Introduction to the design of a 48V hybrid battery system

1. Bosch

Bosch 48V Mixture Products

In 2017, Bosch made significant progress in the area of electrification. Bosch's newly developed 48V hybrid battery can be quickly integrated into new models, helping existing carmakers and similar start-ups shorten the development cycle and save costs.

The lithium-ion battery can be installed in many models, such as compact cars, Mini cars and mini cars. It is expected that the battery will begin mass production by the end of 2018.

In view of the huge market demand for entry-level hybrid models, Bosch will also provide power assembly components other than the 48V battery. Bosch estimates that by 2025, about 15 million 48V hybrids will be on the road.

Bosch Electric Drive Bridge Products

By 2019, Bosch's new electric bridge will further increase the range of electric vehicles.

It is reported that Bosch's electric axle drive system(eAxle) has brought electric power to car manufacturers through an extensible and modular platform. The cost efficiency of the drive system can be increased by 5 % to 10 % compared to the independent drive components. The eAxle can be used on multiple automotive platforms to combine Bosch's top powertrain components into a system.

Bosch said the new "fully integrated powertrain" is 20 % smaller than the traditional electric vehicle powertrain, and the production cost of the new powertrain is also lower. Bosch did not disclose the specifications of the "eAxle" power unit.

Bosch abandons electric car battery business

After careful consideration, Bosch announced that it will abandon self-made power cell units and instead provide customers with a complete battery system through outsourcing battery units and its own powerful battery management system technology and system integration capabilities.

RolfBulander gave four reasons for this:

Market level: The global power battery market is dominated by five Asian companies (Ningde era, Matsushita, South Korea Samsung, South Korea LG, Shenzhen BYD), and these have become the climate. If Bosch is put into production at this time, it will not only take advantage of it. There are also significant market risks to be taken.

Technical aspects: new power cell technology emerging, the replacement is urgent. At present, the energy density of lithium batteries based on liquid electrolytes can not fully meet the demand for electric vehicles. Bosch is more optimistic about solid-state batteries and next-generation lithium battery technology, but it is expected to mature by 2025.

Cost level: 75 % of the cost of a battery unit comes from raw materials such as lithium. With the costs of processing, packaging, and transportation, the profit space is very limited. Once the price war starts, it can be said that it will not make a few money.

Investment: by 2030, global power battery capacity will reach 1000gkWh. If Bosch's market share is to reach 20 %, it will need to invest at least 20 billion euros to purchase battery unit production, testing, recycling and other equipment. The money is no small sum for any component company. And if there is a revolutionary innovation in technology, there is a good chance that early investment will go nowhere.

However, this does not mean that Bosch will abandon the development and manufacturing of battery systems. Instead, Bosch continues to step up research and development efforts in this area.

RolfBulander is full of confidence in the future of power cell technology. He believes that Bosch's advantages in this area are concentrated in three aspects:

The integrated capabilities of the "three electric"(battery, motor, and electronic control) systems, Bosch is one of the few companies in the world that has fully developed powerful electric drive systems, battery management, and vehicle electric control R&D capabilities and core technologies.

Know-how, the energy efficiency core, Bosch is developing a more energy-efficient next-generation motor, inverter, and car heat management system. Using Bosch's system, vehicles have longer range of endurance with the same amount of power.

Standardization, Bosch's goal is to continuously improve electric technology and reduce costs through standardized design and management, so that electric drive vehicles truly enter the era of large-scale application.

2. ZF

ZF hybrid products

In the hybrid drive system, the ZF can provide a full range of hybrid components for the vehicle manufacturer. Whether it is micro-mixing or full-mixing, ZF can tailor specific solutions to customers based on the different hybrid levels of the transmission.

At present, the ZF Hybrid Edition of the 8-block automatic transmission has been used in many mass-produced models (such as the BMW Activehybrid 7 model and the Audi Q5hybridquattro model).

According to the manufacturer's introduction to the future, Zephyr also plans to launch a hybrid version of the 9-block automatic transmission, which is designed for passenger vehicles that match the front transverse engine. At home, the company actually does a lot of matching work, such as matching engines and gearboxes for many car companies.

Zephyr is also committed to the development of advanced automatic transmissions, such as the 8-block plug-in hybrid transmission system. It integrates a high-performance motor into the bell hood, replacing the torque converter, allowing vehicles to use pure electric driving to reach a maximum speed of 120 kilometers per hour, thus achieving local zero emissions.

Zephyr's hybrid product mix includes a variety of performance categories of motors and is equipped with fully compatible control units, software and power electronic components designed and manufactured by Zephyr.

Zephyr electric drive bridge and integrated electric drive system

In order to achieve pure electric power and zero emissions, ZF has developed a central electric drive for small and medium-sized passenger vehicles to adapt to the increasing number of car companies engaged in the forward development of electric vehicles. This product is located in the middle of the bridge and has a maximum power of 120 kilowatts. Even at low speeds, it can still output high torque values, and its acceleration performance is no less than that of traditional internal combustion engines.

In addition, this central electric drive product has a compact structure and weighs only about 45 kilograms. It facilitates the layout of power cells in the front and rear space of the vehicle to achieve better handling and stability. The balanced layout of power cells before and after is considered to be the current mainstream. Layout method, the new electric car chassis design models such as BMW i3 and teslamodels all use this arrangement.

For many pure electric vehicles, electric motors and inverters can cause a certain amount of energy loss when they run together in a specific operating condition, and the electric drive device introduced by ZF provides a solution to this problem. The performance optimization of the entire electric drive system, Make the power conversion efficiency increase by 6 %.

The integrated power supply is a major feature of this device. At the same time, Zephyr is also developing modular systems that are suitable for various output levels to better meet the needs of different customers and vehicles. In the future, ZF electric drive system will no longer only apply to small cars and compact cars, but will rely on the hybrid vehicle bridge module to further expand the product line to high-level front-wheel drive cars.

ZF chassis, electric drive and transmission

In terms of chassis, Zephyr provides everything from ball hinges to shock absorbers to the entire vehicle bridge system. Its advantage in this area is that it can provide solutions for the entire vehicle bridge system (such as the chassis and suspension can be adjusted according to the model)., including chassis NVH optimization, In China, it provides ABB with the entire vehicle and bridge service) and provides some highly technical products. For example, ZF's stepless variable damping control damper (CDC) can optimize the damping force on each wheel in real time according to different driving conditions.

The Zephyr active rear wheel steering system(AKC), which was put into mass production in 2013, assisted the steering action of the front bridge by changing the front beam angle of the two rear wheels through the electromechanical execution mechanism, providing the handling and safety of the vehicle; For example, in terms of chassis lightweight technology, ZF's newly introduced glass fiber plastic (GRP) leaf springs can reduce the weight of lightweight axles developed by ZF compared to traditional steel axles. The 15% lightweight pillar suspension module is half the quality of traditional steel-aluminum construction products.

Similarly, Zephyr provides a fully integrated transmission system and chassis solution for traditional vehicles in the form of a modular rear bridge concept. Thanks to the electric bridge drive and ZF's Active Rear Steering (AKC), this revolution for the steering function is easy to upgrade.

For example, compared to the current mainstream horizontal 6-block gearbox, the large tooth ratio of the Zephyr 9-block automatic gearbox(9HP) up to 9.81 can reduce fuel consumption by an additional 16 %, but note that this efficiency is 120 kilometers per hour. When driving at a uniform speed, So the actual fuel economy is definitely not that obvious.

3. Japanese electric equipment

Together with Toyota and Mazda

Toyota, Mazda and electronics, the big auto parts makers, announced that the three companies had signed a contract to collaborate on the development of technology related to electric vehicles and decided to set up a new company for this purpose.

In a joint press release on the 28th, the three companies said that Toyota, Mazda, and electric equipment will invest a total of 10 million yen (112.7 yen for a total of 1 US dollar) in 90 %, 5 %, and 5 % respectively.

The new company is headquartered in Nagoya City, not far from the headquarters of Toyota. It is mainly engaged in the research and development of basic construction-related technologies for electric vehicles that can cover all levels and models. The new company's full-time engineers are mainly seconded from three companies.

Establishment of a plant in the United States to produce electrical control components

In recent years, many countries and regions in the world have increasingly strict restrictions on greenhouse gas emissions. In some places, even a certain proportion of electric vehicles must be sold.

Japan Denso will invest $1 billion to renovate its Maryville, Tennessee facility to produce electric vehicles, hybrid cars and self-driving auto parts.

As more and more carmakers announce their plans to make electric cars in the United States, the huge investment in Japanese electric equipment has helped to solve the problems that have plagued the electric car industry recently.

Japan Denso will invest in three production lines in the United States, namely: EVinverters,special components and data control modules for future connected cars, while other Japanese auto giants It is the production of these accessories in Japan.

This move has solved Toyota's urgent needs. Toyota is the largest customer of Japanese electric equipment and is also a major shareholder of Japanese electric equipment. Toyota plans to build a factory in the United States to produce one or more electric cars with Mazda, but the name of the car is uncertain.

Japanese executives at the Maliweier plant said last week that they would expand production lines to produce the electrification needed for hybrid and electric vehicles, which are safe enough to connect networks. In addition, they will provide these components to customers throughout North America.

Electric cars are no longer on the sidelines. Gm, another important customer of Japanese electronics, said last week that it would introduce two new electric vehicles in the next 18 months. In addition, by 2023, the company will add 20 electric cars or hydrogen fuel cell cars.

Japan Electric and Kyoto University jointly developed electronic control products

FLOSFIA, a technology startup founded by Japan Electric and Kyoto University, announced that it will invest in and develop a new generation of power semiconductor devices, which is expected to reduce and reduce the energy consumption, cost, size and weight used in electric vehicle inverters. Through joint development projects, the two companies aim to improve the efficiency of the electric vehicle power control unit, which is the key to promoting the widespread use of electric vehicles.

In addition, Electric received new shares issued by FLOSFIA in its 800 million yen (approximately US$ 7.1 million) C round financing. Other investors in round C include Mitsubishi Heavy Industries, Mitsui Mining Smelter's SBI Materials Innovation Fund (MitsuiKinzoku-SBIMaterialInnovationFund) and EightRoads Investment.

FLOSFIA successfully fabricated Schottky barrier diodes (SBD) with α-Ga2O3, which reduced conduction loss by 86% compared to SBD based on SiC. Electrical equipment indicates that α-Ga2O3 can replace the current Silicon (Si) and Silicon carbide (SiC) power semiconductors and help to further develop technologies that support future electric vehicles. The two companies will further develop technology for hybrid and high-pressure products including semiconductors and electric vehicles.

4.Schaeffler

Scheffler's Mixture Products

While the Chinese government has spared no effort to promote electric cars as a way forward, some car makers and core component manufacturers have not abandoned the hybrid technology route. On March 16th, the world's leading automotive engine, gearbox and chassis components and the system supplier Scheffler Group's first P2 hybrid module were put into production at the Taicang plant in Jiangsu Province to provide domestic car companies with hybrid models. Systematic solutions.

The P2 hybrid module is a representative product of Scheffler in the field of electric drive. This product can be applied in a modular manner to models using different types of gearboxes to achieve hybrid power. According to the location of the hybrid module, there are many configurations such as P0, P1, P2, P3, and P4.

The P2 hybrid module is located between the engine and the gearbox. Unlike the PS configurations of Toyota THS and General Voltec, the P2 configuration is relatively simple and suitable for different gearboxes and engines, especially for dual-clutch gearboxes. Moreover, the P2 configuration is less expensive.

The Scheffler P2 hybrid module consists of a high power density permanent magnet synchronous motor, a dry K0 clutch and a central motor actuator. The entire system can integrate 25kW to 80kW Motors, passing torque up to 250Nm through the clutch (which can be increased to 800Nm after combining one-way clutches).

The module can implement a variety of driving modes, including pure electric drive vehicles start and drive, pure engine drive, motor power, motor start engine in pure electric drive, and braking energy recovery.

Schaeffler sets up new electric drive department

In the middle of last year, Schaeffler announced that it will establish an independent electric drive business unit under the Automotive Division from January 1, 2018 to integrate all products and system solutions related to hybrid and pure electric applications. The new operations department is located in Boer, Germany, and is the new headquarters of the Scheffler Group's automotive division.

In addition, the company has a preliminary sales plan for electrification, which is expected to generate more than 15 % of the total revenue from the electric car business by 2020.

On January 16, 2018, Scheffler officially appointed Dr. Jochen Schr? Der) is the head of the newly established electric drive business Department of the Scheffler Group. He will formally take office from April 1, 2018. In this role, Dr. Schroeder will report to Madis Chinke, CEO of the Schaeffler Group Automotive Main Business Unit.

Dr Schroeder, 46, worked for ValeoSiemenseeAutomotive before joining the Scheffler Group. As a member of the Management Committee, he is mainly responsible for the company's global R&D business.

Dr. Schroed studied at Hamburg-Haber University of Technology and received his Ph.D. in Control Engineering. He served in BMW and worked in different management positions. He was responsible for system design, electric drive advanced engineering development, and vehicle energy management.

At the end of 2016, after 15 years of service at BMW, Dr. Schroeder joined ValeoSiemenseeAutomotive as CTO.

Scheffler Electric Drive Bridge

Recently, Schaeffler Group released a new strategic goal of “Tomorrow's Plan”. Group CEO Klaus Rosenfeld said: "The automotive industry is undergoing rapid transformation. If we want to catch up with changes in the market, we need to accelerate our own changes. As a result, the Schaeffler Group will transform its pure electric vehicle solutions, Industry 4.0 and smart car digital technologies, which will account for 15% of the Group's sales by 2020. ”

It is understood that the Scheffler Group has now obtained eight series of contracts from different automotive customers around the world on products such as new energy car drive shafts and hybrid power modules. The sales potential of these contracts exceeds 1 billion euros. It is worth noting that the Scheffler Group will also set up a R&D center in China to conduct customized supply requirements for Chinese car brands.

For a long time, pure electric vehicles have been driven in the form of a combination of motors and drive bridges. This form must increase the differential mechanism. However, most of this form is the motor performance can not keep up with the use of speed reducer for deceleration. In the role of these mechanisms, a lot of motor energy is used to overcome friction, which is not conducive to the use of electric vehicles. But this is also the most simple and direct form of layout, more like a traditional car.

Scheffler also has a variety of electric drive solutions. In addition to the P2 hybrid module, Scheffler also produces electric drive bridges. At the same time, it is also developing rims motor technology, but the development of this technology is still in its early stages. According to EV Century, the VV8 model of the premium brand WEY SUV will launch a plug-in hybrid model equipped with an electric drive bridge produced by Schaeffler.

Scheffler hub motor

Future-oriented zero-emission technologies also have a place in Scheffler's development concept. The company also demonstrated its hub motor technology, the "E-Wheel Drive" technology, at the show, placing the motor inside the wheel.

In response to the demand for high power and high torque in the European car market, Scheffler Germany has developed an ultra-high integration hub motor drive system eWheelDrive for Class B and above models. The system places internal rotor Motors, power electronic components, controllers, brakes, and water-cooled devices in 16-inch rims.

As a rear-wheel drive, eWheelDrive(beta version) can provide peak torque of up to 1400 N M and 88KW power on the Ford Carnival Wheel Drive electric test vehicle jointly developed with the Ford European Research and Advanced Engineering Center released in 2013.

Scheffler introduced the new technology E-Wheel Drive. This is actually a combination of wheel side motors and brakes. It has great requirements for the full range torque and speed of the motor. Electric vehicles that use this technology have higher transmission efficiency, while braking is achieved by "kinetic energy recovery" through motor recoil. The built-in brake drum is used in emergency situations and the battery is no longer able to accept electricity.

Although this form is more energy efficient, in addition to the cost, it is necessary to solve the factors affecting the handling of the suspension and the unsprung mass.

Under the "future mobility" strategy, the Schaeffler Group will continue to insist on the development of new energy technologies that include hub motor drive systems, providing more possibilities for future drivers. The eWheelDrive hub motor drive technology integrates independent motors into the two rear wheels of the car, replacing the engines and transmissions in traditional transmission systems and the mid-range generators used in electric vehicles, thus saving a lot of space.

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