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July 2009
Case studies
Bentley Continental Supersports
Mitsubishi i MiEV | BYD e6
GM hydrogen fuel cell
tomorrow’s eco-friendly
vehicles from Mercedes
Exclusive interview with Christian Mohrdieck,
head of fuel cell and battery drive
system development, Daimler
L.H. INDUSTRIES
Cover story:
MERCEDES GOES green
Christian Mohrdieck, head of fuel cell
and battery drive system development
at Daimler, reveals what eco-friendly
engine technologies Mercedes is backing
20
technolo
gy international
Vehicle
case studies
Bentley Continental
Super
Mitsubishi MIeV sports
| BYD
INTERVIEWS:
GM hydrogen fuel e6
cell
July 2009
The inside
tomorrow’s ec track on
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INDUSTRY UPDATE
PSA steps closer to realizing
diesel-hybrid powertrain goal Motor type: Permanent magnet synchronous
Motor max power: 47kW
After unveiling its Hybrid4 diesel-electric
Max torque: 180Nm
powertrain last year, PSA Peugeot-Citroën
has launched pilot-production projects of Drive system: Rear-wheel drive
the technology at the company’s Mulhouse Battery type: Lithium-ion
and Sochaux manufacturing plants. The Total voltage: 330V
French car maker has made no secret Total engine: 16kWh
of its desire to bring to market a diesel Length: 3,395mm
hybrid passenger car by 2011 in an effort Width: 1,475mm
to rival the likes of the Toyota Prius and Height: 1,600mm
Honda Insight models. PSA chiefs hope Weight: 1,080kg
that the pilot production projects will help
the company to keep costs at an optimum
level when the technology goes into mass
production.
CLEAN AIR
Although i MiEV is still in its infancy,
there is no doubt that Mitsubishi’s
future is all about electric vehicles.
Following on from the announcement
of i MiEV, Mitsubishi has also
taken the covers off a stunning
open-top EV called the Sport Air
Concept. According to a Mitsubishi
spokesperson, in order for EVs
to play a key part in achieving
sustainable transportation it’s vital for
A high-tech quick charge system in Japan can refill the the eco-friendly cars to be fun, sporty
Mitsubishi i MiEV with 80% of power in only 30 minutes and desirable. And although there are
no firm production plans for the Sport
with i MiEV. When it finally goes on sale,
Air, the concept “signals the direction
the small eco-friendly city car will cost
in which Mitsubishi EVs may take in
up to US$33,000. With such an eye-
the future”.
watering ticket price, how many people
will be able to buy into Mitsubishi’s green
transportation solution in these tough
economic times? But despite the
unconfirmed pricing of the vehicle,
Mitsubishi is planning to push ahead with
the project and get it on sale in Japan and
the UK before the end of 2009. Rollout
will then hit 10,000 units next year and
The plan is for Mitsubishi to roll out i MiEV in the UK the opening of a new manufacturing
and Japan first, with a global market launch to follow facility in 2011 will see i MiEV production
double by 2012. E&H
INDUSTRY UPDATE
Audi gets clean
Having seen its chief German rival BMW
encounter much success with its
EfficientDynamics marketing campaign –
which includes the use of Bosch’s stop/
start system across the 1 and 3 Series
product range – Audi has announced it
plans to follow suit and introduce the same
technology in its car lineup by the third
quarter of 2009. The new system will make
its debut in the A3 1.4-liter TFSI product,
as well as in the Audi A4 and A5 2-liter
models. Audi says that early tests have
shown the stop/start system will help to Flybrid systems has finished development
reduce CO2 emissions by around 5g/km. of a 2009-spec flywheel KERS for Formula 1
FUTURE SHOCK
With the F1 season well under way, E&H asks what next for KERS?
■ The kinetic energy recovery system So far, the FIA has been careful to try to
(KERS) has not played the key role that was frame the regulations so that different KERS
expected of it during the 2009 Formula 1 systems do not prove more advantageous
Audi will debut a new stop/start system in the A3
season, and as a result doubts are being than others. The weight of a KERS system
placed over the technology. can be accommodated given the amount of
So far, KERS has been an option for F1 ballast most teams carry, but the possible
Magna on electric wave teams, and although its main proponents negative implication may be the effect on
insist that they will continue to develop it, weight distribution. Toyota’s senior general
Magna Electronics, an operating unit of
Magna International, has announced the others are planning to steer clear. Max manager for engines, Luca Marmorini,
acquisition of BluWav Systems, a developer Mosley should have realized by now that the explains, “It is expected that our car with
of electric and energy-management only way to get teams to play ball is to make KERS would still be at the minimum weight
systems for hybrid electric vehicles, plug- rules and enforce them. Not everyone can yet as defined in the rules, because at the
in hybrid vehicles, and battery electric see the value in adopting such systems in moment our car is much lighter than the
vehicles. Located in Rochester Hills, order to establish the sport’s green credentials. 605kg minimum, but we comply with the
Michigan, BluWav will enhance Magna The two concepts most likely to see the regulations by using ballast.”
Electronics’ position as a supplier of light of a racing day are the electric Along with weight, safety has also been an
components and systems to the emerging
supercapacitor system under development at issue with KERS. Toyota’s technical director,
market for electric and hybrid vehicles.
BMW, and the Magnetically Loaded Pascal Vasselon, addresses the issues of
Composite Flywheel Energy Storage System battery fires and explosions. “Going through
(MLCFESS) being tweaked by Williams the possible failure modes of the KERS
Fiat to start/stop with Bosch Hybrid Power. “For us, KERS is an extremely system is just what we have to do,” he says.
Bosch’s innovative start/stop system – exciting project and a great opportunity,” says “We will all be trying to overheat or
which is already used by BMW, Mini and BMW Motorsport director Dr Mario overcharge batteries. We will all be trying to
Kia – is next to be deployed in Fiat Theissen. “We are standing at the threshold crash flywheels for those who will use
vehicles after the Italian OEM signed a between a conventional package of engine flywheels. We just have to do that, so it will
deal with the German supplier. The first and independent transmission and an be all about making sure that we keep these
Fiat car to feature the technology will be integrated drive system. KERS will see F1 failures under control on the test bench, and
the award-winning 500, driven by a 1.2- take on a pioneering role for production later on the track. So for sure, yes, you will
liter engine. technologies going forward.” hear about battery fires and things like that,
In April last year, Williams F1 acquired a simply because we will have to gain
shareholding in Automotive Hybrid Power experience in this direction.”
Limited. Renamed Williams Hybrid Power And there is no question that KERS will
Limited (WHP), the company, led by increase costs at a time when teams are
engineer Ian Foley, is developing a hybrid looking at ways to reduce them. That’s why
system based on a composite flywheel some believe it should be mandatory, rather
rotating at up to 100,000rpm, which will than optional, because then all would be in
capture energy generated under braking. “At the same boat. “Inevitably, a new technology
AHP, we had begun to develop our own of this kind requires resources in order to
advanced flywheel system for application in develop a safe and effective solution,”
vehicles. As Williams Hybrid Power, we will confirms Marmorini. “Costs have been high
make use of the higher profile and F1 with KERS because it is a new technology
development program to bring it to market for F1 and there are a number of potential
Fiat will use Bosch’s stop/start system in the 500 more quickly,” says Foley. solutions that had to be investigated.” E&H
environment for electric drives and alternative vehicle concepts. This development
time and cost efficient development processes for the automotive industry.
12
WHAT’S NEW?
INDUSTRY UPDATE
Total ethanol efficiency
Engineers at Ricardo have developed a
new technology that optimizes ethanol-
fueled engines to a level of performance
that exceeds gasoline engine efficiency.
The new technology, called Ethanol
Boosted Direct Injection (EBDI), takes
full advantage of ethanol’s very best
properties – higher octane and higher heat
vaporization – to create a renewable
scenario that is independent of the cost
of oil. “This all means we can use a high
level of turbocharging to achieve the high
cylinder pressures that ethanol enables,”
explains Rod Beazley, director of Ricardo’s
gasoline product group. “Add in some Emitting only water vapor, GM’s HydroGen4 fuel cell
vehicle represents the future for the auto industry,
other advanced technologies such as
but the technology is at least five years away
direct injection, variable valve timing,
optimized ignition and advanced exhaust
gas recirculation, and we’re squeezing out
more power than is possible with gasoline.”
The EBDI technology is currently being
applied to a 3.2-liter V6 engine, and
Ricardo says it could ultimately serve
TOMORROW’S WORLD
as a replacement for a large gasoline or GM’s fuel-cell program is a decade old, but never before has the
turbo-diesel engines in a large SUV. Other
companies
involved in
US car maker’s emissions-free technology been so advanced
project EBDI
■ GM’s HydroGen4 is the product of 10 vehicle packaging and lower the center of
include Behr,
Bosch and years’ and US$1 billion R&D. The Chevy gravity. An electric-turbo compressor rather
Delphi. Equinox body may not look a billion dollars, than a screw type is used at the cathode to
but beneath the humdrum contours lies one provide the fuel cells with oxygen, increasing
of the most advanced powertrains in the world. efficiency and aiding the acoustics.
EBDI has been “HydroGen4 is powered by GM’s most The fuel-cell is supported by a 1.8kWh
applied to a 3.2-liter sophisticated fuel-cell system and marks NiMH buffer battery fitted under the floor in
V6 prototype engine an important milestone on the road toward the center of the vehicle, which improves
completely emissions-free, competitive driving performance by covering electrical
New Indian base for Romax fuel-cell technology in the automobile,” says peaks in the vehicle’s load demands.
Carl-Peter Forster, president of GM Europe. The buffer battery creates further efficiency
Romax Technology is scheduled to open a
Under the hood, the fuel-cell stack improvement over the vehicle’s predecessor
center of excellence for CAD and CAE
later this year, in Pune, India. With India’s (developed in-house) comprises 440 series- as it enables regenerative braking. When
automotive and transmission markets connected cells, producing up to 93kW. braking, or driving downhill, the electric
continuing to grow, Romax plans to Traction is provided by a 73kW/100bhp motor reverses to generator mode and uses
expand its existing highly skilled team to synchronous electric motor, good for the electrical energy produced to charge the
more than 50 employees within the next acceleration from zero to 100km/h in 12 battery. If the driver has to brake hard, the
few years. seconds due to 320Nm of instant torque. A ESP system will also brake-blend using
top speed of about 160km/h is achievable. conventional hydraulics.
AVL continues with innovation The hydrogen-storage system, developed Road testing revealed that the system gives
AVL has announced it plans to forge by Quantum, comprises three 700bar high- the brakes a very ‘wooden’ feel, and that they
ahead with advanced R&D work, despite pressure tanks made from carbon-fiber need a lot of foot pressure to operate. This
the global financial downturn. “Innovation composite material, holding 4.2kg of problem is presently being addressed by GM
is an essential value within AVL and we hydrogen. This capacity gives the vehicle engineers as part of its efforts to make
strongly drive this forward,” commented a range of 320km. HydroGen4 drive just like a regular car.
AVL CEO, Helmut List. The Austrian Whereas HydroGen3 featured vertically Thermal insulation, water management,
firm has revealed that it was granted 60
stacked cells, the cells of HydroGen4’s stack and a revised operating strategy were put in
invention patents in 2008, making it one of
the most innovative suppliers, and in
are now positioned horizontally to improve place to achieve start and run in subzero
recent times AVL has focused a lot of temperatures – one of the key usability
its research work on the optimization needs for the new model. A further such
of battery technology and other eco- requirement was a short start-up time, so
friendly green powertrain innovations, GM engineers strived to provide full power
such as turbo-hybrid systems and range within 6-8 seconds of turning the key.
extender units. The first of the prototypes are now on the
road in the USA as part of GM’s test program.
AVL headquarters
in Graz, Austria
In Europe, the company has 10 HydroGen4
vehicles in the Clean Energy Partnership
program. Drivers with differing profiles are
testing the HydroGen4’s everyday suitability,
Developed by Quantum, the hydrogen-storage system in and GM engineers are already using the
Equinox is made up of three 700bar high-pressure tanks feedback for the fifth generation model. E&H
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14
WHAT’S NEW?
INDUSTRY UPDATE
Full charge ahead
Valence Technology has announced it
has supplied over 200,000 Li-ion batteries
to the automotive industry in less than
four years. The news supports market
forecasts that predict that Li-ion
technology will become the main battery
type for electric vehicles in the long term,
surpassing NiMH systems that can be
found in the current Toyota Prius and
Honda Insight models. “The 200,000
battery installations is an important
e6 features a lithium-iron phosphate battery pack and two electric motors, all of which have been developed in-house
milestone that demonstrates that our
large-format batteries, incorporating our
POWER RANGER
safe chemistries, intellectual property and
customized solutions, meet the needs of
a wide range of vehicle makers,” said
Alastair Johnston, Valence Technology’s
UK-based vice president for global sales.
BYD Auto has taken the covers off an all-electric crossover vehicle
that the Chinese car maker claims has a range of 250 miles
■ There’s no doubt that electric vehicles further develop so the cars will be sold to
were a hot topic at January’s NAIAS in government offices and big corporations for
Detroit, and the Geneva Motor Show in fleet trials in big cities. It’s hard to say exactly
Valence Technology helped to power a bike March. But while the Congress-friendly EV what the production numbers will be; a few
in the world’s first zero carbon Grand Prix
concepts from the likes of Chrysler and GM hundreds perhaps.”
were to be expected, a battery-electric vehicle The e6 features regenerative braking and
Longer battery life from China’s BYD Auto was not. the claimed range is an astonishing 250
A new high-energy cathode material that BYD hit the headlines in 2008 with its miles. Instrumental to that is the enormous
is capable of greatly increasing the life of F3DM plug-in hybrid sedan. Now the e6 LFP battery pack slung under the central
Li-ion batteries has been developed. represents the company’s vision of an all- tunnel of the crossover, from front to back.
The breakthrough was a result of an electric future. BYD sales executive King Kaid LFP batteries are said to provide higher
international collaboration of researchers Hu told E&H that the e6 features a lithium- resistance to thermal runaway compared to
led by the US Department of Energy’s iron phosphate (LFP) battery pack and two lithium cobalt oxide batteries and longer
Argonne National Laboratory and South electric motors (one front, one rear for cycle and calendar lives, but the penalty for a
Korea’s Hanyang University. “The basic
AWD). These and up to 90% of the car’s new battery is lower specific energy, resulting
idea behind our novel approach is to
design a particle that has a very high-
other components and subsystems are made in a bigger battery for the same capacity. “The
energy composition at the bulk and an in-house by BYD, which began making battery is relatively big,” Hu concedes. “But
outer layer composition that is very stable batteries in 1995 and claims to be the world the important thing is that the capacity is still
against any reactivity with electrolyte,” number one in rechargeable batteries, with huge for a similar size and weight to other
explained Khalil Amine, manager of the 30% of the cell phone Li-ion battery market. technologies. The technology also provides
advanced battery technology group at Under development for more than three good safety – we’ve done testing under all
Argonne. “These two design features will years, the e6 shown at Cobo Hall was a kinds of conditions – and the cost is lower
be able to greatly improve the life and pre-production car, according to Hu. “We than other Li-ion technologies, so it’s the
safety of lithium battery materials, and envisage a Chinese market launch in the perfect battery for an EV.” The automotive
offer very high-energy characteristics for
second half of 2009,” he said. “The market world now waits with baited breath for the
possible use on PHEVs.” The innovative
cathode development could help the US in China is small because of the high price official launch of the e6 later this year, which
government to realize its goal of one of the car compared to a gasoline vehicle, will be covered in the January 2010
million PHEVs by 2015. and the limited infrastructure for electric issue of Electric & Hybrid. E&H
vehicles. It’ll take time for the EV market to
Battery deal sealed
Johnson Controls-Saft and Azure
Dynamics have announced a new, five- JUDGE AND JURY
year supply agreement that will see both
partners provide advanced lithium-ion We weren’t able to drive the e6 but did take a good look over the Detroit
hybrid battery technology to power showcar. It’s far from finished, but BYD is to be admired for pushing ahead with the
commercial vehicles in North America. development of such an advanced vehicle. We have some reservations however, chiefly
the vehicle’s packaging. The battery pack is slung very low; the e6 needs to be a high-
riding crossover just to get sufficient ground clearance. BYD says the car is designed
for urban use, but we’re not convinced the cells would survive too many speed bumps
in Europe. Inside, the e6’s has a reassuringly conventional cabin and while headroom is
good, the rear floor feels much too high for comfort, and trunk space isn’t vast.
INDUSTRY UPDATE
Tata invests in EV supplier
The UK subsidiary of Tata Motors has
bought a 50.3% holding in Miljø Grenland/
Innovasjon, a Norwegian-based high-tech
company that specializes in developing
solutions and components for electric
SCORPION KING
Can India’s second-largest car manufacturer build a high-
vehicles. It’s thought that the investment
will cost the Indian OEM more than quality and environmentally friendly SUV for the US market?
US$1 million. Miljø will help Tata to bring to
market the company’s first electric vehicle, Scorpio during a recent trip to Mumbai. The
the Indica EV (scheduled for launch in bluff-faced and slab-sided Scorpio isn’t as
Europe in 2009), which Tata Motors huge as it appears in photos. At 4,495mm
claims offers improved practicality and long, it is roughly the same size as a Land
acceleration on existing EVs.
Rover LR-2 or Honda CR-V. However, the
Scorpio’s 1,975mm height makes it more
than 250mm taller than either.
A key part of Mahindra’s sales strategy rests
upon its new 120bhp 2.2-liter turbocharged
and intercooled ‘mHawk’ diesel engine. In
Above and below: Mahindra’s all-new Scorpio SUV is the USA, this motor will be fitted to a six-
likely to benefit from Bosch’s stop/start technology
speed automatic transmission. Fuel economy
An electric-powered Indica will soon be launched ■ Mahindra & Mahindra is betting that US should average 30mpg. Mahindra has also
car buyers aren’t quite ready to abandon the introduced a diesel-powered micro-hybrid.
Reva expansion once-loved SUV market. The Mumbai-based Developed in cooperation with Bosch,
auto company arrives in the USA later this Mahindra’s Stop/Start hybrid turns the engine
In an effort to meet increasing global
year, with two- and four-door versions of its off when the vehicle is idling or in neutral,
demand for its electric vehicles, Reva
has announced that it is building a new rugged-looking pickup model. An as-yet- and the engine restarts once the clutch is
assembly plant in Bangalore, India. The unnamed version of Mahindra’s Scorpio SUV pressed. For now, the micro-hybrid is offered
new facility, which will start rolling out is scheduled to arrive stateside in 2010. only on selected models of the company’s
models later this year, will have an annual As chief executive of Global Vehicles USA Bolero. Mahindra claims the system provides
production capacity of 30,000 units. (the Atlanta-based import company tasked a 5-10% fuel economy improvement.
with bringing Mahindra to the US market), Dr Arun Jaura, Mahindra’s outgoing CTO,
John Perez believes Mahindra has done its confirmed that the micro-hybrid will soon
homework in terms of tailoring the vehicles appear in Indian-market versions of the
INDIA to US tastes. A fleet of US-spec vehicles are Scorpio and new Xylo crossover. “As a diesel-
being put through up to 3.2 million miles of centric company, it was natural for us to get
road tests before the US launch, says Perez, into diesel hybrids,” he explains. “But
who adds that it is Mahindra’s attention to ultimately, technology itself will not have a
detail – and willingness to listen – that made lot of traction. Technology that is affordable
Bangalore
him a believer in the brand. and seamless is what is needed.”
In February 2006, soon after US sales Jaura believes that developing a hybrid
plans had been given the green light by Dr culture in India remains top priority. “Our
Pawan Goenka, president of the automotive primary goal is to get hybrids into the Indian
Lithium investment sector at Mahindra & Mahindra, Perez says marketplace [so that we can] educate and
Despite having to make cutbacks in he and 14 dealers paid a visit to the build hybrid awareness with the public.”
other business areas, Conti chiefs have company’s factory in Nasik, India. Located After proving the technology at home,
given the green light for the company’s 120 miles northeast of Mumbai, the plant Mahindra will then consider marketing it
powertrain division to spend almost US$4 has an annual capacity of 200,000 units. The outside of India. E&H
million on upgrading its Nuremberg state-of-the-art factory provides employment
production facility, which started series
to more than 3,700 workers and 1,300
production of lithium-ion batteries late last
year. Discussing the outlay, Dr Karl- engineers within its 0.5km2 plant site.
Thomas Neumann, Conti CEO, said, “This “Mahindra gave [the dealers] the opportunity
underlines our claim that by developing to critique what they saw,” says Perez, who
and manufacturing state-of-the-art drive admits dealers were stunned at Mahindra’s
systems, we can contribute to a great openness to criticism. Comments were made
reduction in fuel consumption.” about the cup holders (they were too small
for US super-sized drinks), the seats,
dashboard materials (a higher quality was
requested), and the cargo hooks in the
pickup bed (a change of location was
suggested). Safety features such as
multiple airbags, ABS, and electronic
stability control will also be added
to US-spec models.
Not ones to wait, the Electric &
Hybrid Vehicle Technology team
Continental has upgraded its Nuremberg facility
climbed aboard an Indian-spec
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20
WHAT’S NEW?
Length: 4,987mm
Width: 1,984mm
Height: 1,330mm
Wheelbase: 3,160mm 6
Go to page 56 to find out more about the future plans of Fisker Automotive
DAVIS
MATTDAVIS
MATT
It is slowly dawning, even on the US
customer, that the old swaggering
belief of ‘there’s no substitute for
more large-capacity horsepower’ is
losing its good-ol’-boy glow
■ ‘Downsize’ remains a leading battle cry, but it’s a It is slowly dawning, even on the US customer, that
reflection of the times that the number one recurring the old swaggering belief of ‘there’s no substitute for
word in corporate speak today is ‘cut’. Once the more large-capacity horsepower’ is losing its good-ol’-
product plans (not to mention entire divisions) have boy glow. The pockets of cultural resistance to this
been axed, lift up that surface layer, and you see that unstoppable trend are massive, but there’s no turning
the real cuts are being made to engine programs and back to the V8 as ‘the heartbeat of America’.
R&D budgets. Although I stand by my thinking that Why US auto makers can basically only cut, cut, and
out of such difficulties come the real genius cut again is that they haven’t had a homegrown small-
innovations, things are not pretty out there right now. engine strategy or small-car strategy since the early
One could easily say that forced downsizing (not the 1970s oil crisis. All the rest of the world – and even
voluntary move, as it was until about 12 months ago) Holden-loving Australia – has long ago embraced small
is a brilliant consequence of the recession. I love this, motors as an outstanding solution to minimizing the
too, and the VW 1.4-liter Twincharger may just be my sense of feeling beholden to oil imports.
personal Jesus. I haven’t met a single engine expert This is the current chief frustration about the USA:
who can wholeheartedly deny that he or she will miss the market, mind-set, and corporate thinking are
big motors once there isn’t a vehicle left in any arcane by any standard whatsoever. All new ideas in
driveway carrying anything larger than a 3.5-liter V6. the region are actually reactionary copycat thoughts.
This sapping of old-school testosterone leads me to No longer can the continent lead by any example in
predict brisk business in the future for performance automotive circles. And now they’re cutting so much
exhaust systems and fiber-optic acoustic enhancers. that soon I won’t refrain from overuse of the nose-to-
Tied in with recent cuts, not only is Chrysler forced spite-the-face metaphor.
to accelerate its exit from the Hemi strategy, but GM Something problematic is happening, too, with
has put a lid on the inspiring 4.5-liter V8 diesel sans long-approved product and engineering that has the
traditional intake and exhaust manifolds. This latter misfortune of launching today. I refer particularly to
tough call hurts the most, if I have to choose, because the 6.2-liter LS3 V8 in the new Chevy Camaro SS. A
it’s based purely on a desperate need to cut anything year ago we were all falling over ourselves at this
that isn’t turning a profit right at this instant. perceived savior of the brand – come to think of it,
The fact that, in GM’s case, it’s all being done with much in the vein of the Pontiac Solstice that went
a government gun to the head makes me fret all the flaccid, too – but now the whole Camaro franchise is
more about long-term consequences. In the meantime, probably destined to be snuffed out really soon in its
GM’s rival Ford is coming off as the smart guy for second life.
committing early and often to the EcoBoost strategy These old-tech engines (don’t argue with me over
(which, for the USA, is rebranding of long-existing this – they are old tech) will be gone for good by
European small-displacement turbocharged direct- 2013, if not sooner. I love them dearly, but they must
injection technology). go away forever and as quickly as possible. It’s not my
preference but a necessity, and the USA needs to get
Matt Davis is one of the world’s leading motoring journalists. Davis 100% more serious about it. Cut away, gentle folk,
not only writes for several automotive titles, but he also sits on but invest big in perfecting anything with up to six
the judging panel of the International Engine of the Year Awards
cylinders. E&H
+1.877.435.6477
TAWA S I N C – PA R T N E R I N G F O R Y O U R S U C C E S S !
24
OPINION
OFFER
GREGOFFER
GREG
The biggest feather in the EV cap
versus other alternative engine
technologies is that the refueling
infrastructure already exists,
with power sockets everywhere
■ Electric vehicles will save the world – or at least number of different sizes for small, medium and large
that is the message many are keen to convey. But is it vehicles so that an OEM can play with energy sources
true? And why do so many well-informed engineers and design, thus allowing for flexibility in vehicle types
seem to think that EVs are the savior? with complete interchangeability. For city cars, I would
Perhaps it is because electricity can be generated boost the batteries to give a reasonable range of up to
from numerous sources and therefore breaks the 60 miles. For those who might be put off because of
stranglehold that the oil industry has on the transport battery range limitations, I’d develop a range-extender
world – a future that can’t come soon enough for me. system that’s similar to GM’s E-Rev technology.
Electricity is also cheap, and EVs are very efficient. A great example of this is the PML Mini QED, which
Even when electricity is produced from fossil fuels, the has batteries and supercapacitors giving it a range of
energy cost per kilometer is at least half that when up to 250 miles and four 120kW electric motors, and
compared to a combustion engine. But the biggest then a small petrol generator giving a range of 932
feather in the EV cap versus other alternative engine miles with fuel economy of 80mpg.
technologies is that the refueling infrastructure already Once the costs of range extender technologies, such
exists, with power sockets in every building. So it as fuel cells, have decreased to a profitable level, these
would seem EVs are a win-win solution for all can be easily inserted into existing vehicle platforms
concerned – except, of course, the oil companies. with minimal integration problems. Mercedes seems to
But there has to be a but, and there is a major ‘but’ have realized the benefits of such an approach, and is
to discuss: battery technology. The biggest challenge is producing an electric version of A- and B-Class models.
low energy density, which means that for a reasonable The MB BlueZero has a 120-mile range (a two-hour
range, batteries are large, heavy and expensive. This is charge gives 60 miles) with a 100kW electric motor
a fundamental problem because energy conversion and giving 320Nm of torque. MB says it will launch this
energy storage are coupled in a single device, which model within 18 months with a three-cylinder petrol
means if you want to double the range, you also end engine to give a range of 370 miles. Very impressive.
up doubling the power, weight and cost – a ‘no-no’ in My personal favorite is the Ford Edge, which uses a
today’s economic climate. HySeries Drive powertrain with a fuel cell generator
So, what would be my ultimate vehicle to achieve and Li-ion batteries. The only downside is it is
sustainable transportation? I’d build an electric modeled on a gas guzzler, so is heavy and delivers
powertrain with modest batteries, and perhaps throw 41mpg, but with zero emissions and 80mpg in electric
in a few supercapacitors to handle high-powered mode that can last up to 50 miles a day, the technology
acceleration and braking. It’s key to keep it all simple is more than impressive.
and make no more than four common platforms in a For those that are still keeping their electric and fuel
cell programs separate, my advice is to combine the
Gregory Offer is a fuel cell scientist and engineer at Imperial College two. I would regard as foolish any attempt to deliver a
London. With a PhD in electrochemistry, Offer was a parliamentary zero emissions vehicle that is capable of delivering all
advisor before joining Imperial College. our capricious consumers’ demands with a single
technology. You have all been warned. E&H
Register at www.drivenet.org.uk
26
DIESEL HYBRIDS: BEGINNING OF THE END?
Last chance
saloon?
Most agree that diesel hybrid powertrains are the optimum solution
for car makers obsessed with fuel economy and emissions.
But will the technology ever become production-ready?
Words: Dean Slavnich
Late last year, the Citroën Hypnos was unveiled. The concept
features a diesel hybrid engine, called HYmotion4, which
the French car maker will be using in 2011 production cars
a diesel engine are much diesel engine is far more Killman’s four-point attack developed a diesel-hybrid
stronger during starting and expensive than a petrol engine. makes for a compelling case system powering a Citroën
stopping of the engine than for A simple hybrid system is a against diesel hybrids. But four Berlingo that achieved 76mpg
a petrol engine. This would more expensive transmission years ago, PSA Peugeot Citroën on combined mode and a tank-
make the change from electric than a normal automatic boldly announced that it to-wheel CO2 emissions rating
vehicle drive to engine drive transmission or manual planned to launch such a of 99g/km. The car featured a
less comfortable, and therefore transmission, so adding two passenger car by 2010, and that 1.6-liter HDi diesel engine, a
we see stronger diesel hybrid expensive units – diesel and it would cost just US$2,500 permanent magnet synchronous
application potential for hybrid – would make it difficult more than a standard diesel motor, a Li-ion electric motor
commercial vehicles.” for the customer to recoup the Peugeot/Citroën model. with inverter, and a 228V DC/
The second factor for Toyota higher cost of the car in overall “Diesel hybridization is the DC converter. The results of
is based on the environment, fuel savings.” only short-term available project Efficient-C were
as Killman explains: “Diesel And the final hurdle for solution capable of bringing a impressive, and in a parting shot
engines still cannot achieve the Toyota is simply based on considerable breakthrough in to those that are pushing
same emissions levels as petrol markets: “At the moment, only terms of consumption and CO2 forward with gasoline hybrid
engines, and even with our Europe is strongly focused on emissions in the European technology, Peugeot adds, “It
D-Cat system, where NOx diesel technology for passenger market,” believes Robert must be said clearly that the
emissions are drastically cars,” says Killman. “Other big Peugeot, PSA vice president. petrol hybrids available today
reduced, NOx is still higher markets, like the USA and Peugeot completely disagrees reach homologated consumption
than with petrol engines.” Japan, are almost completely with statements from Honda fairly close to that of an
Killman says another reason petrol orientated, and this limits and Toyota. In a recent research equivalent vehicle fitted with a
for Toyota not offering a diesel the potential number of sales of project, Peugeot, along with modern diesel common-rail
hybrid car is to do with cost: “A a diesel hybrid.” partners Ricardo and QinetiQ, engine, which actually leads to
a very narrow advantage in CO2 the rear electric motor, front- 2012 or 2015, there will be a
emissions at a significant cost.” mounted high-voltage alternator price to pay for overall CO2
But therein lies the problem. and power electronics. reduction,” he says. “Clearly, as
Bringing down cost is a hurdle But it’s not just PSA and commercial organizations,
that PSA is finding very difficult Bosch that are championing the automotive manufacturers will
to overcome. The car maker has diesel hybrid cause. UK-based want the most cost-effective
pushed back its goal to launch a consultancy, Ricardo, has routes to making that CO2
diesel hybrid car by at least one experience in this area dating reduction, and the quickest
year on the original 2010 back to 1999, when it undertook “I don’t think the ways of them achieving this is
timeframe, despite unveiling the a project with Valeo to develop a actually around less headline-
Peugeot Prologue and Citroën mild-diesel hybrid. Following need for diesel grabbing processes, thus doing
Hypnos concept cars at last his involvement in project small things that added together
year’s Paris Motor Show. Efficient-C with PSA, David hybrid powertrains make a real difference.
At the turn of this year, PSA Greenwood, chief engineer for “I don’t think the need for
joined forces with Bosch in an technology at Ricardo, is well has gone away” diesel hybrids has gone away,
effort to push forward the diesel qualified to comment on diesel but, because of the cost
hybrid project. The German hybrids: “If you look at the DAVID GREENWOOD, RICARDO involved in securing the benefits
supplier will provide PSA with proposed CO2 legislation for CHIEF TECHNOLOGY ENGINEER of diesel hybrids, it’s not one of
the first things an OEM will today are powered by nickel- will give better power and a crossover point between 2010
introduce.” metal hydride (Ni-MH) overall energy levels.” and 2011 where the cost of the
So regardless of which side of batteries, and that’s really But the real problem is that battery pack is about the same
the diesel hybrid fence one sits, because of their power density, lithium-ion is far more whether you go for Li-ion or
the underlying issue is always energy density cost and expensive than the Ni-MH Ni-MH, and that could be
the same: cost. Up to 66% of durability. Essentially, Ni-MH is technology: “If you wanted to the trigger for diesel hybrids.”
the total outlay in hybridizing a well understood, is relatively put a production hybrid on the Yet despite the financial
powertrain is spent on the mature as a technology, and road in niche volumes, you’ll downturn in the global
battery, with the remaining although it is not cheap – typically be paying US$2,000/ automotive industry, and having
expense going on components typically you’ll pay around kWh of Li-ion battery capacity,” been developed over a decade
such as the motor and power US$800/kWh of battery energy Greenwood continues. ago, Greenwood does not think
electronics, says Greenwood. – it is reliable and also robust. “Now, the advantage of the that diesel hybrids are a
“If we’re looking to see diesel “The successor to Ni-MH is Li-ion battery is that it has the technology that history will
hybrids achieve penetration in lithium-ion, and we’re tracking opportunity to see costs reduced show as an almost-ran: “I really
Europe, the real key will be something like 43 different as production volumes increase. do feel that diesel hybrid
getting acceptable battery costs,” Li-ion chemistries at the So, we do see the potential technology has not missed the
emphasizes the Ricardo moment. It is this family of for that to come down to boat. I’d just say that the boat
engineer. “Most of the hybrid chemistries that will drive the US$1,000/kWh for mass- has left a little later than people
vehicles you see in production next-generation of batteries that production vehicles. We expect expected.” E&H
The Efficient-C project highlighted the benefits of a diesel hybrid engine: the Berlingo VW engineers placed the NiMH battery in the trunk of a diesel hybrid concept Golf.
demonstrator vehicle emits 99g/km of CO2 and is good for 76mpg on combined mode Weighing 45kg, the battery pack supplies the E-machine with 202V of energy
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Words: Keith Read
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t: + 44 1273 668897
e: info@parkandpower.co.uk
General Motor’s high-tech Fuel Cell Development Center in Honeoye Fall, New York State A gasoline processor is being prepared for rapid testing at GM’s Rochester facility
cell technology in a
standards, including drop, how they’re driven,” states up from bench testing. Some
fire-resistance, leak potential, Maini. “A lot of effort goes into simulation and modeling at cell
Dream TT
The world’s first zero-carbon grand prix took place during the Isle
of Man TT in June 2009, and there was much technology to see.
E&H hitched a ride on the UK’s Kingston University entry
FUTURE RACE
It is one of the oldest race festivals, undoubtedly
the most challenging and demanding circuit, but
the Isle of Man TT is also the world’s most innovative
bike race. The fact that it hosted the world’s first
zero-carbon grand prix is a case in point.
The race is the brainchild of Azhar Hussain, a
British entrepreneur and co-founder of Mavizen.
Hussain’s electronics firm is most famous for producing MP3
players, but it has recently started to design and manufacture
electric bikes, one of which was entered into the 2009 TTXGP.
Hussain says he came up with the idea in 2008, and after
presenting a business case to the Isle of Man government and the
race organizers in June of that year, he was given permission to
organize two 37.7-mile races.
The top riders compete in a professional class race, but Hussain
also laid on an open class event for innovative teams who are
experimenting with alternative energy sources for the first time.
The 2009 event was a great success, but will it prove to be a
one-off? “We are already in talks with the organizers about staging
an event next year,” reveals Hussain. “The challenge now is to grow
the TTXGP. We have had a lot of interest from teams as far afield as
China and Malaysia, and in 2010 the race will be extended to two
laps. There are plans to introduce a five-minute pit-stop facility, so
teams can change battery packs.
“But we can’t forget that the race is in its infancy,” he continues.
“I think this year the challenge for most teams was simply to finish
the race. However, I believe that in five years’ time, the technology
will become so advanced that we will have caught up with the
petrol-powered bikes.”
Emissions
are important.
Even to us
here at
Bentley
Words: Dean Slavnich
EVO Electric Ltd, Unit 14 Woking Business Park, Woking, Surrey GU21 5JY
Phone: +44 (0) 1483 745 010 General enquiries: info@evo-electric.com
47
OEM INTERVIEW: BENTLEY
automotive emissions output,”
he states.
“There are 70 million cars
sold every year – perhaps that
number will be a few million
down this year – and we only
build 7,000 Bentleys. That
makes a very, very small
contribution to emissions, and
typically our vehicles are not
driven a lot.”
Eichhorn’s engine team has
calculated that the emissions
contribution from all Bentleys
ever built is so miniscule that it
cannot be measured. “I think
the best analogy is of a few
droplets of water in an Olympic-
sized swimming pool,” says
Eichhorn. “Bentley does not
have any influence on total
CO2 emissions output on a
worldwide scale.”
With his sharp designer
Italian suit, exclusive Breitling
watch, a preference for a
Lamborghini Miura, and an Above and below: In addition to the Nobody can even measure this system harnessed from within
almost politician-style polished new flexfuel engine in the Supersports, amount of emissions.” the VW Group? The man
argument, Eichhorn presents a Bentley is said to be also working on a Over the last six years Bentley shaping Bentley’s engineering
hybrid powertrain for future products
compelling case that the onus is has reduced CO2 output by future is tight-lipped: “I can give
not on the exclusive automotive 15%. The aim for the next you full details of it in 2011,” he
top tier to make a difference: three years is to further reduce laughs. Rumor has it, though,
“I’m not looking for a cop-out; emissions across the Bentley that Bentley is going down the
my analogy merely puts things range by another 15%. This will hybrid route.
“A flexfuel vehicle
CO2 from crops, and then the the notion that cars are run on reiterates. “In the USA, where
car burns it back out into the crops that could feed starving they grow corn for biofuels, you
problem because
enough biofuel is produced so Biofuel is typically grown on price of oil drives the price of
that it can be used in plowing wasteland, where nothing was food. We are advocating second-
ethanol or petrol”
column on page 24) that first- food for humans was grown was the logical choice. “It is
generation biofuels got (from there, only food for cows,” he capable of running in a
modified petrol engine,” says
Eichhorn. “There is also an
industrial-scale production and
distribution system behind
ethanol, whereas for most
other biofuels the support
infrastructure is lacking.
“A flexfuel vehicle does away
with the chicken and egg
problem because essentially the
car can run on ethanol, petrol or
any mix of the two. This means
you’re not relying on petrol
stations that might, or might
not, sell ethanol, as there’s
always a petrol backup.”
Eichhorn says around 70
billion liters of bioethanol has
been produced to date. It’s this
staggering statistic, combined
with the fact that a large number
of vehicles can run on E85, that
has led to Eichhorn’s underlying
confidence in flexfuel engines
Despite building only 7,000 cars a year, Bentley is having to adapt to market needs and develop eco-friendly powertrain solutions for Bentley. E&H
Electric avenues
The S400 BlueHybrid sedan is just the start of Daimler’s assault on the emerging
electric- and fuel-cell vehicle market, says research chief Christian Mohrdieck
Words: Graham Heeps
■ Mercedes-Benz’s satisfaction much earlier point in time and you always have to go through
at getting the S400 BlueHybrid have to redo many of the the same processes in order to
to market later this year might development cycles.” have a reliable product. Once
be tempered by the knowledge Up to the C-samples – the you have solved the functional
that the car’s battery technology final development units before issues with the technology, such
is already some months behind production – all the prototype as cold-start and total lifetime,
the cutting edge, because of production was done by then you have to go through the
the lengthy testing and quality Daimler engineers in house, Mercedes-Benz presented Concept systematic process of making a
engineering processes of the following a development BlueZero earlier this year: three tech system suitable for automotive.
automotive sector. program with cell-supplier Saft. demonstrator vehicles that prove “Our industry is very different
“Being an engineering guy at The technology was then Daimler is exploring three different to aerospace, for example – we
routes to sustainable transportation.
heart I always want to do better handed over to Continental for Pictured above is the electric vehicle
require very high numbers with
than I can do today,” admits manufacturing and production. the same high quality. In an
Christian Mohrdieck, head of Daimler began lithium-ion aircraft you can afford to have
fuel cell and battery drive research projects as early as redundancy, but the cost rules
system development at Daimler 1994. Mohrdieck still sees the that out in cars.”
Corporate Research and technology as immature in The S-Class hybrid sedan is a
Advanced Engineering. “At automotive terms, but he milestone for Mercedes-Benz,
some point in time you have thinks it’s the best bet for the but Mohrdieck considers that it
to fix the technology and then near future. is just the beginning for Daimler’s
work exclusively on quality and “At this time I don’t see any electric- and fuel-cell vehicle
maturity. Otherwise you can other technology giving the future. The Concept BlueZero
never guarantee an automotive- same performance in terms of trio of battery-electric vehicle,
type of maturity in a vehicle. power, energy density, and range-extended battery-electric
“The lithium-ion technology cold-start capability, which is vehicle, and fuel-cell vehicle, is
in the S-Class project was fixed a clear advantage of Li-ion indicative of the company’s
some months ago and we are versus NiMH batteries,” he three-pronged future strategy.
now in the very final phase of says. “However, for high-power “No single one can address all
development – so we’re doing hybrid batteries, we need a few the customers’ requirements,”
things like reliability testing more years of development to The hybrid powertrain in the upcoming argues Mohrdieck. “The battery-
S400 BlueHybrid features a disc-shaped
and quality engineering,” he reach the same level as NiMH electric motor that serves as starter
electric vehicle is excellent
continues. “The Continental/ batteries, especially because and alternator. During acceleration, the for urban
Johnson Controls-staffed high-energy batteries require a motor provides a torque boost of 160Nm
production line for this lithium- specific safety concept.
ion cell was implemented some “Maturity takes time,” he
two years ago; but we’re not in a continues, “and
position to change that because
then we’d start at a
driving with short ranges. If you battery technology, which batteries and battery systems for test rigs but there are now
want to go longer distances and means range-extended vehicles automotive applications, the standards for doing certain
have to refuel during the day and fuel-cell vehicles.” staff levels at Nabern are likely testing, such as accelerated
then you need longer range and Advanced work continues to increase slightly. Daimler lifetime testing using increased
shorter refueling time, which apace on all three options at already has a joint-venture temperature. The key is
essentially means fuel-cell Mohrdieck’s base in Nabern in with Ford following the two calibration because you have to
vehicles. Then there’s the fact suburban Stuttgart, where more companies’ acquisition of extrapolate; you need to know
that batteries are likely to than 400 people are at work on Ballard’s acclaimed automotive what final conclusion you can
remain restricted to A- and B- fuel-cell and battery-electric fuel cell business in 2007. draw from certain test results.
Class-sized vehicles because of drivetrains that will one day be Mohrdieck’s powertrain “After a lot of investigation
the batteries’ weight and size. So driving Mercedes-Benz vehicles. engineers have already we believe we’re in a position
if we want to continue making He says that following Daimler’s achieved much on the process to say that, for example, the S-
vehicles the size of the C-Class acquisition of a stake in Evonik development side to get robust Class hybrid battery will meet
and bigger – and those are our subsidiary Li-Tec in late 2008, batteries into automotive its specification by lasting 10
core vehicles at Mercedes – then and the formation of a joint- production, but he’s keen to years. That’s good for a start but
we need to look at other venture company with Evonik see further advances. “We’ve not long enough; I’d rather see
technical solutions besides to further develop and produce had to build a lot of our own 15 years.” E&H
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59
OEM INTERVIEW: FISKER AUTOMOTIVE
Although headquartered in
Irvine, California, Fisker has
established its engineering and
development center in Pontiac,
Michigan, to be the focus of test
and development activity. “In
California we do a lot of the
design and powertrain work,
but Detroit has everything
for car development and
production, which is why we
have our engineering center
here,” Fritz explains. “Michigan
is also a more central working
location for us: it’s three hours
to California, and seven to our
production facility in Finland,
with a good time overlap.” Q DRIVE technology will provide a base for all
The 3,200m2 facility brings future derivatives from Fisker Automotive
together up to 200 engineers
and designers from Fisker and
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Extreme environments
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Bus breakthrough
Buses that consistently run on time? Such a radical concept might soon become a reality
due to new and advanced battery technology being pioneered by a German company
■ One of the greatest journalists volumes. It is the body language Words: James Gordon bus manufacturer EPT. The
of the 21st century, Ryszard of passengers unaccustomed to technology enables 25 buses in
Kapuscinski, once remarked delay. And it’s all due to the Turin and eight in Genoa – each
that people standing at bus Inductive Power Transfer with a state-of-the-art onboard
stops look the same the world Charge system (IPT) pioneered battery management system –
over. Kapuscinski observed by Conductix-Wampfler, a to run for long periods without
that those waiting for buses leading supplier of energy a break. The system is a
everywhere from Vienna to supply and data transmission contactless power transfer unit
Vanuatu carry the same tired systems, which helps to ensure that enables the battery to be
and defeated expressions on passengers are not kept waiting. Mathias Wechlin, senior product charged without any mechanical
their faces. The German company, part of manager at Conductix-Wampfler, is contact or intervention.
But the Pole, who died in the Conductix-Wampfler group now working hard to install contactless The IPT charge system
power transfer units in vehicles
January 2007, probably never with over 1000 staff members, reduces the need for overnight
had time to visit Genoa or is headquartered on the banks or daily charging due to an
Turin. If he had done so he of the Rhine. However, it chose underground IPT charge system
might have noticed the five Italy as the testing ground to that transmits electricity to the
passengers waiting to board the launch the technology that bus every time it stops at a bus
number 23 bus on Via Colombo could revolutionize bus travel, stop.
Cristoforo in downtown Turin. not to mention boost sales, One man with an in-depth
Somewhat curiously, their faces which last year exceeded understanding of the IPT
display none of the negative US$309 million in the group. technology is Mathias Wechlin,
characteristics that Kapuscinski The IPT system, which has a senior IPT product manager
describes. An elderly woman now been functioning in the who has worked for Conductix-
smiles at her friend across a northern Italian cities of Turin Wampfler for 18 years. Speaking
street, and a teenager sits and Genoa since 2002, is the by phone from the USA,
serenely on the bench beside result of a partnership between Wechlin, who was educated
her. Their body language speaks Conductix-Wampfler and Italian in Germany and Switzerland,
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United Kingdom
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CLEAN STREETS
It’s the ‘city that never sleeps’, and certainly the garbage
produced every day by New York’s eight million residents
gives the city’s refuse collectors ample opportunity to work
late into the night.
Every day more than 2,230 garbage trucks patrol New
York’s five boroughs, collecting over 12,000 tons of
residential and institutional refuse and recyclables a day
– and that’s just the bags the collectors pick up at the side
of the road.
“It’s a real challenge to keep the garbage at bay,” says
Rocco DiRico, the DSNY’s deputy commissioner, “so
when Bosch Rexroth came to us and suggested we field
test its HRB system, we were delighted. We hope that the
technology can improve efficiency, and it represents an
important step toward achieving the commercialization
As well as targeting sanitation vehicles, Bosch Rexroth engineers are also working of heavy-duty hybrid hydraulic vehicles. That has to be a
hard to adapt HRS for bus applications and other commercial truck applications
good thing.”
advertising agency before But DuHadway is confident Although nobody is sure exactly how cost-efficient the
joining Bosch in 2006, says that that the HRB team can succeed technology will prove to be, Michelle DuHadway thinks
making the transition from the with the support it receives from that the HRB system could help DSNY to reduce brake
off-road to the on-road market Bosch Rexroth. “We are very maintenance costs on its large fleet of vehicles. “On
presented the company with its excited about the future,” says average DSNY replaces brakes approximately once a
greatest challenge. “Taking DuHadway. year,” she says, “which takes the truck out of service for
proven parts and hydraulics “When the testing is at least two days. We hope to improve that figure by at
knowledge and applying it to successful we would like the least 50%.”
the on-road market has been a technology to be rolled out in She concludes, “We should have a clearer idea how the
rewarding challenge. states across the USA. And I can trial is progressing by the end of this year.”
“Additionally, having the confirm that we are involved in
support of our parent company, advanced talks with a private
we are involved in
has been a great asset. But if the system universal.” says. “This is an infinitely
the technology is to be globally And so while Bosch Rexroth’s variable transmission (IVT) that
a private sanitation
must ensure that older vehicles, applications, the system is also a propietary high effciency
which have been equipped with available for bus applications pump and motor technology.”
fleet in California”
standard braking equipment, and it is being further developed By then it is likely that the
have the opportunity to upgrade for other commercial markets crippling global recession that
to the HRB system. Therefore, around the world. has altered the USA’s automotive
we’re currently investigating a “In the next few years, we landscape, bankrupting US car
retrofit strategy.” also plan to unveil a series giants Chrysler and General
Motors, will have eased. But
even in this most difficult of
financial times, Bosch is
committed to injecting a great
chunk of capital back into its
research and development
budget. This year alone,
DuHadway says, Bosch will set
aside more than US$5.7 billion,
or 8% of its sales revenue for
research and development. She
also confirmed that the Tier 1
supplier will invest a large
portion its R&D expenditure
on products that protect the
environment and conserve
resources. “We’ve been very
fortunate to keep our team
together. However, the HRB
technology we are working on
now is in great demand. And it
makes me proud to know that
we are working on solutions
Instead of allowing braking energy to be lost during the journey of a garbage truck, the HRB system converts braking energy
that can help US businesses in
back into hydraulic energy and stores it. The next time the vehicle accelerates the stored energy is fed back into the transmission this severe downturn.” E&H
High voltage
Never before has EV development been so popular. E&H takes a look at who’s
doing what in the global automotive industry
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Tesla Roadster
Company: Tesla Motors
Cost: Over US$100,000
Batteries: Custom microprocessor-controlled lithium-ion battery
pack with 6,831 individual cells
Range: 354km (220 miles)
Charging: Full charge in less than four hours
Power output: 248bhp, 375Nm of torque
Top speed: 201km/h (125mph)
0-100km/h: Around 4.1 seconds
Weight: 1,113kg
We say: Tesla is an interesting case. The company benefited
from a lot of media attention a few years ago, but over-ambitious
growth plans along with technical issues with the Roadster have
hampered progress. E&H went to test the Roadster toward the
end of 2008 and the car failed to start due to onboard diagnostic
problems. Despite this, a second product, the Model S, is due
soon and it could be key to future growth for the company
Z.E. Concept
Company: Renault
Batteries: Lithium-ion pack produced by the Automotive Electric
Supply Corporation, a joint-venture company between Nissan
and NEC. The battery pack comprises 48 modules, each of
which incorporates four elementary cells
Range: Around 60km (37 miles)
Charging: Full charge in eight hours
Power output: 95bhp electric motor with 226Nm of torque
We say: Renault’s take on emissions reduction and enhanced
fuel economy is simple: further optimization of IC engines along
with the full development of EVs. The French car maker will
have no fewer than three EV products on the market
within six years, one of which will be heavily based
on this concept
e2
Company: GEM (owned by Chrysler)
Cost: Around US$8,000
Batteries: 72V system
Range: 48km (30 miles)
Charging: Full charge in eight hours
Power output: 15bhp
Top speed: 40km/h (25mph)
Weight: 517kg
We say: Despite Chrysler’s recent plight, the US car maker is
standing firm over its support of GEM. Chrysler’s Pea-Pod EV
concept harnesses many technologies from GEM
TH!NK City
Company: TH!NK
Cost: Around US$23,000
Batteries: Lithium-ion pack
Range: 170km (106 miles)
Charging: 80% in eight hours
Power output: 40bhp
Top speed: 96km/h (60mph)
0-100km/h: Over 17 seconds
Weight: 1,113kg
We say: Rumors earlier this year indicated that TH!NK was about
to embark on a collaboration with a large OEM to develop a
four-seater electric vehicle in sedan format, but such a deal has
not yet materialized. Plans are in motion, however, to roll out the
current TH!NK City range to nearly all European markets and
North America
Fetish
Company: Venturi
Cost: Over US$250,000
Batteries: 31 modules of lithium-ion batteries placed in a T
formation in a central unit. The battery pack weighs around
248kg and is liquid-cooled
Range: 250km (155 miles)
Charging: Full charge in three hours
Power output: Electric motor produces 180kW and 220Nm of
torque
We say: Developed and produced in Monaco, Venturi is an EV
for the super-rich. The worry is that it might be surpassed by
Fisker Automotive’s Karma (see page 20), Tesla’s Roadster, and
Lightning Car Company’s Lightning GT. Watch this space
Alias
Company: Zap
Cost: Around US$35,000
Batteries: Lithium-ion pack
Range: Over 161km (100 miles)
Charging: Full charge thought to be around eight hours
Top speed: 241km/h (150mph)
0-100km/h: Around six seconds
Weight: 733kg
Nissan Electric Vehicle We say: The Robin Reliant of the EV world, but there’s more to
Company: Nissan Zap vehicles than just the three-wheel design. The Alias is a
The product: The production version of Nissan’s various EV futuristic-looking car that’s raised the profile of the company, but
concepts is due to be launched in late 2010 will Zap ever manage to branch out from its super niche market?
Cost: Expected to be around US$25,000
Batteries: Lithium-ion batteries developed in conjunction
with NEC
Range: Around 160km (99 miles)
Charging: Nissan engineers are intent on realizing an 80%
charge in 15 minutes. This could be a major breakthrough
Power output: 80kW from the motor and inverter
We say: Like its Alliance partner Renault, Nissan also
sees a future for electric vehicles. The Japanese
OEM’s EV program dates back to the mid-
1990s, and this concept is more than
just a tech demonstrator. The
batteries, motor, and many
subsystems will be used in
Nissan’s production
EV in 2010
R1e
Company: Subaru
Cost: Around US$17,500, but this price will probably drop to
around US$13,000 by 2013
Batteries: Lithium-ion pack
Range: 200km (124 miles)
Charging: Full charge in eight hours
Power output: 40bhp
Top speed: 104km/h (65mph)
We say: Although not quite yet ready to deliver a production EV,
Subaru is hot on the heels of Mitsubishi and the i MiEV product.
The R1e will be ready for market launch by 2011. A testing
program is currently being undertaken in the USA
EV Network
URL: http://www.ev-network.org.uk
e-mail: admin@ev-network.org.uk
Phone: 01268 541502
78
PRODUCTS AND SERVICES
The multiple operation modes of the Dynamic All-Wheel-Drive Hybrid System from Giant Lion. The technology has been designed to make use of reliable, low-cost components
NEW HYBRID
ARCHITECTURE combination with the clutches in the
powertrain can be used to realize different
An advanced powertrain technology has been released operation modes of the system.
There are numerous driving modes
that incorporates a wide range of hybrid functionality available. An integrated control system
that is connected to the clutch and brake
■ Giant Lion Know-How has developed a efficiency levels. In particular, it is not actuators, as well as to the automatic
hybrid powertrain architecture designed for advisable to use an IC engine for propulsion gearbox control, has been developed to
use in SUVs, small trucks and logistic under part load, as the electric machine reliably regulate those driving modes.
vehicles. The Dynamic All-Wheel-Drive offers a much higher efficiency level. DAHS offers the flexibility to choose a
Hybrid System (DAHS) is a four-wheel- A powertrain layout has to be designed driving mode that is suitable for the
drive technology that includes a hybrid in such a way that both machines can be situation at hand and accommodates input
powertrain and incorporates a range of operated and combined very efficiently. The from the driver. It is possible to run in
hybrid functionality, yet maintains a simple DAHS system provides the opportunities to four-wheel-drive hybrid mode, thus using
layout. It has been designed as a system achieve that goal. both machines for optimal traction and
that is easy to manufacture and to assemble The IC engine is connected to a driving performance. If the all-wheel drive
and uses reliable, low-cost components conventional automatic gearbox and can be is not required, the front axle can be
that are readily available off the shelf. A decoupled from the rest of the powertrain decoupled from the rest of the powertrain
sophisticated operating strategy uses the by a friction clutch. An intermediate so that friction losses occurring at that axle
implemented hybrid functions and realizes transmission distributes the power to the are avoided. By opening the clutch, the
a considerable mileage improvement. rear and front axles, both of which can be vehicle runs in a force-addition hybrid
A hybrid system consists of two different disconnected by two additional friction mode, using the electric motor to power
energy converters and storage systems. In clutches. However, the electric motor is the rear axle and the IC engine for the front
this case, an IC engine has been coupled attached through a differential gear, axle. All those three hybrid modes offer
with an electric machine. The main goal realizing a speed increase for the motor and start-stop operation of the IC engine, load
is to avoid those regions of operation in the engine. Friction brakes on two of the fencing, recuperative braking and boosting.
which the IC engine shows very poor three terminals of the differential in A driving mode with locally emission-free
The technical layout of the inner working of the Dynamic All-Wheel-Drive Hybrid System from Giant Lion in Taiwan
propulsion can be chosen with the pure A sophisticated powertrain model has Operating points of the IC engine are
electric rear-wheel drive. For driving been used in order to assess the total fuel shown for both base and hybrid powertrain
scenarios where the hybrid functions would saving potential and the performance configurations. It can be clearly seen that
not net a fuel benefit, such as on more characteristics of the DAHS. In addition during hybrid mode the IC engine is
long-distance journeys, it is possible to to this, it is possible to employ a rapid- operating at a much higher efficiency than
disconnect the electric motor entirely from control prototyping process using software a conventional system. In addition to this,
the system and use only the IC engine for modeling so that the control strategy can the IC engine is shut off during the start
propulsion of the vehicle. be tuned, tested, and verified. For the and stop phases, thus resulting in a
The operation strategy for the DAHS simulation, vehicle parameters have been reduction of idling losses.
has been optimized to minimize fuel extracted from the SUV Ford Escape, which DAHS presents a way to easily add
consumption in urban driving scenarios is powered by a 2.3-liter engine. An electric hybrid functionality in a four-wheel drive
with a high degree of start-stop operation. motor has been modeled according to a powertrain. By adding an electric motor
The basic strategy focuses on stopping the commercially available motor model. The and a multiway terminal battery pack
IC engine when it would run under part- permanently synchronous motor has been consisting of a low-cost, high-reliability
load conditions, and thus with a low- designed for a peak power output of 30kW. VRLA battery, and by implementing the
efficiency level. During those phases, the A lead-acid multiway power battery pack electrical components into the mechanical
vehicle uses the electric motor for propulsion. designed by Giant Lion Know-How with a powertrain via a differential, it is possible
In the event of a power demand that capacity of 90AH(3c) at 72V normal voltage to achieve a great improvement in fuel
exceeds the electric motor’s capabilities, is being used as the energy storage. Power economy and acceleration capability.
the IC engine has to be started again. This density is rated at 470W/kg (>soc 40%). Simulation runs have been conducted,
decision is based on driver input as Internationally standardized driving using standardized testing methods such
indicated by the pedal position and the cycles such as the NEDC and Federal Test as the NEDC and FTP regulations. Those
vehicle speed. An additional control layer Procedure (FTP) have been used as inputs simulations have been run with a
ensures the safety of the electric storage for the simulation runs. Results of the simulation model of a conventionally
device and alters the IC engine switching NEDC simulation are shown on the next propelled reference vehicle and with the
points based on the state of charge of the page, comparing the DAHS vehicle and the modified hybrid vehicle. During test
battery pack. Ford Escape 2.3-liter reference vehicle. simulation runs, the operation strategy of
PPS TECHNOLOGY
The PPS hybrid powertrain system, jointly
studied by Giant Lion and fka mbH,
integrates the electrical driving capability
into a conventional powertrain by a
clutching unit and two electrical machinery
units that provide much less power
capacity then the onboard internal
combustion engine. The operating principle
of the PPS powertrain is simple: while the
engine is running at a low efficiency region,
the clutching unit is disengaged. The
mechanical power output from the IC
engine fully drives the generator to
generate the electrical energy to the
traction motor for vehicle motion. While
the vehicle is driving at high speed, the
clutching unit is engaged, with the
mechanical power of the engine running at
a high efficiency level to drive the vehicle
directly. The switch condition of the
clutching unit is based on vehicle speed
and the sensor signal of engine torque
value. The main feature of the PPS system
is that it does not use a main-battery pack,
which eliminates the dependence on main
battery pack of hybrid powertrain, and
avoids the induced problems on cost and
The technical layout of PPS hybrid powertrain system, which has been jointly developed by Giant Lion and fka system reliability.
Monitoring
and efficient battery charging for all kinds of vehicles, including electric
Track
Supply VDC Data cars and buses, industrial trucks and most other similar vehicles.
Rectifier
Unit charge@conductix.com
Energy Storage www.conductix.com
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ONLINE READER
ENQUIRY SERVICE The futu
Is the ga re for hybrid
diesel hy me already over
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Develop ertrains? r
The future A look m ent tech
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Is the game for hybridarse ev at how testing logies
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UKIP Me
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UKIP Media
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www.ukintpress.com/recard/evcard.html
82
PRODUCTS AND SERVICES
We provide hybrid vehicle and renewable energy system simulation, design, engineering,
integration, packaging, and prototyping expertise
t System modeling, including performance, energy efficiency, and emissions
t Software development & hybrid control strategies
t CAD, FEA, CFD, and eCAD tools
t Prototype development and manufacturing
t EMC, RFI, and High-Voltage specification and testing
t Hybrid & renewable technology training
t Industry & technology reports, benchmarking, and market analyses
t Project proposals, financial analyses, and program management
ENERGY-EFFICIENT
stock utilization are linear designs. These
would include ‘slinky’ strips and linear,
formable stators, with the most efficient of
these being nested in the strip. Such
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Engine Technology
International goes digital!
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TURBO HYBRID
DEMONSTRATOR
An innovative demonstrator project has shown that it’s possible
to combine high fuel efficiency with a fun-to-drive element
Above: AVL built its Turbo-Hybrid powertrain last ■ Fuel consumption and CO2 emissions start) have less potential; this can be gained
year and applied it to a BMW 3 Series. The engine reduction will remain the key challenge for only by a hybrid system. The overall
was developed in cooperation with Bosch and LUK
the automotive industry for many years due powertrain has to be optimized in order to
to legislative, social, environmental and achieve the maximum fuel reduction.
economic reasons. However, for most Downsizing the combustion engine and
vehicle classes, this can’t be the only focus downspeeding by wide ratio spread and
as customer expectations regarding proper final drive ratio leads to a
drivability and the fun-to-drive element tremendous increase in fuel efficiency. The
also have to be met. If two vehicles show impact on drivability due to these measures
the same fuel consumption, in most cases is compensated or even over-compensated
the one that will be purchased will be the by the additional use of an electric drive. To
product that offers sporty characteristics or avoid suffering a low battery, which would
high comfort levels. disable the torque support from the e-drive,
A detailed analysis of the fuel economy Austria-based AVL has developed and
potential offered by hybridization of a patented a special strategy to guarantee a
gasoline engine shows that the shifting of high level of battery charge. Energy needed
the operation points of the IC engine is a for support at low engine speeds is gained
major effect. The classical hybrid functions back at higher speeds by using the
(brake energy recuperation and idle stop/ overboost capability of the turbocharged
combustion engine. Under full load requirements of lowest NVH levels, smallest of the specific drivetrain system layout, the
conditions, a reloading of the battery is package space, high power/weight ratio, electrical system and the internal
possible. Thus, the Turbo-Hybrid was born. system integration, and competitive combustion engine can be optimized for
In 2008, AVL built its Turbo-Hybrid production costs. single point operation. All the range
powertrain in a BMW 3 Series demo vehicle To reduce costs and vehicle weight, the extender functionalities are integrated in a
in cooperation with Bosch and LUK. In battery size and output are optimized for modular package to minimize interfaces
comparison to a 2008 reference vehicle, a the majority of driving schedules. Longer with the vehicle.
fuel reduction of 10% in the NEDC could driving distances, which are driven less The AVL range extender solution can be
be demonstrated, and the overall driving frequently, will not be covered by the tailored to meet specific customer vehicle
performance and fun-to-drive aspect is battery alone. For these longer distances, a requirements. There are also benefits from a
improved. The strategy of recharging user needs to extend vehicle driving range. reduced development effort due to the
the battery by engine overboost was The AVL range extender is an independent reduced system complexity and optimum
successfully demonstrated on the test track auxiliary power unit added to pure electric system efficiency with minimum fuel
and in real-world operation. With moderate drive vehicles to extend the operational consumption in addition to a production
add-on costs for the combustion engine, driving range beyond what is possible in volume design.
the required add-on costs for the electric pure electric mode. Based on highly integrated core
components can be reduced, resulting in The modular design of the AVL range competencies in powertrain engineering,
lower drivetrain costs and a better benefit- extender has focused on the acoustics, testing, and simulation, AVL’s specific range
to-cost ratio than other hybrid systems. weight, and packaging space, with extender services encompass concept
The driving range of electric vehicles is a competitive production costs and development and simulation to technical
fundamental element in market acceptance system efficiency for the required output. specification development, IC engine and
and success. An intelligent system approach Depending on the specific application, electronic system integration, model-based
using new range-extender technologies the internal combustion engine can be component optimization, operation
addresses this primary requirement. AVL designed as a two- or four-stroke piston strategies, and controls, up to verification
has developed an innovative range extender engine, or, for the lowest NVH and and prototype and production
technology demonstrator to meet the compactness, as a rotary engine. Because development. E&H
More: Less:
25% fuel savings Fueling stops
Bosch Rexroth AG
www.boschrexroth.com/hrb
TIME-TO-MARKET
Designed for a junction operation
temperature at 150°C, the module
accommodates a six-pack configuration of
third-generation Trench-Field-Stop IGBT
48 hrs @ 50% RH
24 hrs @ 50% RH
Adhesion test per ASTM 3359 tape test method (0=Poor; 5=Excellent)
ADVANCED VEHICLE
COOLING
The ever-increasing need to equip vehicles with energy-efficient
components is being catered for by a leading Italian supplier
■ Reducing total vehicle energy demand sine-wave sensorless drive, the SBL 300 can the overall motor dimensions and weight
and managing its energy consumption reach a remarkable electrical efficiency of are greatly reduced so that the SBL300
better is increasingly important as energy 85%. This makes it one of the most efficient can offer a 650g weight saving over other
becomes an evermore precious commodity. motors in the 300W power range. This is motors of comparable power.
The value of a vehicle’s energy-efficient further sustained by the use of dedicated Another important aspect that has been
system or components is gaining high-performance fan designs that optimize taken into account during the design of the
importance due to the rising cost of fluid dynamic performance. The result is SBL300 is the need to operate with a low
traditional fossil fuels and the increasing high airside performance at minimum NVH, given the reduced noise levels of an
investment in alternative propulsion electrical load. electrically driven vehicle. The low inertia
systems to produce low-emission and The SBL300 is IP68 and IP6K9K rotor greatly reduces mechanical unbalance,
zero-emission vehicles. compliant, and that means that the motor is and an optimized fan design further reduces
SPAL, a technology leader in the field of fully sealed and can operate in the presence mechanical and air-rush noise.
electric ventilation systems, has analyzed of any aggressive or hazardous substance. For the highest overall system efficiency,
the growing needs of vehicles equipped The integrated power and control it is important not to waste energy. The
with hybrid, electric, and fuel-cell-based electronics are separated within the motor SBL300 is continuously regulated by a
propulsion systems. The Italian supplier to ensure the control electronics operate at PWM signal, which enables the fan to run
has worked closely with leading vehicle lower surface temperature levels, this at the ideal speed to perform the required
manufacturers to design and develop a greatly increasing durability and overall function. Personalized advance control
series of key functions for the vehicle product reliability. strategies are available at a customer’s
cooling system. The SBL300 has a double-sealed ball request, and the onboard diagnostic
The company’s new range of brushless bearing design, guaranteeing an impressive capabilities and built-in protection features
motors equips axial fans and centrifugal product life of more than 30,000 hours. are readily available.
blowers for applications such as energy Compact vehicle designs and the need As a company that continues to expand,
storage cooling, engine cooling, and HVAC to contain vehicle weight require small, SPAL addresses the ventilation needs of the
– including the SBL300 sealed brushless lightweight components. An innovative upcoming hybrid, electric and fuel-cell
motor that features a wide range of benefits. inner rotor design uses rare-earth magnets vehicle applications, new-generation
Because of the use of high-energy in place of traditional ferrite magnets and internal combustion engines, and advanced
rare-earth magnets, and a state-of-the-art an all-aluminum body construction. Both HVAC systems. E&H
FAST-CHARGING
SYSTEMS
Having supplied the forklift market with fast-charging units
for over a decade, Aker Wade is now turning its focus to EVs
it can take 10-30 minutes for a full charge
using current battery technologies. For fast
n Fast-charging systems for EVs are not of battery swapping have embraced fast charging to be adopted across the world,
a new concept. They first began to be charging to reduce their battery inventory.” BMS and connector standards are critical.
adopted for electric forklift fleets more than Aker Wade has developed several fast Aker Wade is working with several
10 years ago, and today, tens of thousands chargers for leading EV makers and organizations to advance these standards,
of forklifts are fast charged. Many of these network implementers. It is also adapting and its fast chargers are being designed to
chargers come from Aker Wade Power their chargers into Level 3 DC fast-charging charge EVs from most major US, Japanese
Technologies, based in Virginia, USA. stations. These have the ability to charge and European car makers.
The company has now launched a full Li-ion batteries in as little as 10-15 minutes, “The eventual goal is for all manufacturers
line of intelligent fast chargers, developed similar to the time to pump gas. of EVs to adopt a common connection
by its power electronics engineers and “People are already comfortable buying standard worldwide,” explains Aker. “We’re
industrial software specialists. With wireless and pumping gas and the EV fast-charging working to make sure that happens soon.”
networking and web-interface capability, experience should be no different to that,” So what role will fast charging play in the
they have alerted the forklift industry to says Aker. future? Proponents are convinced it is one
the value of a smarter, faster charger. The company’s EV charger technology is of the keys to EV adoption.
Aker Wade rose to the top end of the similar to that used in their industrial “Fast charging means we can provide
industry through a better technology and chargers. The major difference is that, with consumers with what they want – a quick
a simple business model. CEO Bret Aker forklifts, the charger dictates the power in-and-out – using off-peak energy, stored
states, “We only build fast chargers.” output, based on feedback from the battery. locally,” says Aker.
The EV world is waking up to the need Charge rates for EVs are usually controlled “Electrical energy can be distributed,
for fast charging, and the company is ready. by a battery management system (BMS) that stored, and used much as hydrocarbon
Aker explains, “Fast chargers will play a comes with each battery. fuels are today,” he adds.
pivotal role in the adoption of EVs. “The BMS tells our charger how much “This is a ‘win-win-win’ situation as the
“Although the majority of infrastructure power to deliver,” says Aker. “Lithium-ion economics are attractive for the consumer,
will be for standard-rate chargers, fast chemistries vary, and they each need to be the energy provider and also the energy
charging solves a variety of problems for charged differently. ” reseller. By shifting the load to the grid at
different users including those wanting to One of the major implications here is night, we save money, and avoid adding
travel long distances and fleet operators that the speed of the charge is driven by the load to the electricity grid when power is in
with heavy usage vehicles. Even proponents BMS. Depending on the battery chemistry, high demand.” E&H
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Engine Technology
International goes digital!
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98
PRODUCTS AND SERVICES
TEST SOLUTIONS
Hybrid and Electric Vehicle Development
Center (HEVDC) in Auburn Hills,
Michigan. This center includes: hybrid
powertrain test cells capable of testing
2010 AT ENGINE
EXPO 2010
!
22, 23, 24 June 2010
Messe Stuttgart, Stuttgart, Germany
www.engine-expo.com
Experts in:
• EV Battery Components
• Ultrasonic Welding
• E-coat
• Swiss Turning
HICCON II
• Metal Stamping
Standard and Tailor-Made
• Injection and Insert Molding Plug-In Connectors
up to 400 A
• Strategic Program Development up to 1200 DC
for shielded cables
For more informtion on Adventec’s with pilot contacts
unique capabilities contact us at:
Opal-RT Technologies
From Imagination to Real-Time
www.opal-rt.com ECU Development & Testing Platform
108
PRODUCTS AND SERVICES
NEW PROPULSION
This philosophy is in line with UQM’s
history of dedication to hybrid and electric
vehicle development. Roberts addresses the
legacy by saying, “We are typically known
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better vehicles
demand and maintaining market share as
the market expands.
The exceptional growth in lithium
demand has come from developments in
A lithium deposit in Nevada promises secure supplies to new lithium-ion battery technology over
the past decade. Lithium-ion has replaced
support a new generation of hybrid and electric vehicles almost all other battery technology for
small electronics over the past 10 years.
n The downturn of the global automotive further developing its Kings Valley lithium Today’s lithium supply goes into batteries
industry makes it clear that it is imperative deposit – one of the world’s largest known for portable electronic equipment, alloys
to come up with a new business model deposits of lithium – in Nevada, USA. Its that make lighter metals, and industrial
based on electric vehicles. strategy is to enter the market as a major use in the area of ceramics, aluminum,
“We see that the economic recession has long-term supplier of high-quality lithium and lubricants.
actually forced governments, corporations, carbonate. Western Lithium’s Nevada lithium
and consumers to make decisions that At the moment the company is deposit was first discovered in the 1970s
will return future benefits with respect to positioning itself to be the next large-scale, by the US Geological Survey. Chevron
profitability and sustainability,” says Jay high-quality supplier of battery-grade Resources took an interest in the project
Chmelauskas, president of Western lithium carbonate for the emerging and spent several years drilling the deposit
Lithium. “We believe lithium is the building automotive lithium-battery industry. The and advancing metallurgical and various
block for better performing company’s target is to produce over 10% of economic studies. The historical Chevron
and green transportation the world’s lithium supply by 2013. The work identified approximately 11 million
and electrification timing of production is planned to meet tonnes of lithium carbonate equivalent, but
technology, and that anticipated growth of the lithium market. the size of the market at that time did not
our lithium project in Most of the global supply of lithium warrant further work. The US Bureau
the USA is positioned currently comes from salt brines in Chile of Mines began studying the deposit in
to benefit during this and Argentina. However, hard rock mines the mid-1980s and carried out its own
shift toward electric in Australia and China also supply the metallurgical and economic studies. It
transportation, lithium market. New salt brine producers advanced the project to a pilot plant using
renewable energy, in South America and China are expected a conventional process.
and smart grids.” to push production costs higher into Western Lithium is now looking to
Through various technically and geographically more conventional technology to progress
engineering challenging production. engineering work in 2009 and 2010 toward
studies Western Lithium expects that the a construction decision by the end of 2010.
with URS economics from mining its Nevada Over the coming months, the company
Corp, hectorite clays will compete favorably with expects the engineering feasibility studies to
Western these potential new brine and hard-rock be completed, and that, in turn, is likely to
Lithium producers. The location of the deposit in increase interest from major industrial
is now the USA is a major benefit and its size groups. E&H
Westfield Electric
Race Car
Hydrogen Reformer Controller
www.potenza-technology.com
112
PRODUCTS AND SERVICES
■ The Electric Vehicle (EV) Network exists to document electric vehicle ■ EVO Electric Limited was established in June 2007 to commercialize a
charge points in the UK and to encourage provision of such facilities. Prior to new design of Axial Flux permanent magnet synchronous AC motor/generator
the formation of EV Network in 2007, such charge point information was divided developed by researchers at Imperial College, London targeting electric and
between numerous different web sites such as those of local authorities or grant- hybrid vehicle applications.
making bodies, but no sites were comprehensive – they listed only the charge Axial Flux machines have inherently higher torque and lower costs than
points provided by this local authority in the UK or that grant-making body. conventional radial flux machines due to the greater availability of active
The EV Network allows electric vehicle users to find charge points by several electromagnetic area per unit of volume. EVO has taken this promising concept
means including a searchable online database; interactive maps; and point of from lab to market through innovations in machine cooling, winding and
interest files for satellite navigation systems. Using a suitable satellite navigation, manufacturing. For example, increasing the surface area for cooling has enabled
a user can locate charge points by proximity to their current or any other position higher currents and hence even higher continuous power and torque than
or plan a route via charge points. previous Axial Flux designs. The ultra-light and compact EVO design also
Although the UK public charge point network is in its infancy, it is easily enables a very high peak torque. The 380mm diameter and 40kg model
exceeded by the relatively small numbers of electric vehicles in use. There are produces 400Nm for 45 seconds and up to 600Nm in short bursts, thus
more privately-owned locations than public ones where electric vehicles are eliminating the need for gearboxes in many applications and facilitating
charged since, uniquely in the alternative fuels sector, electric vehicle users can hybridization of existing vehicle models. The short axial length and flat mounting
normally easily refuel their vehicles at their own homes or businesses. faces make the machine very suitable for direct mounting onto a combustion
In addition to documenting public charge points, the EV Network also uniquely engine, low material costs give EVO motor/generators a cost advantage over
provides a membership scheme giving access to a larger private network of conventional motor/generator designs.
charge points provide by other members. These charge points are offered on an EVO is now working with a number of strategic partners to build and
exchange basis as EV users cooperate to extend the use of their vehicles. demonstrate advanced hybrid and electric vehicles based on this technology.
HEV AND EV RECRUITMENT SPECIALISTS WHOLE VEHICLE DESIGNS, INTEGRATION AND HV COMPONENTS
Consilium Group R&D Vehicle Systems
✆ +44 1386 835 910 @ info@rdvs.co.uk
: www.cgl.eu.com : www.rdvs.co.uk
@ response@cgl.eu.com ✔ ONLINE READER ENQUIRY CARD NO. 531
✔ ONLINE READER ENQUIRY CARD NO. 529
■ R&D Vehicle Systems, along with its sister company R&D Vehicle
■ Consilium Group (UK) provides a unique, dedicated and comprehensive Components, are leaders in the field of electric & hybrid vehicle systems
recruitment service to HEV and EV organizations and professionals both in the integration and high voltage power distribution.
UK and on an international scale. Building on a long history of whole vehicle electrical system design and
Due to the sustained growth within this technology sector, and the projected powertrain transplants, in markets as diverse as sports cars and military vehicles,
future demand, the competition for qualified and experienced professionals is RDVS moved into the EV field four years ago, growing strongly in the process.
very high. The company’s experience now includes the electrical leadership of OEM EV
With more than 10 years HEV and EV experience, Consilium Group is projects, whole electrical system design and bespoke component designs in key
established as a market leader on a global scale. Consilium Group’s enviable areas – HV power distribution and control systems; CAN-based controls and
database and network of both candidates and vacancies provide a unique interfaces. All components are designed and manufactured in house in both
ability to match the most technical roles with industry specialists. prototype and production volumes.
Consilium Group recruiters are
degree qualified in engineering with
actual real-world industry experience,
so whether the client is looking to fill
a role or find a new job, Consilium
Group recruiters can talk technically,
whatever the discipline.
Consilium Group services cover
the full range of technology from
vehicle manufacturers to electric
motors, from batteries to systems
integration. This is supported with a
long and successful record of building
complete teams of engineers for
major international clients, through to
one-off placements at small design
consultancies.
HYBRID DEVELOPMENT
TorLab AB
@ tor.anderson@torlab.com
✔ ONLINE READER ENQUIRY CARD NO. 530
■ TorLab AB in Gothenburg,
Sweden, provides electronics product
development and services.
Concept studies, auto electronics
including power electronics and
software development are areas that
Tor Anderson, founder of TorLab, has
been working in for over 20 years,
starting with the development of
electric hybrid vehicles in 1982.
Most technologies exist today for
building different types of hybrid car
configurations. But developing hybrid
technologies is quite costly and not
easy to achieve. The weight of the
electrical system with batteries and
the cooling of the electric components
are challenging factors.
The Swedish Energy Agency is
supporting 17 Swedish research
projects, and the goal is to reduce
emissions and fuel consumption in
light and heavy vehicles. TorLab AB
is participating in a Rear Axle Hybrid
Project for cars, and other members in
the project include OEMs, universities,
supplier Haldex Traction AB and
development companies QRtech.
Engine Technology
International goes digital!
l l l# : c \ ^ c Z IZ X ] c d a d \ n > c i Z g c V i ^ d c V a # X d b
117
PRODUCTS AND SERVICES
CHARGING ZONE
Sustainable Vehicle Engineering Centre, Oxford Brookes University
: http://tech.brookes.ac.uk/svec
@ svec@brookes.ac.uk
✔ ONLINE READER ENQUIRY CARD NO. 532
■ Householders across Oxfordshire in the UK will soon get the chance to feedback, allowing experts from the University’s Sustainable Vehicle Engineering
find out just what it’s like to own an electric car thanks to an exciting project run Centre (SVEC)), based in the School of Technology at Oxford Brookes University,
by BMW and Oxford Brookes University. to gauge the feasibility of the commercial roll-out of electric vehicles.
But will a 40-strong fleet of battery-powered Minis mark the next step in the Professor Allan Hutchinson, Head of the SVEC, says of the project: “It is
evolution? BMW, Scottish and Southern Energy, Oxford Brookes University and essential that the environmental challenges facing the global automotive industry
SEEDA, who are together running the ambitious Mini E Research Project, are tackled now. Car makers are increasingly looking at ways to replace
certainly hope so. The project represents a hugely exciting moment for the conventional engines with low- or zero-emission alternatives and help meet
fledgling UK electric car industry as, for the first time, company bosses and climate change targets.”
academics will discover exactly how a large number of zero-emission vehicles Both the academics and BMW bosses want the Mini Es to be treated just
cope with the demands of day-to-day driving. like any other family car to discover how running one of these battery-powered
The project is centred around Oxford and will look at the way 80 volunteers vehicles fits in with lifestyles today. Carefully assessing user attitudes to, and
drive their electric Minis in two back-to-back six month trials. The year-long trial their experiences of, these electric cars will give the best indicator of future public
will produce data both from the battery-powered cars and in terms of driver acceptance of low carbon vehicles. Subjective feedback, gleaned by a team of
Brookes’ psychologists, will provide one of the best insights yet into public
attitudes toward electric vehicles.
Engineers, mathematicians and statisticians from the SVEC will collect and
analyze all the technical data and subjective driver feedback, supported by
the psychologists from the School of Social Sciences and Law. This panel will
study the fleet of electric Minis across their disciplines from both a technical
and lifestyle standpoint.
SVEC’s industry network, DRIVENet, is hosting a two-day Whole Life Vehicle
Conference at Turweston Aerodrome from November 18-19, 2009, at which there
will be an opportunity to test drive the latest electric and low carbon vehicles.
SVEC is at the forefront of developing new technologies to help the motor
industry meet the sustainability challenges of the future. Its research is
concerned with the whole lifecycle of the motor vehicle from raw materials, to
design, powertrain, alternative fuels, manufacture, disassembly, recycling and
reuse of components and materials. The Centre also specializes in forecasting,
Engineers and mathematicians from the Oxford Brookes University’s Sustainable Vehicle strategy, business models and the implications of new legislation for the
Engineering Centre will collect and analyze all technical data from the Mini E project automotive industry.
Large format battery cells for electric vehicles today come in a wide variety of both shapes and sizes, including the nested (left), the slim (center), and the wide (right) module formats
INDEX TO ADVERTISERS
A&D Technology..................................outside back cover EV Network..................................................................77 Pfisterer Kontaktsysteme...........................................103
Adventec Manufacturing Inc..................................9, 103 EVB Technology / Gold Peak Batteries..........................86 Pihsiang Energy Technology Co Ltd.......inside back cover
Aker Wade...................................................................53 EVO Electric Ltd...........................................................46 Potenza Technology...................................................111
Arbin Instruments........................................................23 EVtransPortal.com.....................................................113 R&D Vehicle Systems Ltd.............................................77
Arsenal Research.........................................................11 EVWorld.com.............................................................112 REAP Systems.............................................................65
Automotive Testing Expo North America 2009..............61 FEV..............................................................................66 Ridek Systems...........................................................119
AVL List GmbH...............................................................3 Finnish Electric Vehicle Technologies Ltd......................69 Rinehart Motion Systems...........................................116
Bitrode Corporation......................................................36 Flybrid Systems...........................................................36 Romax Technology.......................................................97
Bosch Rexroth AG........................................................89 Giant Lion Know-How..................................................54 Scientific Climate Systems Ltd.....................................77
Conductix Wampfler.....................................................81 Hybrid Design Services................................................83 SPAL Automotive..........................................................13
Consilium Group..........................................................53 Impact Automotive Technologies................................119 Specialty Coating Systems...........................................62
D&V Electronics...........................................................58 Infineon Technologies AG.............................................19 Stridsberg Powertrain..................................................49
Danfoss Silicon Power GmbH.......................................61 International Battery Inc...............................................65 Swedish Hybrid Centre................................................74
Design Investment.....................................................115 Isabellenhutte Heusler.................................................73 Tawas Inc....................................................................23
Digatron Firing Circuits..............................................103 LH Industries........................................inside front cover Thermal Hazard Technology.......................................119
DRIVENet / Oxford Brookes University..........................25 LiFeBatt.......................................................................17 TM4...........................................................................109
Electric & Hybrid Vehicle Technology International Li-Tec Battery............................................................107 Torlab..........................................................................65
Online Reader Enquiry Service...............................81 Lithium Balance...........................................................25 UQM Technologies Inc..................................................58
Electric Drive Transportation Association (EDTA)...........86 Maccor Inc.................................................................105 Valence Technology Inc................................................21
Electric Mobility Canada.............................................114 MES-DEA.....................................................................46 VOGT Electronic Components GmbH..............................7
Engine Expo 2010................................................99, 101 Midtronics...................................................................46 Western Lithium Corporation........................................39
EngineTechnologyInternational.com...............85, 97, 116 Opal-RT.....................................................................107
EV America..................................................................15 Park and Power...........................................................36
What career did you want when you straight-six. I suppose for Europe, a diesel engine is really an attractive
were growing up? product because it enables the driver to get a good range on a single
As I child, I spent lots of time playing tank. I think the industry has made very good progress over the past
with Lego and Fischertechnik. I few years in terms of the performance of diesel powertrains.
suppose I’ve always had an interest in
technical stuff and it became pretty What do you think is the best engine that has ever been produced?
clear from a young age that I wanted I think one of the best is the four-cylinder multivalve engine that was
to study mechanical engineering. in the Corolla GT. That 1.6-liter, naturally-aspirated, twincam four-
The OEM I worked for was Volvo cylinder was named 4A-GE, and it was really famous. It was impossible
and I was with them for 10 years. to break it. You could do whatever you wanted to it and many people
I’ve been with Toyota for 12 years. used it in rally motorsports.
When did you first start playing Which manufacturers do you have particular respect for in terms of
around with powertrains? their engine development, and why?
It all began when I was around 15 It’s accepted that BMW develops very good powertrains. But for me, the
years old. My friend’s older brother great thing about BMW is its consistency across all its engines.
was replacing an engine on his car,
which was very old. They lived What is the proudest achievement of your career so far?
around 5km from where we lived. I It’s not that I’m proud of any one specific product that I’ve helped to
took a wheelbarrow, walked the 5km develop, it’s more to do with getting people together to take part in
to collect the old engine and then I teamwork across the board. I’m very proud of establishing a drivetrain
disassembled it in my backyard. design section at Toyota Motor Europe.
What are the best and worst What personal career goals do you have for the future?
elements of your job? I’ve always been a powertrain guy. What we see now is that the
After 22 years in the industry, I’m powertrain world is in a transition phase – powertrains are starting to
pleased to say my job still enables me be electrified. So my next step will be to broaden my activities outside
to work with technology. Working for purely mechanical development. With all these hybrids coming, there
Toyota, we do not just sit at our desks will be interesting challenges ahead, especially at Toyota where we want
and design; we really get our hands to broaden efforts in this area.
dirty and actually work with the
parts. Because of the type of job it is, In your opinion, what will be powering passenger cars in the year
sometimes it can be stressful. I 2025?
suppose that, getting a bit older and Combustion engines will still be around in 15 years’ time. Some people
having a young family, it’s not always predict that the IC engine will be dead by then, but I disagree. It will
easy to find a balance between work be around for a few more decades because it is a reliable power source.
and life. I also think there is still scope for its development, as we have shown
with the third-generation Prius. The industry simply can’t switch to
What car do you currently drive? anything else overnight. What is becoming clear, however, is that the
A Toyota Avensis Wagon with a 2.2- IC engine will be supported in various degrees by electrical parts.
liter diesel engine.
What would you like to see the legislators and manufacturers do in
Emissions legislation aside, what the immediate future to improve engine efficiency?
would be your ideal engine design Incentives are an important tool. There are several countries in Europe
specification? that use them, and customer behavior really changes as a result. People
It all depends on the type of car. If buy certain cars because of governmental incentives. As engineers, we
I had the choice between a V8 or a like to be challenged, and the dynamics between the car maker and
straight-six, I’d have to go for a legislator will continue to push the boundaries even further. E&H
Pihsiang Energy Technology Co., Ltd. -- PHET® is maximizing her efforts to manufacture the World Pat. C-LiFePO4
based Lithium batteries. Until today PHET® is the only manufacturer mass producing consistent C-LiFePO4 batteries
in-house through fully automatic production lines including computer sorting. The World Pat. C-LiFePO4 cathode
material is licensed via a powder manufacturer from Hydro-Quebec, the University of Texas, CNRS, and University of
Montréal.
PHET® designs and manufactures EU / RoHS compliant battery products according to customers’ requests or given
specification which are either individual cells or complete packs with fault-tolerant DOSBAS® safety device. The
DOSBAS® safety device prevents high temperature rise caused by unexpected physical impact to the battery packs
and safeguards against internal short-circuiting.
www.aanddtech.com