Lightweight vehicle and power

Power electronics roadmap train roadmap

Mass Reduction -200kg -435kg
(on 2012 mass)
Power electronics roadmap Magnesium structural (castings)
Hybrid materials
Metal matrix composites
Magnesium (sheet)
High power Titanium
density
Mass inverters
Reduction LW transmission & driveline
11kW/kg + 9kW/l 12kW/kg
-170kg + 12kW/l 14kW/kg + 13kW/l
-425kg
(on 2012 mass)
Low cost inverters Aluminium (BIW, bolt-on
7.9$/kW panels, chassis)
5$/kW 3.3$/kW
Lightweight
High temp inverters roof systems
~90 C
o
Lightweight seat systems
Mass Reduction
-120kg High temp inverters >150
-290kgC
o
(on 2012 mass)
Sheet moulding compound panel IGBT(SiC/GaN/SICN) drive
Lightweight structural plastics
Power electronics monitoring
Lightweight seat systems
Autotuning invertors
Steel (UHSS, tube hydroforming, hot stamping)
Resonant convertors
Aluminium thin-wall HPDC casting
PE system level integration Integration of invertors & motors
Carbon composite BIW
PE system level compositeIntegration
integration
Carbon bolt on panelsof DC/DC & chargers

Medium
General
Radical
Alternative lightweight vehicle architectures

Large
Small
2010 2015intensive computing 2020
Numerically 2025
& CAE multi-physics optimisation 2030
Prototype
Real world data (RWD) & structural health monitoring
Production
2010 2015 2020 2025 2030
EU Fleet Average 130 95 Source:Automotive
TBD Council Technology Group 2013
CO2 Targets (g/km)
Source:Automotive Council Technology Group 2013
 Lightweight
Traction vehicle
motors and power
& generators train roadmap
roadmap (<40kW)
Mass Reduction -200kg -435kg
(on 2012 mass)
Traction motors & generators roadmap (<40kW)Magnesium structural (castings)
Hybrid materials
Metal matrix composites
Magnesium (sheet)
Titanium
Permanent Magnet PM LW content reduction
transmission & driveline
Mass Reduction
(on 2012 mass) -170kg -425kg
Induction
Aluminium (BIW, bolt-on panels, chassis)

Traction Motors
Development of lighter weight induction machines
Lightweight roof systems
Hybrid motors
Lightweight seat systems
Mass Reduction -290kg
(on 2012 mass) -120kg
Switched reluctance
Sheet moulding compound panel
Synchronous
Lightweight structural plastics reluctance
Advanced electronics and control provides
Lightweight seat systemsstep change
Steel (UHSS, tube hydroforming, Multistage
hot stamping)
Aluminium thin-wall HPDC casting
48V Micro/mild hybridBIW
Carbon composite
Carbon composite bolt on panels

&

Medium
Systems Integration
General
Thermal management

Radical
Integrated electric powertrain & vehicle cooling
Alternative lightweight vehicle architectures

Large
New Architecture

Small
Numerically intensive computing & CAE multi-physics optimisation
Modular single speed Integrated single speed traction motion gearbox
Real world data (RWD) & structural health monitoring

2010
Traction motion gearbox 2015Multispeed torque2020
cut gear shifts Multispeed
2025 power shift 2030
EU Fleet Average 130 Wheel motors:
95 geared drive
TBD
CO2 Targets (g/km)
Wheel motors: direct drive
Source:Automotive Council Technology Group 2013

2010 2015 2020 2025 2030

Prototype Production
Source:Automotive Council Technology Group 2013
 Lightweight
Traction vehicle
motor and power
& generator train (100kW
roadmap roadmap+)
Mass Reduction
Traction motor & generator roadmap (100kW +)
-200kg -435kg
(on 2012 mass)
Magnesium structural (castings)
Hybrid materials
Metal matrix composites
Magnesium (sheet)
Permanent magnet PM content reduction Titanium
Mass Reduction LW transmission & driveline

Traction Motors
(on 2012 mass) Induction -170kg -425kg
Aluminium (BIW, bolt-on panels, chassis)
Hybrid motors
Lightweight roof systems
Mass Reduction
Switched
Lightweight reluctance
seat systems
-120kg -290kg
(on 2012 mass)
Sheet mouldingSynchronous
compound panel reluctance
Lightweight structural plastics
Multistage
Lightweight seat systems
Steel (UHSS, tube hydroforming, hot stamping)
Thermal management Integrated electric powertrain
Aluminium thin-wall HPDC casting & vehicle cooling

New Architecture &

Integration
Modular single speed Integrated single speedCarbon
tractioncomposite BIW
motion gearbox
Carbon composite bolt on panels

Medium
General
Radical
Traction motion gearbox Multispeed torque cut gearlightweight
Alternative shifts Multispeed power shift
vehicle architectures

Large
Small
Numerically intensive computing & CAE multi-physics optimisation

Systems
Wheel motors:
Real world geared
data (RWD) drive
& structural health monitoring

2010 2015 2020 2025 2030

Wheel motors: direct drive
EU Fleet Average 130 95 TBD
CO2 Targets (g/km)

2010 2015 2020 Source:Automotive

2025 Council
2030 Technology Group 2013

Prototype Production

Source:Automotive Council Technology Group 2013

 Lightweight vehicle and power train
Power train (ICE) technology roadmap roadmap
Mass Reduction -200kg -435kg
(on 2012 mass)
Magnesium structural (castings)
Power train (ICE) technology roadmap Hybrid materials
Metal matrix composites
Euro 5 Euro 6 Euro 7 Magnesium (sheet)
2014 Air Quality
2009 2019? Titanium
Mass Reduction Fuel injection system optimisation
LW transmission & driveline
(on 2012 mass) -170kg -425kg
Increased charge air boost efficiency/range
Aluminium (BIW, bolt-on panels, chassis)
High efficiency low NOx combustion concepts
Lightweight roof systems
Reduced combustion heat losses
Mech. turbocompound Lightweight seat systems

Efficiency
Mass Reduction -290kg
-120kg

Thermal
(on 2012 mass) Electrical turbocompound
Sheet moulding compound panel
Organic rankine
Lightweight structural plastics cycles
Split/recuperated cycle
Lightweight seat systems
Lower mechanical friction (coatings/bearings/etc)
Steel (UHSS, tube hydroforming, hot stamping)
Downsizing & boosting technologies
Aluminium thin-wall HPDC casting
Downspeeding for lower friction
Carbon composite BIW

Efficiency
Variable power ancillaries

Systems
Carbon composite bolt on panels

Medium
Low thermal inertia/fast warm-up systems

General
Radical
Alternative lightweight vehicle architectures

Large
Small
Thermo-electric generators
Numerically intensive computing & CAE multi-physics optimisation
Integrated electrification & world
Real energy datarecovery technologies
(RWD) & structural health monitoring

2010 Flexible valve trains (timing/lift/actuation)

2015 2020 2025 2030
Model
EU Fleet Average Based Control Real Time Models Closed loop/feed back tuning
130 95 TBD
CO2 Targets (g/km) Integrated PM and NOx emissions control systems

Technologies
Active charge thermal management/control Source:Automotive Council Technology Group 2013

Enabling
Advanced/new lightweight materials
Flexible/fast response boost
Thermal energy storage/fast warm-up
2010 2015 2020 2025 2030
EU Fleet Average CO2
130 95 TBD Targets (g/km)
 Lightweight
Automotive vehicle
technologies: the and
UK’s power
current train
capability
Passenger car low carbon technology roadmap roadmap
Passenger
Mass Reduction Car Low Carbon Technology
-200kg
Roadmap -435kg
(on 2012 mass)
Magnesium structural (castings)
Hybrid materials
Metal matrix composites
Magnesium (sheet)
EU Fleet Average 130 95 Titanium
TBD
Mass 2 Targets (g/km)
COReduction LW transmission & driveline
(on 2012 mass) -170kg -425kg
Demonstrators Fuelchassis)
Aluminium (BIW, bolt-on panels, Cell Vehicle
Lightweight roof systems
Fuel Cell & H Supply/Storage Breakthrough
H2 Infrastructure 2
Lightweight seat systems
Mass Reduction Niche EVs Mass Market EV Technology
-120kg -290kg
(on 2012 mass)
Charging Infrastructure Sheet moulding compound panel
Energy Storage Breakthrough
Lightweight structural plastics
Demonstrators Plug-In Hybrid
Lightweight seat systems
Energy Storage Breakthrough
Steel (UHSS, tube hydroforming, hot stamping)
Full Hybrid
Aluminium thin-wall HPDC casting
Carbon composite BIW
Carbon composite bolt on panels
Micro/Mild Hybrid

Medium
General
Radical
Alternative lightweight vehicle architectures

Large
Small
Numerically intensive computing & CAE multi-physics optimisation
IC Engine and Transmission innovations (gasoline/diesel/gas/renewables)
Real world data (RWD) & structural health monitoring

2010 2015 2020 2025 2030

Vehicle Weight and Drag Reduction
EU Fleet Average 130 95 TBD
CO2 Targets (g/km)
2000 2010 2020 2030 2040
Source:Automotive Council Technology Group 2013
 Lightweight vehicle and power train roadmap
Commercial and off-road technology roadmap
Mass Reduction -200kg -435kg
(on 2012 mass)
Magnesium structural (castings)
Commercial and off-road technology roadmap Hybrid materials
Metal matrix composites
Breakthrough in energy storage Magnesium (sheet)
Titanium
Mass Reduction LW transmission & driveline
(on 2012 mass) Niche EVs Commercial/Off-Highway
-170kg EV’s -425kg
Aluminium (BIW, bolt-on panels, chassis)
H2 infrastructure Lightweight roof systems
Fuel cell vehicles
Mass Reduction
Lightweight
Fuel Cell APUs seat systems
-120kg -290kg
(on 2012 mass)
Demos Sheet moulding compound panel
Plug in hybrid
Full hybrid Lightweight structural plastics
Micro/Mild hybrid Lightweight seat systems
Steel (UHSS, tube hydroforming, hot stamping)

Duty Cycles
IC Engine efficiency improvements
Aluminium thin-wall HPDC casting

Heavy Duty Cycles

Light Duty Cycles

Waste heat recovery Advanced thermodynamic cycles
Carbon composite BIW
Carbon composite bolt on panels

Medium
General
Biofuels SustainableAlternative
liquid/gaseous fuels

Radical
lightweight vehicle architectures

Large
Small
Powertrain efficiency improvements/ancillary electrification
Numerically intensive computing & CAE multi-physics optimisation

Medium
Real world data (RWD) & structural health monitoring
Intelligent2010
vehicles logistics – operational efficiency
2015 2020 (On & Off-highway)
2025 2030
Advanced
EU Fleet Average highway vehicle aerodynamics/selective
130 95 lightweighting
TBD
CO2 Targets (g/km)
CO2 reductions limited by “Zero” Air
Source:Automotive AirTechnology
Council Quality Group 2013
air quality regulations Quality Impact Improvements
Drivers

LD Van CO2 Possible HD/MD UK CO2 CO2 and GHG GHG -

Regulation CO2 Regulation Target greenhouse
reduction gas
2010 2020 2030 2040 2050
Source: Automotive Council Technology Group 2012
 Lightweight vehicle and power train roadmap
Lightweight vehicle and power train roadmap
Mass Reduction -200kg -435kg
(on 2012 mass)
Magnesium structural (castings)

Lightweight vehicle and power train roadmap Hybrid materials

Metal matrix composites
Mass Reduction Magnesium (sheet)
-200kg -435kg
(on 2012 mass) Titanium
Magnesium structural (castings)
Mass Reduction LW transmission & driveline
(on 2012 mass) -170kg Hybrid materials -425kg
Metal matrix
Aluminium (BIW, bolt-on panels, chassis) composites
Magnesium (sheet)
Lightweight roof systems
Titanium
Mass
Mass Reduction
Reduction
Lightweight seat systems
LW transmission & driveline
-120kg
-170kg -290kg
-425kg
(on
(on 2012mass)
2012 mass)
Sheet moulding
Aluminium (BIW, bolt-on compoundpanels, panel
chassis)
Lightweight
Lightweight structural plastics
roof systems
Lightweight
Lightweightseat seatsystems
systems
Mass Reduction -290kg
(on 2012 mass) -120kg
Steel (UHSS, tube hydroforming, hot stamping)
Sheet moulding compound
Aluminium thin-wall HPDC casting panel
Lightweight structural plastics
Carbon composite BIW
Lightweight seat systems
Carbon composite bolt on panels

Medium
General
Radical
Steel (UHSS, tube hydroforming,
Alternative lightweight hot stamping)
vehicle architectures

Large
Small
Aluminium thin-wall HPDC casting
Numerically intensive computing & CAE multi-physics optimisation
Real world data (RWD) & structural health monitoring
Carbon composite BIW
2010 2015 2020
Carbon composite 2025
bolt on panels 2030

Medium
General
Radical
EU Fleet Average 130 Alternative
95 lightweight vehicle
TBD architectures

Large
Small
CO2 Targets (g/km) Numerically intensive computing & CAE multi-physics optimisation
Real world data (RWD)Source:Automotive
& structural health monitoring
Council Technology Group 2013
2010 2015 2020 2025 2030
EU Fleet Average 130 95 TBD
CO2 Targets (g/km)
Source:Automotive Council Technology Group 2013
 Lightweight vehicle and power train
Energy storage Echem Tech roadmap roadmap
Mass Reduction -200kg -435kg
(on 2012 mass)
Magnesium structural (castings)
Hybrid materials
Passenger Car LCV Energy Storage Echem Tech Roadmap Metal matrix composites
Magnesium (sheet)
Titanium
Lithium mixed metal phosphate
Mass Reduction
Lithium nickel cobalt manganese oxide LW transmission & driveline
Adv lithium nickel cobalt manganese oxide
(on 2012 mass) -170kg -425kg
Lithium iron phosphate Adv lithium iron phosphate
Aluminium (BIW, bolt-on panels, chassis)
High

Lithium mixed metal phosphate

Lightweight roof systems
Lithium titanate Adv lithium titanate
Mass Reduction
Lightweight
Lithium nickel cobalt manganese oxide
seat systems
Adv lithium nickel cobalt manganese oxide
-120kg -290kg
(on 2012 mass) Lithium iron phosphate Adv lithium iron phosphate
Sheet moulding compound panel
Advanced lithium mixed metal phosphate
Lightweight structural plastics
High energy (overlithiated) lithium nickel cobalt
Lightweight seat systems
Medium

manganese oxide v Silicon based composite electrodes

Volumes

Steel (UHSS,
Lithium manganese oxidetube
spinelhydroforming, hot stamping)
Lithium nickel cobalt manganeseAluminium
oxide Adv lithium nickel
thin-wall HPDC casting cobalt manganese oxide
Lithium iron phosphate Adv lithium iron phosphate
Carbon composite BIW
Lithium sulphur/ Rechargeable Lithium-Air
Carbon composite bolt on panels

Battery ‘pure’ EV (250-Medium

General
Radical
High energy (overlithiated) lithium nickel cobalt
Alternative lightweight vehicle architectures
Low

Large
Small
manganese oxide v Silicon based composite electrodes

500v)
Numerically intensive computing & CAE multi-physics optimisation

Plug in hybrid (200-400V)

Lithium titanate
Real world data (RWD) & structural health monitoring
Lithium nickel cobalt manganese oxide
2015
2010Lithium iron phosphate 2020 2025 2030

Full Hybrid (<400V)

Mild Hybrid (48V)
EU Fleet Average 130 95 TBDcobalt manganese oxide
Adv lithium nickel
CO2 Targets (g/km)
V. Low

Micro Hybrid
Lithium mixed metal phosphate
Lithium titanate Adv lithium titanate Source:Automotive Council Technology Group 2013
Lithium iron phosphate Adv lithium iron phosphate

(12V)
Advanced Lead Acid Cell eg Lead-carbon/asymmetric capacity
2010 2015 2020 2025 2030

Source :Automotive Council Technology Group 2013

 Lightweight vehicle and power train
Intelligent mobility technology roadmap roadmap
Intelligent
Mass Reduction
mobility technology roadmap -200kg -435kg
(on 2012 mass)
Magnesium structural (castings)
Hybrid materials
Metal matrix composites
Magnesium (sheet)
Autonomous vehicles
Titanium
Mass Reduction Safety critical systems & driveline
LW transmission
(on 2012 mass) -170kg
Multi-modal journey planning & optimisation systems -425kg
Aluminium (BIW, bolt-on panels, chassis)
Congestion & Intelligent mobility
Value Increased mobility
Lightweight roof systems
pollution reduction objectives delivered

Mass Reduction
Lightweight seat
Recognition & control algorithms systems
-120kg -290kg
(on 2012 mass)
On-board sensors Sheet & actuators
moulding compound panel
V2V communications Lightweight structural plastics
Value Cost reductions Lightweight seat
Safety systems
improvements
(service & maintenance)
Steel (UHSS, tube hydroforming, hot stamping)
HMI Aluminium thin-wall HPDC casting
V2I communications Carbon composite BIW
A-V Systems Carbon composite bolt on panels

Medium
General
Connected travellers
Radical
Connected vehicles
Communication Alternative lightweight vehicle architectures

Large
Small
Intelligent mobility
Value &Entertainment Business & Commercial Benefit
Numerically intensive computing & CAE multi-physics optimisation
Real world data (RWD) & structural health monitoring
Processing Fast Faster Even faster
2010 2015 2020 2025 2030

acquisition &
Storage Local Mixed CloudTBD

processing
EU Fleet Average 130 95
CO2 Targets (g/km)
Transfer 3G 4G 5G
Source:Automotive Council Technology Group 2013
Data
2010 2015 2020 2025 2030
Source: Automotive Council Technology Group 2013
 The motorsport technology roadmap focuses on chasing integrated
performance efficiently with cost-effective CO2 reduction
Formula “E”
High Level Technology Roadmap for Motorsport FE New F1 engine regulations
The motorsport technology roadmap focuses on chasing
New LMP regulations integrated
F1
Road relevance, technology transfer
performance efficiently with cost-effective CO2 reduction
KERS DRS
LMP Cost and sustainability
Formula “E”
Drivers
High Level Technology Roadmap for Motorsport
Market engagement - spectators, customers
FE (especially ageing
New F1 demographic),
engine regulations the show, service industry
New LMP (transmission)
Performance: reduce CO2 and increase kW/l (engine) and Nm/kg regulations for efficiency and “green” image
F1
Road relevance, technology transfer
KERS DRS Safety
LMP Cost and sustainability
Engine down-sizing and down-speeding, friction reduction
Drivers Market engagement - spectators, customers (especially ageing demographic), the show, service industry
Fuel systems: Direct injection, alternative fuels, fuel flow limits
Propulsion E-machines
Force India, Ford Racing,

Performance: reduce CO2 and increase kW/l (engine) and Nm/kg (transmission) for efficiency and “green” image
Advanced boosting systems
Safety
Energy recovery/split cycle/fuel cells
Engine down-sizing and down-speeding, frictionand
Low friction design reduction
lubrication
Transmission/ Fuel systems:
Cost Direct
effective injection,semi-autos
fast-shifting alternative fuels, fuel flow limits
Propulsion E-machines
F1,Racing,

driveline Materials, structures and manufacturing processes

Advanced boosting systems
Integrated hybrid systems
Energy recovery/split cycle/fuel cells
India, Ford
with Williams

Moveable
Low frictionaerodynamics
design and lubrication
Transmission/ Lightweight
Cost effective structures
fast-shifting semi-autos
F1, Force

driveline
Vehicle Materials, structures and manufacturing processesEnclosed cockpits, covered wheels
, nterviews

Thermal management, efficienthybrid

Integrated powersystems
electronics
BrakeMoveable
electrification (linked to energy storage)
with Williams

aerodynamics
Tyres
Lightweight structures
Ricardo analysis
Alcon, Lola and Dallara

Kinetic energy recovery

Enclosed cockpits, covered wheels
Energy
Vehicle Energy
Thermalstorage (on-board/remote batteries, flywheels, ultra-caps, hydraulic ... )
Source:, nterviews

management/ management, efficient power electronics

Waste heat
Brake electrification recovery
(linked to energy storage)
infrastructure
Tyres Battery/system charging/safety/management at venue
Source: Ricardo analysis

ITS
Alcon, Lola and Dallara

© Ricardo plc 2013 Telemetry, data/information feed direct to consumers

Kinetic energy recovery
Energy
2005 Energy
2010storage (on-board/remote2015batteries, flywheels, ultra-caps,
2020 hydraulic ... ) 2025
management/
Confidential 31 July 2013 Waste heat recovery
Version 10 © Ricardo plc 2013 1
infrastructure
Battery/system charging/safety/management at venue
ITS © Ricardo plc 2013 Telemetry, data/information feed direct to consumers
2005 2010 2015 2020 2025
Confidential 31 July 2013 Version 10 © Ricardo plc 2013 1
Bus technology roadmap
Breakthrough in energy storage

Niche EVs Mainstream EVs

H2 infrastructure Fuel cell vehicles

Breakthrough in energy storage Plug in hybrid

Mild/mild hybrid

Powertrain
Niche EVs Mainstream EVs
Full hybrid
H2 infrastructure Fuel cell vehicles
IC Engine efficiency improvements
Plug
Waste heat in hybrid
recovery Advanced thermodynamic cycles
Mild/mild hybrid

Powertrain
Biofuels Sustainable liquid/gaseous fuels
Full hybrid Powertrain efficiency improvements/ancillary electrification
IC Engine efficiency improvements
Reducing body energy consumption
Waste heat recovery Advanced thermodynamic cycles
CO2 neutral improved bus desirability (driver/passenger)

Vehicle
Biofuels Sustainable liquid/gaseous fuels
Intelligent vehicles logistics – operational efficiency
Powertrain efficiency improvements/ancillary electrification
Reducing rolling resistance/lightweighting
Reducing body energy consumption
CO reductions limited by “Zero” Air Quality Air Quality
CO2 neutral improved bus desirability (driver/passenger)

Vehicle
2
emissions regulation Impact Improvement
Drivers

Intelligent vehicles logistics – operational efficiency

LD Van CO2 Possible HD/MD UK CO2 GHG = greenhouse
Target CO2 and GHG gas
Regulation CO Regulation
Reducing rolling resistance/lightweighting
2 reduction
Now 2020 2030 2040 2050
CO2 reductions limited by “Zero” Air Quality Air Quality
emissions regulation Impact Improvement
Drivers

LD Van CO2 Possible HD/MD UK CO2 GHG = greenhouse

Target CO2 and GHG gas
Regulation CO2 Regulation
reduction
Now 2020 2030 2040 2050