L'evoluzione delle propulsioni elettriche e ibride nei ......C02 REDUCTION TARGET Emissions of CO2...

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.


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%


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)


Urban goods delivery

Electric Vehicles

1903 - Geo. Ehret's Hell Gate Brewery, N.Y.C Electric

The electric delivery service is not new…


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


Key elements

Hybrid and Electric powertrain

HV batterypack

ICE

Transmission

VehicleManagement Unit (VMU)

Electricmotor

DC/DC converter


Line-up


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



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


HV Battery development

11

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


Energy Storage System

Technological Roadmap

Source: Automotive Council Technology Group 2013



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



14

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



15

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


� Ramp and thermal stability

� Fire exposure

� Storage temperature

� Rapid charge/discharge

� Thermal shock cycling

Electrical overload leading to


� Overcharge / overvoltage

� Short circuit

� Overdischarge (forced discharge)

� Partial short circuit

Mechanical & thermal

influence


E-motor development

16

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


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


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


Model-based Development

19

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


Vehicle Management Unit (VMU)

20

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


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.


Iveco solution for urban mobility

Dual Energy

pure electric mobility

hybrid mode

mobility


Urban mobility evolution

Iveco «Vision» of the future

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L'evoluzione delle propulsioni elettriche e ibride nei ......C02 REDUCTION TARGET Emissions of CO2...

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