E-M bilität Mobilität - Ch d H f d Chancen und ...€¦ · E-M bilität Mobilität - Ch d H f d Chancen und Herausforderungen für Automobilzulieferer 05. ... PHEV: plug-in hybrid

E M bilität Ch d H f d E-Mobilität - Chancen und Herausforderungen für Automobilzuliefererfür Automobilzulieferer

05. Feb. 2013 | TU Braunschweig Dr.-Ing. Dirk Hoheisel

C/OFE43 | 1/10/2013 | 13-002 | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.1

E-Mobilität - Chancen und Herausforderungen

A dAgenda

Introduction Bosch Group

Market trends and success factors

Systems and implementationsSyste s a d p e e tat o s

Chances and challenges

Summary



O hi t tOwnership structure

R b t B h Stift G bHRobert Bosch Stiftung GmbH92% share of equity

No voting rights

Bosch Family7% h f i d

Robert BoschI d t i t h d KG7% share of equity and

7% voting rightsIndustrietreuhand KG

93% voting rights

Robert Bosch GmbH1% share of equity

No voting rightsNo voting rights



B h G k fi

2010 2011

Bosch Group key figures

2012*2010

47 3

2011

51 5Total sales [EUR bn]

2012*

52 3

77

47.3

77

51.5Total sales [EUR bn]

Sales outside Germany [%] 77

52.3

283 500

113 620

302 500

118 800

Number of associates

in Germany

306 200

119 300113 620

169 880

118 800

183 700outside Germany

in Germany 119 300

186 900

3.8 4.2R & D expenditure [EUR bn] ~4.5


*) 2012 preliminary figures


Di t ib ti f l b b i t 2012*Distribution of sales by business sector, 2012*

t t l EUR 52 3 bConsumer Goods andBuilding Technology

total: EUR 52.3 bn

26 %EUR 13.4 bn

Industrial TechnologyAutomotive Technology59 %

Industrial Technology

15 %EUR 8.0 bnEUR 30.9 bn


*) 2012 preliminary figures


A dAgenda





Summary



M k t t ti f EV / HEV / PHEVMarket penetration of EV / HEV / PHEVE-Mobilität - Chancen und Legislative framework Customer requirements

• Mobility needs• Willingness to pay

Herausforderungen• CO2 fleet emission targets (EU, CN)• Fleet consumption targets (CAFE)

Legislative framework Customer requirements

• Image associated with vehicle• Reduction of fuel consumption

• Fleet consumption targets (CAFE)• EV/PHEV fleet share targets (CARB)

EV / HEV / PHEV market volume

i i h l

market volume

• Advances in reduction of emissions • R&D subsidies

Government incentives Technology

and consumption of ICE vehicles• Cost, range, reliability, and comfort

• Direct subsidies • Fleet purchasing programs


EV: electric vehicle; HEV: hybrid electric vehicle; PHEV: plug-in hybrid electric vehicle


P t i k t d l t 2020Powertrain market development 202078 115104

Sales PC & LCV<6t (mio. vehicles) *

EV

EVCNG/LPG

0 9

CNG/LPG:1

EV3

PHEV3

22.227.6

EVPHEVHEVCNG/LPG

HEV/PHEV4

EV0.1

0.9HEV

6

103 355 457.2

7.8CNG/LPGGDIPFIDiesel

HEV/PHEV 1.1

76.7

98.4 103.351.4

55.4Pure ICE

17.827.023.7

* Prognosis RB2011 20202015

In 2020 ~10 % of global passenger car sales to EV/PHEV/HEV

8 C/OFE43 | 1/10/2013 | 13-002 | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

EV: electric vehicle; HEV: hybrid electric vehicle; PHEV: plug-in hybrid electric vehicle CNG: compressed natural gas; LPG: liquid petroleum gas; GDI: gasoline direct injection; PFI: port fuel injection; ICE: internal combustion engine


N t l i th f Natural gas – in the focus

The Wall Street Journal

The Wall Street Journal

Future market shares of natural gas might be underestimated



CO d ti t ti l li / CNGCO2 reduction potential gasoline / CNGBasis: Compact Class (1400kg); NEDC (New European Driving Cycle)

Gasoline (and also diesel) powertrains still with further CO2-reduction potential even w/o electrification. CNG could be a cost efficient alternative.

C/OFE43 | 1/10/2013 | 13-002 | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.10PFI Port Fuel Injection; DI Direct Injection; DZ Downsizing; Hom Homogenous

even w/o electrification. CNG could be a cost efficient alternative.


P t i di it d Powertrain diversity and convergence

gasolinegasoline

EV / range extender

gasoline

gasoline

dieseldiesel

EV / batterygasoline

diesel

diesel

alternativeEV (battery /

fuel cell)alternative

fuels

EV / fuel celldiesel

fuels

hybrid

hybrid

hybridEV / range extender

1997 2015 future


HCCI: homogenous charge compression ignition; EV: electric vehicle


I t di t St t l t i d i iIntermediate Steps to pure electric drivingMild Hybrid Strong Hybrid Plug-In Hybrid Electric Vehicle

Electric Power 5 – 15 kW 20 – 60 kW 40 – 80 kW 15 – 150 kW

Voltage 100 – 150 V 250 V 350 V 400 V

Battery type medium power high power high energy

Energy 0,6 – 1,8 kWh 5 – 15 kWh > 15 kWh

C ll i 5 Ah 20 40 Ah 40 60 AhCell size 5 Ah 20 – 40 Ah 40 – 60 Ah

FunctionStart/Stop regenerative braking, torque supportfuel reduction 15%

same as Mild HEV+ El.-driving

fuel reduction 25%

same as Strong HEV+ grid charging

fuel reduction 65%

pureelectric driving

el

Fuel

fuel reduction 15% fuel reduction 25% fuel reduction 65% electric driving

Fuel

no F

uel

Fu

Hybrid as bridge technology from conventional to electric vehicle



Ch ll V l tilit f th k t Power-SplitAxle SplitParallel Serial(-Parallel)

Challenge: Volatility of the market Torque SplitMany

ways one goal

devel. /investig. w/ DCT or CVT

PriusTouareg / Cayenne 3008 Volt/ C o C

OEMfocus

EVEV@REX

focus

EV@REX

Effectson OEM

Diversified development strategy & wide range of system know howo O& supplier

$ Broad product spectrum to operate different systems Production sites in the region


REX: range extender; DCT: dual clutch transmission; CVT: continuously variable transmission


Gl b l t ti R&D l ti d Global automotive R&D locations and resources ChinaWestern Europe

CO reduction • “high value”• electrification• fuel consumption

• CO2 reduction • driving pleasure• active safety

Asia Pacific w/o India 13 3,500Europe 24 17,700

North America• emission reduction• “value for money”

Americas 9 1,900Japand i i f t

Indiat ffi i

South Americaethanol / flexfuel

• driving comfort• hybridization

• cost efficiency• low-price-vehicle• two-wheeler

R&D it ith 50 i t R&D i t i i

India 4 6,300

country with one or more R&D sites.

• ethanol / flexfuel

R&D sites with ≥ 50 associates R&D associates in regionAs of June 2012

Diversified development with 50 engineering centers in 17 countries



A dAgenda





Summary



E bilit i th tE-mobility requires more than components

Powertrain components

Charger Inverter Electric motor Control Unit

Battery

High-voltage battery

E-Mobilität -Chancen und HerausforderunRegenerativebraking system

Charginginfrastructure

Automotive workshop

Eco-routing

genCharge spots Navigation Diagnostics

Bosch core competence: Systems Integration



2010 W ld’ fi t t ll l h b id ith IMG2010: World’s first strong parallel hybrid with IMG

Clutch 1 Clutch 2 (T/Con)

VW Touareg / Porsche Cayenneengine

e machine IMG AT VW Touareg / Porsche Cayenne• Gasoline Engine V6 3,6 TFSI 245 kW /440Nm

• Electrical Drive 38 kW / 300 Nm

e-machine: IMG

Electrical Drive 38 kW / 300 Nm

• ECE consumption ~8,2 l / 100km

Bosch Components for eDrive System

E-Machine: - IMG 300mm

Power Electronics: - INVCONDI-Motronic MED17, clutch, clutch actuation and

SW for engine hybrid management and clutch control


SW for engine, hybrid management and clutch control

IMG: integrated motor generator; INVCON: inverter with DC/DC converter


M d f ti P ll l h b idModes of operation: Parallel hybrid

Tank

Conventional Driving with Combustion EngineConventional Driving with Combustion Engine

Torque Support by ETorque Support by E--MachineMachine

E-machine/ TransmissionGenerator

Combustion engine

+ -DC/AC

Inverter

+Battery




Tank

Regenerative BrakingRegenerative Braking

TransmissionE-machine/

Combustion engineGenerator

+ -DC/AC

Inverter

+Battery




Tank

Pure Electrical Driving with EPure Electrical Driving with E--MachineMachine

E-machine/ TransmissionGenerator

Combustion engine

+ -DC/AC

Inverter

+Battery



B h D i C tBosch eDrive Components

E-Machine: IMG 300

Power Electronics: INVCONVoltage Range: up to 400 V DCPeak Current: 370 A

max. speed: 6.700 rpmmax. speed (shorttime): 8.500 rpmPeak-Power: 38 kWPeak-Torque: 300 NmPeak Current: 370 A

Cont. Current: 300 ADC/DC-Power: 3,0 kWWeight: 13 kg373 x 250 x 154 mm (w/ connectors)

Weight: 34 kg(without clutch 14 kg and cable 2 kg)Concentric windings / Integrated clutchPosition sensors: 3 x digital hall sensoren


373 x 250 x 154 mm (w/ connectors) g

IMG: integrated motor generator; INVCON: inverter with DC/DC converter


2011 W ld’ fi t l lit di l h b id2011: World’s first axle split diesel hybrid

reareDrive

engine

clutch

Peugeot 3008 Hybrid4BASM AMT

EDTM Peugeot 3008 Hybrid4• Diesel Engine 2.0 HDI 120 kW

• Electrical Drive 27 KW / 200 Nm

EDTM

Electrical Drive 27 KW / 200 Nm

• ECE consumption ~3,8 l / 100km

Bosch Components for eDrive System

E-Machine: - SMG 180mm

- SMG 138mm

Power Electronics: - INV2CON


SMG: separate motor generator; INV2CON: dual inverter with DC/DC converter


P t 3008 H b id4 A l lit h b idPeugeot 3008 Hybrid4: Axle split hybridInternalInternal

CombustionEngine

High VoltageBattery

Front eDrive: BASMBelt Alternator Starter Machine

Rear eDrive: EDTMRear eDrive: EDTMElectrical Drive Train Machine HPCU:

Hybrid Power Electronics and Control Unit


Source: “The Electric Axle-Hybrid System made by PSA and Bosch”(PSA: Chehab, Le Neindre, Deutrich; Bosch: Küsell, Willke, Barth, Lichtermann)


M d f tiModes of operationZEV Mode

A l tiZEV Mode

D l tiAcceleration Deceleration

N SN SN SN S N SN SN SN S

Improved Longitudinal PerformancesAdded up power of ICE (118 kW i.e. 163 HP)

Sport Mode

eAWD Modep p ( )

and rear motor (27 kW i.e 37 HP) for a total of 200 HP

N SN SN SN SN

SN

S

NS

NS

NNNN NN

Access to 4WDmotivity ability to Take-off

on low adherence roads (snowyor muddy roads) for slopes up to 25%


or muddy roads) for slopes up to 25%Source: “The Electric Axle-Hybrid System made by PSA and Bosch”

(PSA: Chehab, Le Neindre, Deutrich; Bosch: Küsell, Willke, Barth, Lichtermann)ZEV: zero emission vehicle


B h D i C tBosch eDrive ComponentsEDTM: SMG 180/120Low inertia high speed: 7 500 rpmBASM: SMG 138/80 Low inertia, high speed: 7.500 rpmPeak-Power: 27 kWContinuous: 11 kWPeak-Torque: 200 NmWeight 30 kg

/Low inertia, high speed: 15.080 rpmPeak-Power: 8,5 kWContinuous: 7,5 kWPeak-Torque: 52 Nm Weight: 30 kg

Distributed windingsPosition sensor Resolver

Peak Torque: 52 NmWeight: 11 kgConcentric windings

HPCU: INV2CONVoltage Range: 150V – 270V DCg gPeak Current: 340 / 120 ACont. Current: 150 / 60 ADC/DC-Power: 2,5 kW310 x 190 x 156 mm (w/ connectors)


310 x 190 x 156 mm (w/ connectors)

SMG: separate motor generator; INV2CON: dual inverter with DC/DC converter; HPCU: hybrid power electronics and control unit; BASM: belt alternator starter machine; EDTM: electrical drive train machine


P d l f HEV & EV i tPower modules for HEV- & EV- inverterDC/AC-Inverter/focus: costs, power-density,

box-volume, weight power-density, costs EMCcosts, EMC,

robustness

Multi Chip Power Packages (MCPP)Multi Chip Power Packages (MCPP)focus: thermal-AIT Rth, Zth

electric-AIT inductancerobustness temp cycles

P S it h (IGBT SiC)

cooling-effort, energy-efficiency,

il & t

robustness temp. cycles

Power-Switches (IGBT, SiC)focus: static & dynamic power-losses,

tailored for MCPP integration

mileage & costs

g

Bosch power electronics cover the entire value chain from silicon to modules and systems


to modules and systemsAIT: assembly and interconnect technology, IGBT: insulated-gate bipolar transistor; SiC: Silcon carbideEMC: electro-magnetic compatibility


S i d t T h l iSemiconductor TechnologiesSiC application area

100.000

High Power DevicesMOSFET SJ-MOS

IGBT application area

S C app cat o a ea

10.000

Middle Power Devices

g

1.000

(A)

Low Power Devices

Middle Power Devices

EVPHEV

100

Curr

ent ( PHEV

HEV

DC/DC Charger

AutomotiveApplications

MCPP

10eBike

Discretes

110 100 1.000 10.000 100.000

Voltage (V)


Voltage (V)SJ-MOS: super junction mosfet, IGBT: insulated-gate bipolar transistor, MCPP: Multi Chip Power PackagesSiC: silicon carbide


R t f l t i hi lRange management for electric vehicles

E l destinationd f d Example destinationSOC 10 – 40 %21 °C

Prediction of energy usage and active drivetrain control based on

ECO route12 kWh

FCSFCS

Route information (topography, speed limits)L d d i b h i 12 kWh

fast route19 kWh

FCS

Learned driver behavior Current traffic situation Climate and weather forecastClimate and weather forecast…

start SOC: 95 %

19 °C

Electromobility drives networking of vehicles and new business models based on access to vehicle data


SOC = state of charge, FCS = fast charging station

based on access to vehicle data


B h i l tf f bilitBosch service platform for e-mobility

Service Provider Utility OEMDriver Fleet

Charging Billing

Bosch Charging Station Third Party InterfacesDynamic Applications

g g

Access

Telephony

Billing

Charging Station Info

Utility / Smart Grid

Surveillance

Billing

Electric Vehicle

e-mobility Core

Charging

Incentive

Integration

e-mobility CoreLocation Based

Location Based

Third Party Charging StationBusiness Ecosystem

Access

Billing

IntegrationLocation Based



I l t ti j t SiImplementation: project Singapore• Infrastructure service provider for electric

vehicle charging infrastructure 2011-2016

• Support 50+ electric vehicles

• Provide, install, and maintain up to 60 charging stations

• Collect charging data with smart meter

• Billing and pricing plans

• Customer interfaces

• Use CEPAS for identificationcontactless e-purse application (CEPAS) is used for bus, metro, taxi, road toll, parking, retail, and other services.



EV t f t h / t idEV as part of a smart home / smart gridheating applianceventilation with heating applianceventilation with

heat recovery

solar thermalRouter

PV panel

electric

Meter gatewayBSI certified CCU

freezer

WMDW

use of

electricvehicle (EV)

use ofwastewater

Li-ionbattery

thermalstorage

batterychargespot

buffer batteryfor PV & EV



N t f bilitNew competences for e-mobilityElectronics

AutomotiveChemistry

Automotive

Manufacturing

StandardizationLaw conditions

StandardizationSmart Grids

Bat

ter

yInternet of ThingsCloud Computing

Smart Cities



A dAgenda





Summary



F di f t t i tFunding future powertrain concepts

reallocation of reduced spending in reallocation of budget

reduced spending in non-powertrain domains

external funding government subsidies and incentives

coexistencevarious powertrain additional invest

in PT domain standardization

pconcepts in PT domain

reduction of component

optimum allocation of valueadd in supply chain

(volume concentration)costs by

economiesof scale

(volume concentration)

alliances

large global platforms(OEM & supplier product lines)

of scale



B h G R&D ditBosch Group R&D expenditure

A t ti T h l

EURbn

gross R&D rate[% of sales]

12

13

145.0

4.5 12.3

Automotive TechnologyBosch Group 13.2

10 8

9

10

11

124.0

3.510.1 10.2

10.7

9.69.28.8 8.8

8 6

9.4

8 1 8 1

10.8

6

7

8

9

4 2

3.0

2.5

7.47.27.37.1

7.7 7.78.6 8.1 8.1

3

4

5

64.23.83.63.93.63.33.12.92.72.5

2.0

1.5

0

1

2

3

0 0

1.0

0.5

00.0

2011201020092008200720062005200420032002

Bosch R&D expenditures in e-mobility 2011: ~400 Mio. EUR



B tt t h l k blBattery technology as key enabler

E-Machine

Power Electronics

Battery

Weight Volume Cost


Electric motor: 60 kW Battery: 20 kWh


E d it & i L i f CE llEnergy density & price - Learning from CE cells

20102010

300300 670 Wh/ℓ240 Wh/kg

570 Wh/ℓ2,000

2,500

20052005200200 360 Wh/ℓ135 Wh/kg

20002000200 Wh/ℓ

570 Wh/ℓ200 Wh/kg

1,000

1,500

$1,560/kWh

1/3

1/3100100 75 Wh/kg

2.7x

1.8x1.8x

19901990 500

$300/kWh$480/kWh

$1,010/kWh

Energy Density [Wh/ℓ] 100 200 300 400 500 600 700100 200 300 400 500 600 700 20001995 20102005

Year

Within 10 years, Li-ion consumer cells (type 18650) advanced as follows energy density doubled energy density doubled price per kWh reduced to one third production volume increased fivefold


p oduct o o u e c eased e o dCE: consumer electronics


B tt f t t d tl kBattery performance – status and outlook250 AD 1800 AD 1860 AD 1989 AD 1990 AD 201X AD

100.000B d d b tt V lt b tt L d id b tt Ni MH b tt Lithi i b tt Lithi i b tt

10.000

Bagdad battery Volta battery Lead acid battery Ni-MH battery Lithium-ion battery Lithium-air battery

1.000

wer

, W/k

g

100

ecifi

c P

ow

10

Sp

b-A

cid

1300 400 500 600 700 800 900 1000 1100 10 100 200

Specific Energy, Wh/kg

Pb


Specific Energy, Wh/kg


B tt f t d iBattery safety design

CellsCellsCellsCells PackPackPackPackCell Cell MMaterialsaterialsCell Cell MMaterialsaterials VehicleVehicleVehicleVehicle

Design & Manufacturing

i d

Safety Functions

b

Safe Materials

h d

Safety Functions

h l e.g. integrated safety devices:ceramic coated on

e.g. battery state detection and prediction

e.g. shut down separator basedon polyethylene

e.g. thermal management

electrode(PE)



B tt i f l i (US l )Battery price vs. fuel price (US example)

Changes in fuel and energy storage costs and increases in the efficiency of electrified vehicles could alter the total cost of ownership


electrified vehicles could alter the total cost of ownership


A dAgenda





Summary



D i thi ki f bilit S F tDesign thinking for e-mobility: Success Factors•high volumes

bli h d i d • system Know How

f ibl viableDesired Customers

•established industry structure

•affordable battery costs

y•HMI•compact drive unit• consumer cells

feasibletechnology

viablebusiness case

costs•consumer cells

successfulproduct

desireeBike buyer

electrical drive experiencemobility in golden ager sport

comfort, design, coolness, fancy, stylish



F i ti BikFascination eBike

It´s a lifestyle product We sell an experiencep It´s e-mobility It´s Bosch It s Bosch

eMotor powerful battery reliable system drive

functions performance



F i ti BikFascination eBike

k b d / h City Trekking MTBBike brands w/ BoscheBike-System in 2012

City Trekking MTB



O i El t ifi ti t R b t B hOverview Electrification at Robert BoschBatteryE-Machines and Navigation Systems User-centered EV HMI

Power Electronics forHybrids and EV

ABS, ESP, Brake-Booster

Powertrain for ebikes / eScooter

ABS, ESP, Brake Booster

Charging Stations for Electric Vehicles

eScooter

E

Software for Infrastructure Integration

Electric VehiclesFU

TUR

E

Components for CV Electrification

Di ti f S iResearch and Advanced Engineering for futureElectric Vehicle Concepts

Starter and Generatorsfor Start/Stop Systems

Diagnostic for Service



S The future belongs to e-mobility. However, high up-front investment

Summary

required to develop new technology. Systems competence is an enabler for mastering electric vehicle technology.

Cost of EV technology is an important driving force for market penetration Industry can join forces to achieve a competitive cost penetration. Industry can join forces to achieve a competitive cost position. Learning from other industries (e.g., consumer cells) speeds up learning curve.ea g cu e.

Bosch is paving the way for electro-mobility, with the development of innovative electric drive systems and the economic implementation of innovations in the market.




Documents

E-M bilität Mobilität - Ch d H f d Chancen und ...€¦ · E-M bilität Mobilität - Ch d H f d Chancen und Herausforderungen für Automobilzulieferer 05. ... PHEV: plug-in hybrid