İstatistik Sözlüğü

Prepared for FUTURE OF E-MOBILITY
2nd International Automotive THE NEXT GENERATION EV POWERTRAIN

Engineering Conference (IAEC)
Istanbul, 2nd and 3rd of November 2017

Dr.-Ing. Thomas Hülshorst, Group Vice President Electronics and Electrification, FEV Group GmbH
© by FEV – all rights reserved. Confidential – no passing on to third parties

CASE - Introduction
Connectivity, autonomous driving, shared mobility and powertrain

electrification are expected to strongly impact the automotive industry
CASE – CONNECTED, AUTOMATED DRIVING, SHARED MOBILITY AND ELECTRIFICATION

Automated Driving
Connected Services Shared Mobility
„Connectivity, autonomous driving, sharing and electric

drive systems – each of these four trends has the
potential to turn our industry on its head. Yet the real
revolution lies in intelligently linking the four trends.“
Dr Dieter Zetsche, CEO of Daimler AG and

Head of Mercedes-Benz Cars
Electrification and new powertrains
Source: FEV
2nd International Automotive Engineering Conference © by FEV – all rights reserved. Confidential – no passing on to third parties |
Dynamic market modelling # EXAMPLE: EUROPE
Electrification, mobility and automated driving are expected to be

introduced with significant market shares until 2035 time frame
SALES FORECAST IN MILLION UNITS (BASED ON DMM)

14.7 15.0 15.0
 Pure electric vehicle sales are projected to grow
strongly until 2035 driven by
Powertrain 78%
ICE based
types 100%
90%
 Mid-term: governmental regulation
Non ICE  Long-term: cost reduction and consumer adoption
0% 10% 22%
2016 2025 2030 2035  Private ownership projected to remain the dominant
14.7 15.0 15.0 source for vehicle sales throughout 2035
Mobility  E-Hailing seen as major form of shared mobility

97% 88% Private ownership
99%
solutions Car-Sharing
 High level automation (level 3+) is projected to push
E-Hailing
1% 2% 9%
3% into market starting from 2025 onwards
2016 2025 2030 2035
 Top-down market introduction from premium to volume
14.7 15.0 15.0
applications
49% AD level 0-2  Consumer adoption driven by potential to free up time
Automated 84%
100%
AD level 3 for productivity increase and social media
driving 39%
AD level 4-5  First Level 4 users are expected to be commercial
16% 0% 12%
2016 2025 2030 2035
robo-cap fleets for e-hailing
Source: FEV
Powertrain electrification market trends & FEV forecasts
For European market FEV expects a major shift to plug-in and battery
electric vehicles – distribution mainly depending on customer preferences
FUTURE POWERTRAIN SCENARIOS PASSENGER CAR – VEHICLE REGISTRATIONS

FEV Scenario – most likely Scenario “BEV break-through” Scenario “PHEV”
100% 4% 5% 5%
18%
80% 39%
51% 46%
56%
60% 84% 84% 84%
78%
33% 8%
40% 7% 2%
7% 24%
13%
3%
20% 5% 13% 21%
Future of 26%
10%
2% 2% E-mobility
5% 5%
2% 10% 2%
2% 2%
2% 3%
3% 3% 1% 3% 1% 3%
0%
0% 2% 3% 3% 5%
2016 2020 2025 2030 2025 2030 2025 2030
CO2 fleet
emission:
<95 g/km* <75 g/km* <65 g/km* <65 g/km* <65 g/km*
*: normalized to NEDC ICE only Mild Hybrid Plug-In Hybrid Fuel Cell
e-gas: gas produced by electricity from renewable energy
Source: FEV Stop-Start & 12V Energy Mgmt Full Hybrid Battery Electric Natural gas and e-gas
FEV High voltage battery development © by FEV – all rights reserved. Confidential – no passing on to third parties |
What is THE ELECTRIC CAR of Future Mobility?
Future Mobility will be diverse!

Combination of Individual, Shared
and Public Mobility
Micro cars People Mover
Passenger cars Public transportation
High Performance cars Commercial vehicles
There is a wide variety of ELECTRIC CARS already today!
FEV PROJECT EXAMPLES
IMPERIA PPV
Micro cars People Mover
Passenger cars Public transportation
High Performance cars Commercial vehicles
Source: KARSAN, BMW, StreetScooter, Imperia, FEV

EV Powertrain System and Components Today:
Still a quite complex and inflexible system for a wide range of applications
Powertrain Electric Motor

Control Unit
Battery Management Transmission

System
Telematics Chassis Battery Cooling / Heating Onboard charger Inverter
The Next Generation EV Powertrain:
Modular and Scalable Concepts for Wide Range for Electrified Vehicles
Highly integrated and Highly integrated

connected controls and Electric Drive Unit
E/E architecture
Powertrain Control Unit Electric Motor
Battery Management System Transmission

Highly integrated
Telematics Battery Power Electronics
Motor Controller Modular Battery

Charging Control Cooling / Heating
Housing  part of chassis structure
Fast charging

E/E architecture

Scaleable “Skateboard” chassis
Highly integrated
Telematics Battery Power Electronics
Motor Controller Modular Battery

Charging Control Cooling / Heating
Fast charging

E/E architecture

Highly integrated
Motor Controller Battery Inverter
Charging Control Modular Battery
Cooling / Heating
Fast charging
How Connectivity Supports EV Powertrain Operation
Assisted Connected
Predictive Cruise Control Cloud Services
Electric Range Optimizer Highly accurate
Range Prediction
Connected Fast Charging and

Electrified Thermal Management
FEV SMARTDRIVE
The smart vehicle – assisted / connected / electric
Assisted Map based information, ADAS sensors (camera,

LiDar) and V2X communication is used to analyse
route and traffic flow
Objects Data source

speed limit shield, curvature map data and camera recognition
traffic light V2X communication, camera
Average traffic speed, traffic jam, etc. V2X communication, camera, LiDar
70 Predicted speed trajectory of preceding traffic

vLim vLim vLim
50
t t t
Traffic Light
D D D
Static Speed Limit Repetitive Speed Limit Instant Speed Limit
FEV Electronics and Electrification © by FEV – all rights reserved. Confidential – no passing on to third parties |
FEV SMARTDRIVE
Assisted Optimization of speed trajectory using eHorizon to

minimize energy consumption at comparable travel
time.  7.3% energy consumption reduction is
achieved at test track (real life driving cycle)!
FEV SMARTDRIVE
Usage of in-vehicle data for new cloud

services like cloud based range prediction, Connected
real time traffic or blocked road warning
© by FEV – all rights reserved. Confidential – no passing on to third parties | 14

Highly Accurate Range Prediction for Electric Vehicles
IN-VEHICLE DISPLAY OF REMAINING RANGE OF ELECTRIC VEHICLE
 Cloud-based range prediction

service for electric vehicles
 Based on
– recorded historical data,
– driver behavior,
– relevant vehicle and
environment states,
– traffic information and
– map attributes
a range star is calculated
 Test results showed accuracies
better than 40m
iCS = intelligent Connection Services iCU = intelligent Connection Unit
Highly integrated and connected controls and E/E architecture:
The FEV LIION Full Function EV Controller, Stage 1
COMBINATION OF FEV BMS AND FEV VCU TO JUST ONE SINGLE CONTROLLER

E/E architecture

Highly integrated
Cooling / Heating
Fast charging
Battery Housing as Part of Integrated Structure of Vehicle to Reduce
Overall Weight
PROJECT EXAMPLE: SPORTS CAR

Description
 Electric Vehicles often require

all available space for battery
package
 Battery housing can be

designed as part of the vehicle
body structure
 Crash is absorbed also by the

integrated structure battery pack inside battery pack integrated structure within the
integrated structure battery pack
Source: Lampo3b Protoscar, TKSE, Imperia
Weight Dependence on EV Driving Range: Reducing Weight is Key to
Increase Electric Driving Range
ENERGY PREDICTION
Description
24
 Despite regenerative braking:
22
 Linear relationship between
Energy consumption in NEDC
20 energy consumption and

18 vehicle weight:
(kWh/100km)
16
14
12
 Weight reduction key factor to
10
increase electric driving range
8
6
4
2
0
1000 1200 1400 1600 1800 2000 2200 2400 2600
Vehicle weight (kg)
Source: FEV database 2017
M. Jäger / Kraftwerk Batterie 29.03.2017 © by FEV – all rights reserved. Confidential – no passing on to third parties | 19
Due to continuous development of pouch and prismatic cells next
generation cell energy density will catch-up with cylindrical* performance
MARKET TRENDS CELL SELECTION
300
Applikationen
Samsung prismatic cell 63 Ah:

250
Tesla
 BMW i3
 Change from 63 Ah to 94 Ah
spez. Energie [Wh/kg]
200 Kia Soul EV cells: 22kWh  33 kWh,

94Wh/kg  140Wh/kg
150 LG Chem pouch 56 Ah:
 Renault ZOE
100 Renault ZOE
 Chevrolet Bolt
50
Chevrolet Bolt
Fiat 500e SK Innovation pouch 37,5 Ah
BMW i3
Samsung SKI LG Chem KoKam
0  Kia Soul EV
2012 2013 2014 2015 2016 2017 2018 2019
*) 18650 or 20700 used in Tesla vehicles
FEV High voltage battery development © by FEV – all rights reserved. Confidential – no passing on to third parties |
Battery Electric Vehicles need scalable, light and ultraflat Batteries at
highest specific energy densities
SPECIFIC ENERGY ON PACK LEVEL

200 Target 2022 Target Specification
180 Chevy Bolt /  Packaging factor:
160 Opel Ampera-e

Specific energy [Wh/kg]
140
FEV battery „Juliett“
120 HEV
100 PHEV
Tesla Packs
80 BEV
 Current battery packs
60 FCEV
40 FEV battery „Mila“

FEV battery „Tomalina“
20
0
 Future battery packs
0 20 40 60 80 100
Battery energy [kWh]
Source: FEV database 2017, TBC Battery Packs of Modern xEVs Report (2016)
FEV has developed a very compact low weight EV battery for an european
OEM with an outstanding pack factor of 1.5 and ultra-flat design
FEV FLAT EV BATTERY

Key Innovations
Integrated Cooling  High intrinsic strength with low

weight
 Complex and multifunctional

component structures
Sample Picture, Glued connection
not original battery pack  Integrated channels for cooling
fluid
E/E parts  Automated joining by glued or

3% Cold joint connection cold joint connections
Module Housing  Pack factor of < 1,5
12%
67% Cells
 Ultra-flat design:
hcell Total height = Cell height x 1,23

18%
Pack Housing 25mm of additional height only,
1,23 x hcell including bottom plate w/
cooling!
*) Busbars, BMS, wiring, relays

E/E architecture

Highly integrated
Cooling / Heating
Fast charging
Introduction to the FEV Electric Drive Unit
INTRODUCTION
 Today there is an increasing demand for electric drive units
 Traditionally built as „gearbox“ and „E-Motor“ and a
separate, vehicle mounted inverter
 Next Generation is a highly integrated scalable solution,
for front-, rear-, and all wheel application
 Applicable to Hybrid- and Electric-Vehicles
 FEV worked out a highly integrated concept for C/D class,
up to light Duty Vehicles
DEVELOPMENT TARGETS
 High Efficiency
 Low Noise
 High Reliability
 Compact Package
 Lightweight Design
FEV Electric Drive Unit
Key innovations to gain a highly efficient and cost effective solution
FEV SOLUTION
 Coaxial design: Low/No axial forces on housing bearings 
Low noise radiation
 First generation: Oil cooling and water cooling
 Second generation: Oil only with Si-C inverter
 Reduction gear inside E-Motor rotor as „ring gear-less“ PGS
 Park and neutral shift with one electromechanical actuator
 cost reduction
 Total ratio ~ 7.2
 2 Integrated inverters with water cooling for 6 phase EM
 Outer cooling by water jacket and inner cooling by gear set FEV EDU Design
oil and centrifugal pump
Key innovations over existing technology
 Coaxial design
 New compact reduction gear concept inside EM Rotor
 Advanced system cooling with low power consumption
 Two inverters for cost and fail safe reasons
 Overall ultra-compact design
Note: Some key features are displayed on the next pages
FEV Electric Drive Unit
Features and and key innovations for very compact overall package
FEATURES AND KEY REQUIREMENTS (EXTRACT)

 Designed for C/D class vehicle, max weight 2000 kg
 Max. wheel torque 3.500 Nm (Wheel slip limit front axle)
 Peak power 230 kW for 30 s
 Continuous power 100 kW (180 km/h @ 3% inclination)
 Max vehicle speed 200 km/h (Wheel speed max 1.500 rpm)
 System weight (dry) < 85 kg
 Compact solution with E-Motor, Inverter and
gear set in one unit
 Integrated park lock and neutral shift with one actuator
 E-Motor max Torque > 500 Nm; max Speed 10.000 rpm
 Lifetime 15 years / 350.000 km
 Efficiency < 90% in test cycle
 Ring Gear-less planetary gear set  extreme low noise radiation
FEV EDU design in package box
 Low cost architecture
 Power to weight ratio ~ 3 kW/kg (including inverter and transmission)
FEV Electric Drive Unit is scaleable to cover a wide range of applications
from B segment up to medium duty vehicles
60kW/120kW 100kW/230kW 150kW/340kW

Single Inverter / 3-Phase Double Inverter / Multiphase Double Inverter / Multiphase
Integrated ring-gear less PGS Integrated ring-gear less PGS Convential PGS
Next Generation EV Powertrain
The FEV Approach
Highly Integrated and Scaleable

Electric Drive Unit
Modular Battery Pack

with High Energy
Density and Flat Design
Highly Connected Central Control unit enabling Scalable „Skateboard“ Chassis

predictive driving strategy and cloud services
Key take-aways
Next Generation EV Powertrain
KEY TAKE-AWAYS
 Connectivity, autonomous driving, shared mobility and powertrain electrification are highly interconnected and are
expected to strongly impact the automotive industry
 A wide range of different types of electric vehicles will coexist for individual, shared and public transportation
 Modular and scalable platforms are needed to deal with diversification in electric vehicles
 The integration of connectivity and ADAS functionality will help to increase the electric range of EVs by predictive
driving strategies and clod based highly accurate range prediction
 Battery will remain the core component for E-Mobility. Modularity and scalabbilty will come together with highly
integrated cooling/heating. Battery housing will become a part of the vehicle body structure. Fast charging
capability is a key factor for long range EVs.
 Electrical drive units with integrated electric machine, transmission and power electronics will gain a higher
market share. Scalable concepts which are applicable to different kind of PHEVs and EVs in different vehicle
segments will gain price benefits.
 Skateboad chassis based platforms are likely to be extended to other vehicle segments like light duty vehicles
and people mover
BACK-UP
Micro car Public transportation
Passenger cars High Performance car People Mover Commercial Vehicles

Source: Karsan, StreetScooter, Local Motors, Imperia, FEV
Modular and scalable battery Highly integrated

Electric Drive Unit
 Complex and multifunctional
component structures  Scalable and flexible solution,
for front-, rear-, and all wheel
 Battery housing as part of the application
vehicle body structure
 Applicable for Hybrid- and
 Crash is absorbed also by the Electric-Vehicles
integrated structure within the
battery pack Scaleable “Skateboard” chassis  Compact and lightweight
design
 Highly integrated cooling /  Applicable to a wide range of
heating system optimized for vehicles from MicroCar up-to  High efficiency at low noise
fast charging and all weather Commercial Vehicles level
conditions

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Prepared for FUTURE OF E-MOBILITY

2nd International Automotive THE NEXT GENERATION EV POWERTRAIN

Istanbul, 2nd and 3rd of November 2017

© by FEV – all rights reserved. Confidential – no passing on to third parties

Connectivity, autonomous driving, shared mobility and powertrain

CASE – CONNECTED, AUTOMATED DRIVING, SHARED MOBILITY AND ELECTRIFICATION

Connected Services Shared Mobility

„Connectivity, autonomous driving, sharing and electric

Dr Dieter Zetsche, CEO of Daimler AG and

Electrification and new powertrains

Electrification, mobility and automated driving are expected to be

SALES FORECAST IN MILLION UNITS (BASED ON DMM)

Mobility  E-Hailing seen as major form of shared mobility

FUTURE POWERTRAIN SCENARIOS PASSENGER CAR – VEHICLE REGISTRATIONS

Future Mobility will be diverse!

Passenger cars Public transportation

High Performance cars Commercial vehicles

FEV PROJECT EXAMPLES

Micro cars People Mover

Passenger cars Public transportation

High Performance cars Commercial vehicles

Source: KARSAN, BMW, StreetScooter, Imperia, FEV

Powertrain Electric Motor

Battery Management Transmission

Telematics Chassis Battery Cooling / Heating Onboard charger Inverter

Highly integrated and Highly integrated

Powertrain Control Unit Electric Motor

Battery Management System Transmission

Motor Controller Modular Battery

Housing  part of chassis structure

Highly integrated and Highly integrated

Powertrain Control Unit Electric Motor

Motor Controller Modular Battery

Housing  part of chassis structure

Highly integrated and Highly integrated

Powertrain Control Unit Electric Motor

Battery Management System Transmission

Charging Control Modular Battery

Housing  part of chassis structure

Connected Fast Charging and

Assisted Map based information, ADAS sensors (camera,

Objects Data source

traffic light V2X communication, camera

70 Predicted speed trajectory of preceding traffic

Assisted Optimization of speed trajectory using eHorizon to

Usage of in-vehicle data for new cloud

© by FEV – all rights reserved. Confidential – no passing on to third parties | 14

IN-VEHICLE DISPLAY OF REMAINING RANGE OF ELECTRIC VEHICLE

 Cloud-based range prediction

iCS = intelligent Connection Services iCU = intelligent Connection Unit

Highly integrated and Highly integrated

Powertrain Control Unit Electric Motor

Battery Management System Transmission

Charging Control Modular Battery

Housing  part of chassis structure

PROJECT EXAMPLE: SPORTS CAR

 Electric Vehicles often require

 Battery housing can be

 Crash is absorbed also by the

Source: Lampo3b Protoscar, TKSE, Imperia

20 energy consumption and

Source: FEV database 2017

MARKET TRENDS CELL SELECTION

Samsung prismatic cell 63 Ah: