
s
r
t
G
R
H2
ot
at
/N
io
n
at
ur
Di
a
es
l
G
el
as
/C
ru
de
O
il
BT
L
/S
RM
ho
E
LC
rt
G
Ro
H2
ta
tio
/N
CG
n
at
H2
ur
al
/S
G
ho
as
rt
Ro
CG
ta
CG
tio
H2
n
H2
/E
/W
U
El
in
ec
d
tri
cit
y
M
ix
an
ol
e
[kWh/km]
1,20
Et
h
G
as
ol
in
“Well-to-Wheel” analysis
Energy input
1,60
1,40
Renewables
Nuclear
Fossil
GHG emissions
1,00
250
N2O
CH4
CO2
150
100
50
0
Environmental benefit: CO2 reduction in WtW
Electricity Sources by Country
Hydroelectric
100%
80%
60%
40%
20%
0%
U.S.
Nuclear power
Well-to-Wheel CO2 Emissions
Thermoelectric
Wel l-to-Wheel CO2 Emissions
1.0
Gasoline
Japan
E85
France
0.5
Prius
U.S.
Japan
France
Plug-in hybrid vehicle
Cruising range of 25km (13km for electric motor only)
(Toyota’s calculations)
 PHVs make possible reductions in Well-to-Wheel CO2 emissions
 Benefits can be expanded through combination with biofuels
[source: Toyota]
Future Trends in the Transportation Systems
Agenda

Introduction

Transportation Systems future scenario

Energy sources & carriers issues

Powertrain evolution implications & evolution

New competences development needs

Q&A
Evolution of Automotive Propulsion Systems
today
tomorrow
Hydrogen and Fuel
Cell Technology
Hybrid Vehicles
Alternative Fuels
Optimization of Combustion Engines
Powertrains Application Map
High Load
Stop-and-Go
(City)
Cycle
Heavy Duty
Pickup Truck
Duty
Diesel Hybrid
City Bus
Drive Cycle
Continuous
(Highway)
Non-towing
Highway
Gas Car & SUV
Commuter
Car
City Car
Diesel Truck
Light load
City
Intra-Urban
Highway
Cycle
Urbanization shifts market demand
Continuous
Highway
The ideal, sustainable car
The ultimative ECO car
FCHV Fuel cell hybrid
vehicle
Plug-In Hybridtechnology
Biodiesel
Flex Fuel Technology
Valvematic
D-CAT
Diesel
Direct injection
D-4S / Gasolinedirectinjection
VVT-i
Diesel-engine
Stratified charge
Petrol-engine
EV
the right car, at the right time, at the right place
[ source: Toyota ]
Hydrogen
Advanced Propulsion Technology Strategy
Improved
Vehicle Fuel
Economy
& Emissions
Hydrogen
Fuel Cell
Displace
Petroleum
Battery Electric
Vehicles (E-Flex)
Hybrid Electric
Vehicles (including
Plug-In HEV)
IC Engine and
Transmission
Improvements
Time
Petroleum (Conventional & Alternative Sources)
Energy
Diversity
Bio Fuels (Ethanol E85, Bio-diesel)
Electricity (Conventional & Alternative Sources)
Hydrogen
Advanced Propulsion Technology Strategy
Improved
Vehicle Fuel
Economy &
Emissions
Hydrogen
Fuel Cell
Displace
Petroleum
Battery Electric
Vehicles (E-Flex)
IC Engine and
Transmission
Improvements
Energy
Diversity
Hybrid Electric
Vehicles (including
Plug-In HEV)
Time
Petroleum (Conventional & Alternative Sources)
Alternative Fuels (Ethanol, Bio-diesel, CNG, LPG)
Electricity (Conventional & Alternative Sources)
Hydrogen
Conventional Propulsion Systems
Gasoline
Improve fuel efficiency:
 Port Deactivation (DoD)
 Variable Valve Systems (VVT&VVA)
 Direct Injection & HCCI
 Turbocharging (right-sizing)
Diesel
Improve Emissions:
 Low-Temperature Combustion
 Advanced Air Handling & Charging
 Model-Based & Closed-Loop Control
 Efficient NOx aftertreatment
Advanced Propulsion Technology Strategy
Improved
Vehicle Fuel
Economy &
Emissions
Displace
Petroleum
Hydrogen
Fuel Cell
Battery Electric
Vehicles (E-Flex)
IC Engine and
Transmission
Improvements
Hybrid Electric
Vehicles (including
Plug-In HEV)
Time
Petroleum (Conventional & Alternative Sources)
Bio Fuels (Ethanol E85, Bio-diesel)
Electricity (Conventional & Alternative Sources)
Energy Diversity
Hydrogen
BioFuels for Automotive Powertrains
Energy Resources Substitution Potential
[ source: WTW Update 2006 (JRC, EUCAR, CONCAWE) ]
Biofuels are moving up a technology roadmap
Synthetic Biorefinery
Gasification
Cassava
Direct Synthesis?
Algae
Cellulosic Bioethanol
Corn
And we have only just
begun …
Start/Stop system
What is it?
 12V based system
 Auto stops engine during normal idle when the vehicle is
stationary
 Auto starts engine in response to driver or other inputs, usually
determined by clutch action, brake release.
Benefits
 3.0-4.0 % Composite FE benefit (NEDC cycle), substantially
bigger FE (8-9%) in city drives
 Favorable cost/benefit ratio
 Available technology (but not “off-the-shelf”)
 Requires several vehicle updates but not radical changes
Start-stop potential in NEDC
Vehicle speed [km/h]
MVEG-B Cycle
100
50
0
0
200
400
600
Tim e [s]
800
1000
1200
NEDC vehicle stop
Vehicle moving
Vehicle standing
21 s vehicle stop
Gearbox in neutral
16 s
Gearbox in first gear
Engine off
Engine off delay
Engine off MT
Engine off MTA, AT
.5s
MT: Engage
1st gear
15 s engine stop
19 s engine stop
5s
MTA:
Release
Brake
Advanced Propulsion Technology Strategy
Improved
Vehicle Fuel
Economy &
Emissions
Displace
Petroleum
Battery Electric
Vehicles (E-Flex)
IC Engine and
Transmission
Improvements
Energy
Diversity
Hydrogen
Fuel Cell
Hybrid Electric
Vehicles (including
Plug-In HEV)
Time
Petroleum (Conventional & Alternative Sources)
Bio Fuels (Ethanol E85, Bio-diesel)
Electricity (Conventional & Alternative Sources)
Hydrogen
Hybrid Technology Rationales
1/3
2/3
Control Opportunities of Hybrid Powertrain
SOC
driving
speed
requested
torque
…
+
torque
gear
operation options
ICE
ICE
brake
EM
EM
EM-gen
operation mode
operation parameters
brake
-
ICE: combustion engine
SOC: State Of Charge
EM: Electric Motor
OPS: operation point switch
[ source: TU Dresden ]
speed
HEV operative features
Normal Drive
Regenerative Brake
Acceleration
Electric Drive
Hybrid categories
ICE Hybrid
-Hybrid
Mild Hybrid
≈25%
Full Hybrid
Power-split
50%
< 5%
Series
Hybrid
100%
0%
Degree of hybridization Pel / Ptot
GM Hybrid PT technology portfolio
ICE
Hybrid
 Hybrid
Parallel
BAS
Mild Hybrid
Parallel
Full Hybrid
Power-split
Series
Hybrid
BAS+
2 Mode
RE-EV
GM Hybrids approach
BAS mild Hybrid
2-Mode full Hybrid
Hybrid
Battery
Pack Transmission
(includes two
motors)
Engine Control Module
Power Electronics
Advanced Nickel
Metal Hydride
Battery Pack
Electric Motor/
Regenerative Generator
Braking
Main features:
 Engine start / stop
 Early deceleration fuel cut-off
 Regenerative braking
 Charging opportunity
120 Volt
AC Power Outlets
Power Electronics
Additional main features:
 Power-split (1st mode)
 ZEV in only-electrical operation
 Enhanced efficiency (2nd mode)
 Performance enhancement
GM Hybrid System for Saturn VUE Green Line
12 Volt Battery
and Accessories
Engine Control
Module
Power
Electronics
Advanced
Nickel Metal Hydride
Battery Pack
Electric Motor/Generator
Engine Off when Vehicle Stopped
12 Volt Battery
and Accessories
Power
Electronics
Advanced
Nickel Metal Hydride
Battery Pack
Auto-Start, Launch and Electric Power Assist
12 Volt Battery
and Accessories
Power
Electronics
Advanced
Nickel Metal Hydride
Battery Pack
Electric Motor/Generator
Intelligent Battery Charging While Driving
12 Volt Battery
and Accessories
Power
Electronics
Advanced
Nickel Metal Hydride
Battery Pack
Electric Motor/Generator
Early Fuel Cut-Off and Regen Braking During Decel
12 Volt Battery
and Accessories
Power
Electronics
Advanced
Nickel Metal Hydride
Battery Pack
Regenerative Braking
Electric Motor/Generator
Electric-Only Operation During Decel
12 Volt Battery
and Accessories
Power
Electronics
Advanced
Nickel Metal Hydride
Battery Pack
Electric Motor/Generator
VUE Hybrid Instrument Cluster
Tach moves to this position when
the vehicle comes to a stop and
the engine shuts off
Illuminates when you beat the
EPA’s estimated MPG, highlighting
the most effective driving methods
Shows whether the system is
charging the hybrid battery or
providing an electric power boost
Hybrid Systems: Two-Mode Transmission
power-split
ICE
Transmission
EM
Battery
EM
Output
ICE
: internal combustion engine
EM
: electric motor
2-Mode Hybrid System
GM 2-Mode Cadillac Escalade
RWD
300V, 2.2 kW-Hr
NiMH Battery
Power Electronics
System
50% city fuel economy
improvement
City fuel economy
equal to 4-cyl Camry
2-Mode Transmission
Two 60 kW Electric Motors
FWD
Up to 50% fuel economy
improvement
2009 Saturn VUE
Green Line
Power Electronics
System
Provide the basis
for PHEV capability
300V, 2.2 kW-Hr
NiMH Battery
260 Hp, 3.6L SIDI
V6 Engine
2-Mode Transmission
Two 55 kW Electric Motors
FE/CO2 effects by Hybridization
on “homologation driving cycle“
Additional fuel cons by weight increase
Baseline
Fuel OFF when vehicle still (Start/Stop)
~ 25 %
Recuperation, split braking
Adaption of engine (Downsizing, Miller cycle,...)
Shift of operation point, CVT effect
Full-Hybrid
Saturn VUE Green Line 2-Mode Plug-in Hybrid
Potential to achieve double the fuel efficiency of any current SUV on short trips
2-Mode FWD
Power Electronics
260 Hp, 3.6L
SIDI V6 Engine
2-Mode FWD Transaxle
Two 55 kW electric motors
280V, 7.0 kW-Hr
Li-Ion Battery
Recharges
from 110V
household
outlet
Toyota Concept Car 1/X
Plug-In Hybrid
500 cm³ Mid rear engine with hybrid system
Length:
3.900 mm
Width:
1.620 mm
Height:
1.410 mm
Wheelbase:2.600 mm
Seats:
4
Interiour space comparable to Prius
Weight: 420 kg (Prius 1300kg)
Body made from carbon fibre reinforced plastics
Reduction in fuel consumption 50% compared to Prius II
[ source: Toyota ]
(4,3 l/100km)
Europe HEV market growth scenario
Advanced Propulsion Technology Strategy
Improved
Vehicle Fuel
Economy &
Emissions
Displace
Petroleum
Battery Electric
Vehicles (E-Flex)
IC Engine and
Transmission
Improvements
Energy
Diversity
Hydrogen
Fuel Cell
Hybrid Electric
Vehicles (including
Plug-In HEV)
Time
Petroleum (Conventional & Alternative Sources)
Bio Fuels (Ethanol E85, Bio-diesel)
Electricity (Conventional & Alternative Sources)
Hydrogen
… from the Museum of Electrical vehicles …
Electrical car of
Thomas Edison (1913)
"Jamais contente"
of Camille Jenatzy (1899)
EV range requirements
40%
78% of daily trips has a
distance less or equal to 40
miles (64Km)
30%
20%
10%
0%
1-5
6-10
11-15
16-20
Source: the U.S. Bureau of Transportation
21-25
Miles
26-30
31-35
>35
E-Flex System by GM
Flexible Propulsion System Schematic (Petroleum Fuels)
Internal Combustion
Internal
Combustion
Engine (Gasoline)
Engine (EcoFuel)
Generator
Electric
Motor
Battery Pack
12 Gallon
12
Gallon
Fuel Tank
Fuel Tank
Gasoline
Bio-Fuel
Plug-In
110V / 220V
Extended-Range Electric Vehicle (E-REV)
120kw electric motor
Powers front
wheels
Extended-Range Electric Vehicle (E-REV)
16 kilowatt-hour lithiumion battery pack
Stores electricity
from the grid
Extended-Range Electric Vehicle (E-REV)
74 Hp 1.4 liter
4-cylinder engine
53 kW generator
E-Flex
range-extender
Creates electricity
on-board
Extended-Range Electric Vehicle (E-REV)
E-REV charge ports
Recharges battery
from household
outlet
GM E-REV: E-Flex Platform main features







CO2 emissions less than 40g/Km
EV range of 64Km
Total range of 700km
Lithium-Ion battery pack - 181kg
Recharging time from grid of 3 h
Maximum speed 160km/h
Cost/Km equal to 1/6 of an
equivalent gasoline vehicle
 Estimated saving of 2200 €/year for
daily trips of 60km
 Planned SOP in Q3-2010
GM E-REV: E-Flex vehicles
Chevrolet VOLT (MY 2011)
Opel AMPERA
(MY 2012)
Toyota FT- EV Concept
- based on Toyota iQ
- mass production planned from 2012
- 80 km range, urban usage
[ source: Toyota ]
Advanced Propulsion Technology Strategy
Improved
Vehicle Fuel
Economy &
Emissions
Displace
Petroleum
Battery Electric
Vehicles (E-Flex)
IC Engine and
Transmission
Improvements
Energy
Diversity
Hydrogen
Fuel Cell
Hybrid Electric
Vehicles (including
Plug-In HEV)
Time
Petroleum (Conventional & Alternative Sources)
Bio Fuels (Ethanol E85, Bio-diesel)
Electricity (Conventional & Alternative Sources)
Hydrogen
FuelCells & Hydrogen
How a Fuel Cell Works ?
Energy Management Challenge
Fuel Cells
Diesel ICE
Hydrogen energy
Input = 100%
Diesel energy
input = 135%
41
41
18
30
Exhaust enthalpy
=
Partwheel
load at 100 km/h
output
8
47
Exhaust enthalpy
Cooler heat flow
Mechanical
work
FC
vehicle
15
Heat radiation
Mechanical
work
Diesel
vehicle
Cooler heat flow
NB: at Part load @ 100 km/h
NB: FC’s require larger cooler (higher heat flow & Lower operating temperature) !
Subsystems of a Fuel Cell Propulsion System
Air
H2O
Fuel Cell
Motor/
Gearbox
Hydrogen
Electricity
Power
Electronics
Battery
System
Hydrogen
Storage
Fuel Cells Propulsion Module
Common Platform for
Alternative propulsion options
GM’s Fuel Cell Development
Since 2001, GM has developed a range of fuel cell vehicles to
demonstrate its commitment to fuel cell technology
 The HydroGen3 vehicle demonstrated how a fuel cell
system could be packaged into a conventional vehicle
design
 The Autonomy demonstrated how we could totally
reinvent the automobile when combining fuel cells and
by-wire technology
 The Hy-wire was the world’s first drivable fuel cell and
by-wire vehicle
Project Driveway
Largest fuel cell vehicle market test
100+ vehicles in the hands of customers
10 in Europe, 7 in Asia
[ source: Honda ]
[ source: Honda ]
Electrification of the Automobile
Electrical
Interior
High-Voltage
Distribution
HMI
HV Battery
(NiMH)
HV Cables-DC
Power
Electronics
Electric
Waterpump
Hybrid
Transmission
Thermal
Powertrain
Electric A/C
Electric Power
Steering
Regenerative
Brake System
Chassis
HV Cables-AC
Energy Diversity
Gravimetric Energy Density (Wh/kg)
Wh/kg
Highpressure
hydrogen
(35MPa)
10000
CNG
(20Mpa)
Gasoline
Bio-Diesel
Diesel
Ethanol
Liquid fuels
Gaseous fuels
1000
Hydrogen
absorbing
alloy(2wt%)
Batteries
100
Lithium-Ion
Nickel Metallhydrid
Lead
10
0
1000
2000
3000
4000
5000
6000
7000
Volumetric Energy Density (Wh/l)
8000
9000
10000
Wh/L
Hydrogen Properties: On-Board Storage
Weight and Volume of Energy Storage System for 500 km Range
Diesel
Compressed Hydrogen 700 bar
6 kg H2 = 200 kWh chemical energy
Lithium Ion Battery
100 kWh electrical energy
System
Fuel
System
Fuel
System
Cell
43 kg
33 kg
125 kg
6 kg
830 kg
540 kg
46 L
37 L
260 L
170 L
670 L
360 L
EV & FCV Application Map
Duty Cycle
High Load
Stop-and-go
Drive Cycle
Continuous
Light Load
City
Intra-urban
Highway-cycle
Highway
Future Trends in the Transportation Systems
Agenda

Introduction

Transportation Systems future scenario

Energy sources & carriers issues

Powertrain evolution implications & evolution

New competences development needs

Q&A
GM “Road-to-Lab-to-Math” Initiative
Vision
 RLM is the fundamental strategy
leading to higher quality design,
reduced structural cost, reduced
reliance on physical test, and
improved product development time
Strategic Elements
 First Time Capable Designs
 Move Processes that require vehicles
on the Road to Lab or Math
 High Quality Integration Vehicles
HEV Powertrain Test Beds
Int. Comb. Engine
Complete Powertrain
Electric motor
Battery
HEV Simulation Modelling
Interdisciplinary requirements HEV technology
(F.Kucukay-TU Braunschweig , M&U’07 Graz]
Future Automotive Propulsion requirement:
Engineers with broad & deep Technical Knowledge
Source: Ricardo Engineering
Future Trends in the Transportation Systems
Agenda

Introduction

Transportation Systems future scenario

Energy sources & carriers issues

Powertrain evolution implications & evolution

New competences development needs

Q&A
1° Colloquium at PhD’s course of Politecnico di Torino
Torino, Wednesday 20 May 2009
Ingegneria dell’Autoveicolo - Aula Magna Lingotto
Future Trends
in the
Transportation Systems
Thank You for your Attention ! …
… I hope to have stimulated questions from you !?!
Giovanni Cipolla
Director Advanced Engineering & Site Manager Italy
General Motors Powertrain Europe
Torino, Italy