Post on 06-Mar-2020
Marco Aimo Boot
Alternative Traction & Electrification Manager
Turin, Italy
Contains confidential proprietary and trade secrets information of CNH Industrial. Any use of this work without express written consent is strictly prohibited.
April 22th, 2015
L'evoluzione delle propulsioni elettriche
e ibride nei veicoli industrialiIl punto di vista di Iveco
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015 2
European Mobility
Key Figures
CLEAN TRANSPORT
The transport sector contributes 23% of all CO2 emissions
The transport industry represents an important part of the economy:
in the EU it directly employs around 10 million people and accounts
for about 5% of GDP.
ECONOMIC IMPACT
ENERGY USE
The energy consumed by transport systems in the EU-25 is around 32% of the
overall energy consumption
C02 REDUCTION TARGET
Emissions of CO2 should be reduced by around 60% by 2050 compared to 1990.
URBAN POPULATION
Population in urban areas in 2012: 76% of the global population in
EU-27.
TRAFFIC CONGESTION
The urban congestion accounts for about 1% of GDP.
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015 3
Urban Mobility
Trend
LONG HAULAGE
URBAN LOGISTIC
Source Frost & Sullivan
2010 Turnover
2010 Split 2025 Split
2025 Turnover
+46%+ $ 4,5 Trillions
Urban Logistic+230%
70% 55%
45%30%
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015 4
CO2 Legislation
Current scope
GVW
(t)3,5 7,5 12
CO2 HDV
(VECTO Expected 2018)
N1 N2 N3
NOT YET
COVERED
(VECTO
over 2020?)
CO2 LDV
(Reg. 510)
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015 5
Urban goods delivery
Electric Vehicles
1903 - Geo. Ehret's Hell Gate Brewery, N.Y.C Electric
The electric delivery service is not new…
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015 6
Urban goods delivery
Electric Vehicles
2014 – New Iveco Daily Electric MY’14 (3,5 – 5 tons)
Today, what is new?...
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
New components: design & validation
TractionBatteries
Low voltage / High voltage wiring
RechargeInletChargers
Human MachineInterface
Gearshiftlever
ElectricHeater
Supercap
VehicleManagement
Unit
ManagementBatterySystem
ElectricBraking/Steering
Pump
PedestrianAcousticAlertingSystem
Inverter
Daily Electric MY’14
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
Key elements
Hybrid and Electric powertrain
HV batterypack
ICE
Transmission
VehicleManagement Unit (VMU)
Electricmotor
DC/DC converter
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015 9
Line-up
Daily Electric MY’14
NEW DAILY ELECTRIC
35S
CAB 1/2/3 BATTERY + SUPERCAP WHEELBASE 3000 – 3450 – 3750 – 4100
VAN 1/2/3 BATTERY + SUPERCAP WHEELBASE 3000 – 3520 – 3520L – 4100
NEW DAILY ELECTRIC
35CCAB 1/2/3 BATTERY + SUPERCAP WHEELBASE 3450 – 3750 – 4100
CAB 2/3 BATTERY + SUPERCAP WHEELBASE 3450 – 3750 – 4100
VAN 2/3 BATTERY + SUPERCAP WHEELBASE 4100 – 4100L
MINIBUS 2/3 BATTERY + SUPERCAP WHEELBASE 4100L
NEW DAILY ELECTRIC
50C
Line-up & Range
RANGE � 70/150/200 km
RANGE � 70/150/200 km
RANGE � 70/150/200 km
RANGE � 130/180 km
RANGE � 130/180 km
RANGE � 110/160 km
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015 10
Daily Electric MY’14
The Energy Storage System evolution…
MY’ 2009
Battery (Z5)
MY’ 2012
Battery (Z5)
New Energy Storage with Supercap and
Custom Sodium Battery (EV36)
NEW MY’ 2014
MY’ 2014
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
HV Battery development
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Multi-stage process
Battery packaging
Pack bench testing
BMS integration and SW application
Cells bench testingCell
Safe
ty a
nd
du
rab
ilit
y t
esti
ng
BMS
Vehicle testing
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
Energy Storage System
Technological Roadmap
Source: Automotive Council Technology Group 2013
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
HV Battery development
13
Electrical testing
Performance
Electrical performance of the
battery pack under different
electrical loads:
� Energy and capacity
� Power, internal resistance
� Energy efficiency
Performance FunctionalReliability and
robustness
Electrical functions:
standard and safety functions
� Electric shock protection
� Overcurrent protection
� On-board diagnosis
� Isolation resistance
� Reliability and robustness:
deriving warranty concept:
� Failure prediction (statistic)
� High power high frequency cycling impact
Life time testing and estimation
Accelerated test to estimate
the battery life:
� Environmental influence
� Degradation
� Cycle life
Reliability & durability
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
HV Battery development
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Environmental Testing
Mechanical effect:
� Random and SinusoidalVibrationTesting (proving ground and benches)
� Vibration of electronic devices
Mechanical Testing Climatic Testing Chemical Testing
Climatic effect:
temperature, humidity cycle
� Deep fording test
� Temperature cycling tests
� Enclosure protection level (IP degree)
� Humid heat, cyclic test
Chemical effect:
� Salt corrosion
� Chemical agents used for washing and cleaning
� Substances used for operating the vehicle (oils, fuel…)
Mechanical & thermal
effects
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
HV Battery development
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Abuse testing
Mechanical overload leading to
destruction of test sample
� Crush and nail penetration test
� Drop test
� Salt water Immersion
� Roll-over simulation
� Mechanical shock
Mechanical Abuse Thermal Abuse Electrical Abuse
Thermal overload leading to
destruction of test sample
� Ramp and thermal stability
� Fire exposure
� Storage temperature
� Rapid charge/discharge
� Thermal shock cycling
Electrical overload leading to
destruction of test sample
� Overcharge / overvoltage
� Short circuit
� Overdischarge (forced discharge)
� Partial short circuit
Mechanical & thermal
influence
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
E-motor development
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Characterization & validation
� Phase resistance at known temperature
� Insulation breakdown voltage (phases and sensors)
� Assembly and component masses
Isolated Machine Checks
Machine Characterization
Spin & endurance Test
� Torque control map
� Efficiency map
� Max power performances
� Deflux map calibration
� Cooling system flow rate
� Phase rotation and position / speed sensor feedback
� Phase balancing
� Friction losses up
� Rotor inertia (dynamic acceleration / deceleration conditions) and integrity at high speed
� Torque against speed and ripple
� Heat rejection to coolant system
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
Acoustic Vehicle Alerting System (AVAS)
17
Design – testing – validation
Manufacturers shall install AVAS in new types of
hybrid electric and pure electric vehicles by 1 July 2019 (New Homologation 1 July 2021).
Functionrequirements
AVAS on-vehiclecharacterization
Sound design Sound
application & tuning
Measurement and jury test
Finalassessement &
validation
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
EV-HEV Simulation
18
Modeling & design
Key benefits:
� Design logic for supervisory control in line with the product requirements, task
scheduling and fault management
� Improve the realiability of the system by simulation before to launch the code
generation
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
Model-based Development
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ISO 26262
� Development of embedded systems is a time and cost consuming procedure under
growing time-to-market and new quality and
the incoming safety Standards.
� Model-Based Development and autocoding of
safety relevant software is widely applied for
gaining efficiency.
� ISO 26262 specifically addresses Model-based development and testing with
Autocoding to improve quality and ensure the
safety needs.
� Model in the loop validation: Its aim is to
validate the specification before to autocoding
( the same test plan is assured on MIL and
HIL)
Requirements
Specifications
Design
Implementation
ECU test
System test
Validation
CODE GENERATION
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
Vehicle Management Unit (VMU)
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Hardware-in-the-loop (HIL)
Programmable test bench used to verify the
control logics and algorithms executed in real-
time in the Vehicle Management Unit (VMU).
The major benefits are:
• Test repeatability
• Test automation
• Possibility to simulate some dangerous
and complex vehicle manouvres
• Automatic reporting
• Fault injection analysis
• HW scalability
• Easy SW upgrade and modularity
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015 21
Iveco solution for urban mobility
Dual Energy
System includes two kinds of
traction:
� electric mode, to ensure
zero emissions and low
noise pollution;
� hybrid mode, (diesel-
electric) suitable for long-
range travel and suburban
missions.
A light commercial vehicle capable of self-
adapting selectively to the more suitable energy
source, depending on the specific mission.
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015 22
Iveco solution for urban mobility
Dual Energy
pure electric mobility
hybrid mode
mobility
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industrialiApril 22th, 2015
Urban mobility evolution
Iveco «Vision» of the future
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