System Optimization and Vehicle Integration

Abstract

This chapter deals with the most important possibilities for improving the overall vehicle performance of electrified vehicles. Thus, it describes the results and the key messages of several IEA-IA-HEV-Task 17 workshops and studies, by focusing on the following topics: E-Motors: This section is focusing on the advantages and disadvantages of Permanent Magnet Motors with rare-earth permanent magnets, representing one of the most common motors being used so far (based on the reporting year 2012). Additionally it focuses on alternatives for permanent magnet motors, which are currently at a few level. Battery Management Systems (BMS): A BMS constantly controls the functionality and charge of the battery cells. Therefore, it is necessary to lengthen battery life. This chapter addresses concerns for current BMS, provides an overview about their basics and highlights the most important BMS-Tasks for High Voltage batteries as well as the demonstration of a Lithium-Ion battery performance and cost model for electrified vehicles. Thermal Management Systems: The optimization of thermal management has become an important business segment, as it is essential for effective operation of electrified vehicles in all climates. The results and outcomes of a study (Argonne National Laboratory) as well as various workshops addressed innovative methods for Thermal Management Systems. The results are described within this chapter and include specific thermal management technologies, explored innovations on components and Phase-Change-Materials. Simulation Tools: For many years now numerical simulation has become an essential tool to engineers in the product development process. Computing methods have been refined to such an extent that today simulations are more and more referred to as a basis for important product decisions. This chapter deals with a few simulation tools in the field of system optimization and vehicle integration, including “Autonomie”, “Cruise” and “Dymola/Modelica”. Functional and Innovative Lightweight Concepts and Materials: In the future, the proportion of high-tensile steels, aluminium and carbon-fibre-reinforced plastics in vehicles is set to increase from 30 % today to up to 70 % in 2030 (McKinsey & Company, Lightweight, heavy impact, 2013). High-tensile steel will remain the most important lightweight material and carbon-fiber-reinforced plastics are expected to experience annual growth of 20 %.As Lightweight construction of the vehicle body has become a very important field of R&D activities, this chapter focus on the outcomes of a study on the impacts of the vehicle’s mass efficiency and fuel consumption (Argonne National Laboratory) as well as on various methods of light weighting a vehicle, like simulation tools, advanced “smart” materials, bionic concepts and functional integration. Power Electronics and future Drive Train Technologies: Around 40 years ago, the first piece of software was used in a vehicle to control the ignition of the engine. Today, up to 90 % of all innovations in a car are realized with electronics and software, based on the customers demand for new safety and convenience functions—Advanced Driver Assistance Systems—which are the basics for autonomous driving. This chapter points out that modular drivetrain topologies are as much important as the requirement of layered, flexible and scalable architectures. The further improvement of the power control unit as well as the E/E-Architecture will play a key role in the future of electrified vehicles.