New concepts in drive technology - enabled by electrification

18.07.2013 – VDI Seminar Landtechnik: Antriebstechnik für Traktoren und mobile Arbeitsmaschinen

New concepts in drive technology - enabled by electrification

Agenda

1. Trend of electrification in agriculture

2. Challenge of elektrifizierung

3. Short introduction of AVL and AVL CD+TE

4. Example enhancement of process by electrification + Investigation with simulation

5. Generation 0 – concept with virtual prototype using MOBEO, MOTRAN and VSM

6. Power generation in tractor

7. Integration of generator into driveline

8. Optimization of powertrain by hybridization

9. Outlook


3

AEF – Agricultural Electronics Foundation

Organization of tractor and implement related companies with goal of standardization

High-voltage-interface tractor <> implements (up to 170kW)

Control-interface energy flow / e-motors

Motivation:

Increase of process

New or improved performance of implement

Simplification, avoid oil, etc.

AVL CD&TE is member of AEF


Challenge

1. Reach plateau of productivity as fast as possible – example of passcar

Attention

Peak of exorbitant expectations

Trigger of technology

Valley of dissapointments

Path of enlightenment

Plateau of productivity

Time 1997 SOP Prius

2003 VDI

Hybrid

2011 1Mio.

E-Cars in BRD 2020

2013 Project Stops +

Motorensymposium „E-Car steckt“

> 2013 Solutions with real

costomer benefit and consequently optimized

systems: 1st „killer applications“

Identification of killer applications

Concentrate on real customer benefits

It is not only adding electrification

Consequently optimize complete system

Finding Plateau may take some time


http://commons.wikimedia.org/wiki/File:Gartner_Hype_Zyklus.svg

5

IC Engine

Transmission

Electric Motors

Control Strategy

Battery

5 Element of AVL Kaleidoscope

Component configuration

6

Component configuration in tractor and implement –

under consideration of application process

Control Strategy Tractor

5 Element of AVL Kaleidoscope With Tractor to 6 Elements

IC Engine Transmission

Battery

Electric Motors

Prozess

Control Strategy Implement

TU_Dresden_TraktorElectrification pdf.pdf

7 Internal

Traction force distribution

Actual situation: Increase traction power by vehicle weight necessary (ballast)

soil compaction due to higher weight

wheel-soil contact area increasing

bulldozing effect increases rolling resistance


8 Internal

Traction force distribution

Countermeasure

e-driven axle on implement (and tractor front axle)

increase and distribute tractive power

same system tractive power with lower tractor weight or higher system

tractive power with same tractor weight

optimized vehicle slip/ fuel consumption

Benefit:

existing tractor is able to operate with lower fuel consumption or more powerful

implements


9

Actual situation of simulation capabilities

AVL is actually capable to simulate the following effects:

Pulling force of implements and derived power demand of engine

Increase of traction power and ballast reduction and bulldozing effect

Soil interaction with implement

Fuel consumption and emission behaviour of engine

Drivability with respect to performance and comfort related criteria

Tire model will be refined and adapted to embrace better agricultural tires in order to better

describe slip ground contact and pulling effects in the field

=> Simulation video – tractor with plow


tractor_demo.wmv

tractor_demo.wmv

tractor_demo.wmv

tractor_demo.wmv

tractor_demo.wmv

tractor_demo.wmv

tractor_demo.wmv

tractor_demo.wmv

tractor_demo.wmv

tractor_demo.wmv

tractor_demo.wmv

10 Internal

The Powertrain Development is organized in consecutive generations with increased maturity of the powertrain in each generation.

Proj ?:

project kick

off

PTDP 0:

Concept

release

PTDP :

Generation 2

release

PTE Project ProcessPTE

Sales

Powertrain

developme

nt project

closure

CoSy - Control System

Engine Development Process

Driveline Development Process

E-Machine Development Process

Battery Development Process

Powertrain

developmen

t project

initialization

Specificatio

n Phase

Powertrain Development

Generation 2: Production

Validation and Application of

developments for serial

production

Iterations


Generation 1: functional and

durability

development based on

prototypes

Iterations


Generation 0: concept

development and virtual

prototypes

Iterations

PTDP 1:

Generation 1

release

Front Loading

Maturity

AVL System- Development & Integration Process

11 Public

AV

L C

AM

EO

Desig

n o

f E

xperim

ents

MOTRAN

Driveline Simulation Model

AVL EXCITE/FEMAG

Mechanical & E-Motor Simulation

AMESIM

Hydraulic Simulation

MOBEO

Engine Simulation Model

AVL BOOST

Engine Simulation Model

AVL FIRE

Thermodynamic Simulation

VSM / Cruise

Vehicle Simulation

Reservoir

Flow

Element

Intake

Throttle

Intake Manifold

Cylinders

Exhaust Manif.

DOC +

DPF

Pressure Loss

of EAS

LP-

EGR

Take

-off

Comp. Inl.

Ambient

Intake

Cleaner + LP-

EGR Throttle

TC

C T

LP-EGR

Line

Exhaust

Throttle

+MufflerAmbient

Exhaust

CAC

Reservoir

Flow

Element

Reservoir

Flow

Element

Intake

Throttle

Intake Manifold

Cylinders

Exhaust Manif.

DOC +

DPF

Pressure Loss

of EAS

LP-

EGR

Take

-off

Comp. Inl.

Ambient

Intake

Cleaner + LP-

EGR Throttle

TC

C T

LP-EGR

Line

Exhaust

Throttle

+MufflerAmbient

Exhaust

CAC

Method to workout most beneficial configuration – MOBEO + MOTRAN + VSM


12

Involved components in power generation

Optimization of customer benefit by electrification View on tractor – its optimization potential elaborated by simulation

Combustion

engine

Exhaust

aftertreatment

Auxilaries and

implements

Driveline /

Transmission

Power

electronics

Electrical

FWD

E-motor /

generator

Energy

storage

2

1 delta 20°C

13

Involved components in power generation

Weight, dimensioning and product price

Parameters

High Speed instead of high torque

High power density

Optimized sheet metal geometries

Housing, cooling, etc.

Power: 50 kW

Weight: 30 kg Diameter: 150 mm rpm: 15,000



Source: Bosch

Source: Bosch

Source: HermeticDrive

Power Generation in tractor

14

323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340time [sec]

To

rqu

e [

Nm

]

-80

0

80

160

240

320

400

480

560

640

720

800

880

To

rqu

e B

as

e C

yc

le [

Nm

]

-80

0

80

160

240

320

400

480

560

640

720

800

880Base

200Nm

Cut Peak Trq.

Ramp Trq.

Cut & Ramp Trq.

1. Base

2. Increase load to 200Nm to charge the battery

3. Cut the Peak torque

4. Limit the torque gradient during acceleration (Ramp Torque)

5. Combination of cutting the peak torque and limit the gradient (each is compensated by 50% of work available)

2

5

4 3

1

1st rough investigation of tractor hybridization

Tractor and Implement Optimization by hybridization

15

Work from

Battery (kWh)

Tests Fuel Nox EO Nox TP Soot

1,06

Base 100 100 100 100

200Nm 105,6 106,6 90,7 103,5

Cut Trq. Peak 101,7 103,0 84,2 97,3

Ramp Trq. 101,8 103,2 87,4 94,4

Cut + Ramp 101,7 103,1 85,7 95,9

3,00

Cut Trq. Peak 94,9 95,8 77,1 97,1

Ramp Trq. 95,3 96,3 83,3 92,2

Cut + Ramp 95,0 96,2 80,6 93,2

5,00

Cut Trq. Peak 88,1 88,7 71,7 99,2

Ramp Trq. 88,5 88,6 80,0 92,2

Cut + Ramp 88,2 88,5 77,3 95,0

1st rough investigation of tractor hybridization – results NRTC

Tractor and Implement Optimization by hybridization

16

Outlook

Process improvements applying electrification are visible creating real customer benefit

Optimization potential of tractor applying electrification and hybridization is visible

Dynamic of combustion engine may be reduced resulting in lower emissions

Efficiency of exhaust aftertreatment is increased due to more efficient

thermomanagement

Overall fuel consumption reduction – depending on application battery size, engine

and exhaust gas after treatment concept

Generator integration in existing tractor driveline architecture enables mid-term solutions

MOBEO, MOTRAN and VSM is detailed simulation method to workout optimum topology,

functionality and configuration for tractor, implement and its process


Documents

New concepts in drive technology - enabled by electrification