FEV：純電動(dòng)汽車的熱管理和能量?jī)?yōu)化-2024-11-技術(shù)資料

ThermalManagementand

EnergyOptimizationofBEVs

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

FCV

AGENDA

INTRODUCTION(MARKETTRENDS)

THERMALMANAGEMENTOVERVIEW

ENERGYCONSUMPTIONOFCLIMATESYSTEMSANDTHEIRINFLUENCEONTHEDRIVINGRANGE

BATTERYCONDITIONINGCONSIDERATIONSFORTHERMALMANAGEMENTSYSTEM

THERMALMANAGEMENTCALIBRATIONSTRATEGIESTOINCREASEENERGYEFFICIENCYSUMMARY

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

2

WeexpectanoveralllowerlevelofelectrificationintheUSthaninEurope&

China;multiplefactorscanaffecttheBEVtakerateineachofthescenariosFev

14.814.7

15%

24%

15%

10%

13%

11%

12%

17%

45%

35%

1%2%

63%

11%

10%

5%

Moderatetransformation

Salesinmillionunits

ZEVStatesICEban

180g/mi

15.215.0

42%

13%

12%

13%

20%

11%

2025203020352040

15.2

57%

11%

9%

6%

17%

2%

2%

1%

25%

4%

10%

2%

5%

88%

14%

10%

9%

15%

40%

73%

Acceleratedtransformation6)

Salesinmillionunits

ZEVStatesICEban

180g/mi

15.014.814.7

2025203020352040

LIGHTDUTY1)–POWERTRAINMARKETFORECAST

History

Salesinmillionunits

CO2fleet

emissiontarget

projection

◆

226g/mi

14.4

14.1

13.6

74%

12.9

84%

90%

80%

8%

7%

6%

8%

5%

2%

6%

6%

3%

1%

8%

1%

3%

6%

1%

3%

2%

16.0

94%

20192020202120222023

ICEonly&Stop/Start2)MildHybrid3)FullHybrid4)Plug-inHybrid5)BatteryElectricFuelCell

1)Class1&2aincl.BEVderivatives;2)Stop/Startand12Venergymanagement;3)12Vand48Vmildhybrids;4)Includes48Vhybridswithfullhybridfunctionalities5)Includesrange-extenderelectricvehicles;6)BasedonCO2reductiontargets,definedinthe“blueprintfordecarbonizationofUStransport”Source:FEV

3

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

HybridtransmissionsexpectedtobeclusteredintoDHTforFWD

applicationsandmodular(P2)configurationsforRWDapplicationsFev

14.814.7

15%

24%

15%

10%

13%

11%

12%

17%

45%

35%

2%

1%

63%

11%

10%

5%

Moderatetransformation

Salesinmillionunits

ZEVStatesICEban

180g/mi

15.215.0

42%

13%

12%

13%

20%

11%

2025203020352040

>Regulations,governmentpolicies,andcustomeracceptancewill

drivetheoveralldegreeof

electrificationintheUSmarket

>Hybridtransmissions

?Modular(P2)configurationswillcontinuetodominateRWDHEV

?Dedicatedhybridtransmissions(DHT)willcontinuetobeimportantinFWDHEV

>EDUwillcontinuetoproliferateinthefollowingarchitectures

?BEV/FCEV

?P4hybridapplications

?Rangeextenderapplications

LIGHTDUTY1)–POWERTRAINMARKETFORECAST

Acceleratedtransformation6)

57%

11%

9%

6%

17%

4%

2%

2%

2%

1%

25%

10%

5%

14%

88%

10%

9%

15%

40%

73%

Salesinmillionunits

ZEVStatesICEban

180g/mi

15.2

15.014.814.7

2025203020352040

ICEonly&Stop/Start2)MildHybrid3)FullHybrid4)Plug-inHybrid5)BatteryElectricFuelCell

1)Class1&2aincl.BEVderivatives;2)Stop/Startand12Venergymanagement;3)12Vand48Vmildhybrids;4)Includes48Vhybridswithfullhybridfunctionalities5)Includesrange-extenderelectricvehicles;6)BasedonCO2reductiontargets,definedinthe“blueprintfordecarbonizationofUStransport”Source:FEV

4

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

FCV

AGENDA

INTRODUCTION(MARKETTRENDS)

THERMALMANAGEMENTOVERVIEW

ENERGYCONSUMPTIONOFCLIMATESYSTEMSANDTHEIRINFLUENCEONTHEDRIVINGRANGE

BATTERYCONDITIONINGCONSIDERATIONSFORTHERMALMANAGEMENTSYSTEM

THERMALMANAGEMENTCALIBRATIONSTRATEGIESTOINCREASEENERGYEFFICIENCYSUMMARY

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

5

EVs’ThermalManagementSystem(TMS)becomecritical,mainlydueto

increasedrequirementsforcoolingcapacity,thermalcomfort

IMPLICATIONSOFTMSDESIGN/INTEGRATION

THERMALMANAGEMENTSYSTEMS

AREOFTENATTHESOURCEOFCUSTOMER

COMPLAINTS

TEMPERATURENOTACHIEVED,SLOWORNON-REPEATABLECHARGINGSPEED

THEINTEGRATIONOFANEFFICIENT

THERMALMANAGEMENTSYSTEMALLOWS

UPTO20%

RANGEINCREASEINCOLDCONDITIONS

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

ULTRA-FASTCHARGEWITHAPOWER(DC)OF270-350KWREQUIRESUPTO

30-40KW

COOLINGPOWER

SEVERALSUPPLIERSANNOUNCE

~

40%LESSPIPES

INTHEOVERALLTMSINSIDEVEHICLEWITHHIGHLYINTEGRATEDSYSTEM

6

Thethermalmanagementsystemofelectricvehiclesisresponsiblefor

controllingthetemperatureofdrivecomponentsalongwiththecabin

EVTHERMALMANAGEMENT–SYSTEMOVERVIEW

FCV

HVbattery

EDU1)

Power

electronics2)

ThermalManagementSystem(TMS)

Ambientair

Cabin

Heatflow

Heatingrequired

Coolingrequired

>Avehicle’sthermalmanagementsystemhandlestheheat

flowsbetweendifferentvehiclepartsand/ortheambientair

>Inanelectricvehicle,thedrivecomponentsrequirecoolingandthevehicle’scabintemperatureneedstobecontrolled

?Battery,EDU,&powerelectronicsneedtobecooledwhen

operatingunderhigherload/athighambienttemperatures

?Atcoldambienttemperatures,batterymayrequireheatingtooperateinoptimaltemperaturewindow&athighestefficiency

>BEVthermalmgmt.systemslargelydifferfromtraditionalICEsystems,astheICEhightemperatureheatsourceis

missing

?HeatpumporPTCheatergenerateheatforcabin(orbattery)heating

?Dependingonvehicleconfiguration,wasteheatfromdrive

components,cabinorambientaircanbeusedtoheatotherparts

>OEM’sarefocusedonoptimizingthermalmanagementconsideringthedirectimpactondrivingrange

7

1)EDU=ElectricDriveUnit(e-motor,transmission&inverter);2)On-boardcharger,inverter&DC/DCconverterandpotentiallyotherelectroniccomponentsSource:FEVCTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

Therequirementsfortheelectricvehiclethermalmanagementsystemare

influencedbyexternalandvehicleperformanceconditions

FACTORSAFFECTINGTHERMALMANAGEMENTSYSTEM

FCV

PARTIALLIST

EXTERNAL

CONDITIONS

ATMOSPHERICCONDITIONS

USESCENARIO/CONDITIONS

VEHICLE

PERFORMANCE

CONDITIONS

DISCHARGINGPOWEROUTPUT

CABIN

REQUIREMENT

EFFICIENCYOF

TECH.USED

CHARGINGPOWER

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

8

Hardwareselectiontogetherwithcontrolsdevelopmentandoptimizationarekeyto

maximizingsystemefficiencywhileconsideringpassengercomfort

SIMULATION&TESTINGMETHODOLOGY-THERMALSYSTEMFUNCTIONDEVELOPMENT

FCV

Heatpumpintegration

Activegrillshutter

Batteryconditioning

Powertraincooling

Thermal

efficiency

Cabincomfort

Wasteheatintegration

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

>Functiondevelopmentfor:

?Powertrain

e.g.fan,pump,valvecontrol

?Cabincompartment

e.g.compressor,HV-PTC,blowercontrol

?Tractionbattery

e.g.compressor,HV-Heater,pump,valvecontrol

>Requirementspecification>Interfacedefinition

>Softwaredevelopment

>Calibration(SiL,MiL,HiL)andsystemvalidation

9

FollowingtheV-modelprovidesasystemsapproachtothethermal

FCV

managementprocesstoarriveatoptimalperformance

THERMALMANAGEMENTDEVELOPMENTPROCESS

RequirementAnalysis

Systemsign-off

FCVDevelopmentProcess

ConceptDesign

ThermalManagement

VehicleTesting

1DSimulation

ComponentTesting

3DSimulation

Concept

Implementation

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

10

FCV

AGENDA

INTRODUCTION(MARKETTRENDS)THERMALMANAGEMENTOVERVIEW

ENERGYCONSUMPTIONOFCLIMATESYSTEMSANDTHEIRINFLUENCEONTHEDRIVINGRANGE

BATTERYCONDITIONINGCONSIDERATIONSFORTHERMALMANAGEMENTSYSTEM

THERMALMANAGEMENTCALIBRATIONSTRATEGIESTOINCREASEENERGYEFFICIENCYSUMMARY

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

11

Asregulationschange,testproceduresandoptimizationfocusneedto

adaptaccordinglytoaligneffortsforpotentialrangeimprovements

Testeffort

Higherofficialrangecanbe

achievedbyprovingefficient

vehiclesystemsvia

additionaloptionaltests1)

gAggressiveUS06Cycle

Hot35。CSC03Cycle

Cold-7。CUDDSCycle

HighwayHFEDScycle

CityUDDScycle

Regionalregulationsdefineprocedurescontainingmultipledrivecycles

includingoptionaltests

VEHICLERANGEDETERMINATION-THERMALMANAGEMENTANDINFLUENCEOF5-CYCLETEST

FCV

Drivingrangeis

primaryconsumerrequirementforBEVs

OptionaltestsMandatorytests

Labelrange

increase

Optionalbenefit

1)BasedonUSEPAapplicationdata

12

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

Fullunderstandingofoptionaltestconditionsiskeytodeterminingif

benefitsinrangearepossibleviaimprovedadjustmentfactor

FCV

SEQUENCES

SAEJ1634TEST–COLDCO&SC03

ColdCO

>Coldstarttestafterminimum12-hoursoakat-7°C>Chargingisnotpermittedduringthesoakperiodto

ensurebatterybeginstestatsoaktemperature>Defrostnotrequired,Recirculatenotallowed

>Utilizescolddynocoefficientsderivedatsame

temperatureastest

>TestcycleconsistsofrepeatedUDDScyclesat-7°C>Mandatory10-minutesoakafterfirstUDDS

>StartingforMY2025,onlytwoUDDSwillbeusedfor

rangedetermination

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

SC03

>35.0±3.0°Ccelltemperaturewithnorequiredminimumsoak

>Solarloadingprovidedondynoat850±45W/m2>Variablespeedcoolingfantobeusedfollowing

40CFR§86.161-00

>10±1minutekey-offsoakbeforeSC03

>A/CTemperaturesettingatfullcool(forautomaticsystemssetat72°F)

>Windowsclosed,fanspeedsettomax

?(clarifiedbyEPAinCD-2023-06fromJuly5,2023)

13

Dedicatedchassisdynamometertestingisneededtooptimizethe

calibrationthermalmanagementandenergyflowtomaximizeEVrange

VEHICLEDEVELOPMENTCENTER(VDC)

FCV

Dimensions

>2axleswith48”diametereach>FWD,RWDandAWDcapable

>Max.speed:200km/h(124mph)

>Wheelbase:1800mmto4400mm(71”to173”)

>Trackwidth:800mm(inner)to2330mm(outer)

>Max.weight:2500kg(5500lbs)peraxle>Max.Power:155kW(207HP)2WD

270kW(362HP)4WD

>12ft.highx14ft.widedynoentrancedoors

EmissionDriveCycles

>Alldrivecyclescanbeprogrammed(e.g.,FTP75,HWFE,US06,ColdCO,SC03,NEDC,WLTP,RDEwithgradesimulation,customerspecific,etc.)

Temperature

>-20°Cto+40°C(-4°Fto+104°F)

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

14

InthisCaseStudy,theimpactofthethermalsystemisclearlyevidentwith

~5.5%inoverallconsumption(~2.8%ofwhichcomesfromtheblower)

TOTALENERGYCONSUMPTIONDURINGSC03CYCLE,A/CCOMPRESSORANDDC/DC(LOWVOLTAGE)ENERGY

FCV

-5.46%

-2.81%

1.830

1.780

1.730

0.1300.132

0.1040.0910.086

TotalBatteryEnergyA/CCompressorEnergyDC/DCEnergy

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

>~5.5%ofSC03drivecycleenergyconsumptionrelatedtoA/C

usage

>~2.8%oftotalenergy

consumptiondifferencebetweenmax.blowersetting(asrequiredbyEPA)and‘a(chǎn)uto’setting

?EPAstatestheadjustmentfactor

takesthisintoaccountandhencerequiresmax.blowerforthe

regulateddrivecycle

mMax.blowersettingmAutoblowersettingA/Coff

15

Impactofcabintemperaturesettingonenergyconsumptionisclearly

evidentwith~7%additionalconsumptionfor-2。Frequestedtemperature

A/CCOMPRESSORPOWERWITHHVACSETTOAUTOATDIFFERENTTARGETTEMPERATURES(BLOWERONMAX.)

FCV

+6.67%+7.62%

1.1201.130

1.050

A/Ccompressorpower(kWh)

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

>EnergyconsumptionincreaseswithlowersettemperaturesoftheHVACsystem(asexpected)

?Ambienttemperatureandsolarloadingconstant

?HVblowerspeedsettingconstant

72F70F68F

16

Back-to-backUDDScyclesduringColdCOshowsignificantimpactofHVAC

forfirstfewcyclesvsremaining;improvementfromheatpumpalsoevident

HVACSETTO72FAUTO,ENERGYCONSUMPTIONBEHAVIORVSCYCLENUMBER

FCV

EnergyConsumptionperUDDSinColdCO

8000

7000

6000

5000

4000

3000

2000

1000

Wh

0

12345678910

UDDSNumber

VehicleAVehicleBVehicleC

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

>HighestenergyconsumptionduringfirstUDDS

?Drivenbyenergyrequiredfor

propulsionsystemandpassengercabinwarmup

>EnergyperUDDScyclestabilizesbetween2ndto10thUDDS

(dependingonvehicle)

>Highvariationofenergyisnotedbetweenvehicles

?HVACconsumptionforVehiclesA&BhigherthanVehicleC

?VehicleCisequippedwithaheatpump(insteadofPTCheater)

17

Rangebasedon2024regulations(10xUDDS,customAF)comparedto2025

(2xUDDS,standardAF)showsanimpactof4milesinrange

HVACSETTO72FAUTO,ENERGYCONSUMPTIONFOR2AND10UDDS

FCV

2024:

10UDDSusedforColdCOtesting

2025:

First2UDDSusedforColdCOtesting

Efficiency&Range

Efficiency&Range

City

Highway

Combined

City

Highway

Combined

488mi

464mi

477mi

488mi

464mi

477mi

193Wh/mi

203Wh/mi

197Wh/mi

193Wh/mi

203Wh/mi

197Wh/mi

AdjustedRange-Standard0.7AdjustmentFactor

AdjustedRange-Standard0.7AdjustmentFactor

334miles

334miles

AdjustedRange-ManufacturerAdjustmentFactor

AdjustedRange-ManufacturerAdjustmentFactor

338miles

334miles

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

>Nodifferencebetweenreportedcityandhighwayresults

?Basedon2cycleresults

>Individualadjustmentfactorabove0.7whenusingfirst10UDDS

?Individualfactorresultsin4milesofadditionalrange

>2UDDSresultsinadjustmentfactorof0.7andassociatedrangereductionof4miles

18

Energyconsumptionincreasesastemperaturedecreasesdrivenby

passengercomfort(cabinheating)

HVACSETTO72FAUTO,ENERGYCONSUMPTIONFOR2AND10UDDS,VEHICLEC(INCLUDINGHEATPUMP)

FCV

+2.81%

+2.71%

0°C(-7°C)(-20°C)

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

>Energyconsumptionincreasesastemperaturedecreases

>Higherconsumptiondrivenbycabinheating

?Heatpumpscanbecomelessefficientatextremecold

temperatures

OverallEnergyHeatEnergy

19

Detailedenergyflowanalysiscanidentifyhighconsumersanddrawfocus

onareasthatcanbenefitfromcalibrationorotheroptimization

ENERGYFLOWAT0°C

FCV

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

>Sankeydiagramisonemeanstovisualizetheenergyflow

20

Detailedenergyflowanalysiscanidentifyhighconsumersanddrawfocus

onareasthatcanbenefitfromcalibrationorotheroptimization

ENERGYFLOWAT0°CCOMPAREDTO-20°C

FCV

>Sankeydiagramisonemeanstovisualizetheenergyflow

>Higherusagesprimarilyfrom

?1:Heatpumpoperation(~9kWh)

?2:Batteryconditioning(~1kWh)

?3:Drivelinelosses(~2kWh)

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

21

Abatteryelectricvehicle’sdrivingrangecanbereducedupto40%for

extremeambienttemperaturesduetothermalmanagementneeds

AMBIENTTEMPERATUREIMPACTONRANGE

FCV

Vehiclerange[%]

0

20

40

60

80

100

?INDICATIVE

max.

evable

ge

max.

evable

<60%of

rangeachi

Maximumdrivingran

<70%of

rangeachi

Compressor&fansclosetomaximum

power

Lowheating/

coolingpower,

primarilyair

ventilation

Heatingload

Coolingload

PTCheaterand/or

heatpump&other

heating

componentsat

max.power

-20-10010203040

Ambienttemperature[。C]

1)Lossescanalsobesignificantlyhigher,“normal”conditions&typicaldrivecycleassumed

Note:Indicativeforstate-of-the-artBEV,butheatingandcoolingloadsstronglydependingonvehicleandoperatingconditionsSource:FEV

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

>HVACenergyconsumptionandthusBEVdrivingrangelargelydependsonambienttemperature

>Consumptionaround20。Cislowest,aslimitedheating/coolingisrequired

?HVACmightstillbeusedtomaintainairqualitythroughventilationanddehumidification

>Heatingloadstronglyincreasingatnegativetemperatures,maximumrangelossof~40%1)

?PTCheaterorpotentiallyheatpumpclosetomax.power

?Additionalheatingcomponentsrunning(e.g.heatedseats)

?Initialheatingofbatteryrequired(orbatteryoperatinginunfavorableconditions)

>Peakcoolingloadsslightlysmallerthanfor

heat,butcanstillaccountfor~30%rangeloss1)

22

FCV

AGENDA

INTRODUCTION(MARKETTRENDS)THERMALMANAGEMENTOVERVIEW

ENERGYCONSUMPTIONOFCLIMATESYSTEMSANDTHEIRINFLUENCEONTHEDRIVINGRANGE

BATTERYCONDITIONINGCONSIDERATIONSFORTHERMALMANAGEMENTSYSTEM

THERMALMANAGEMENTCALIBRATIONSTRATEGIESTOINCREASEENERGYEFFICIENCYSUMMARY

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

23

Batteryconditioningrequirements(andassociatedTMScalibration)can

haveasignificantimpactonrange

FCV

>Batterieshaveaverysmalltemperaturewindowofoptimaloperation

?Thermalmanagementiskeyforlongevityandperformanceofbatterypacks>Fastchargingisnotpossibleoutsideoptimaltemperaturerange

>Batteriesuseactivecoolingmechanismsduringchargingtoavoid

overheatingordamagetobattery

>Batteryandvehiclecabincanbeconditionedwithenergyfromthecharger

?Vehiclecabinisattargettemperatureatbeginningofthetrip

?Potentialofpre-conditioningisconsideredinJ1634(2021);thisstandardallowsoptionofpre-conditioningforColdCOandSC03testing(currentlynotincludedinexisting

EPAregulation)

>HVACandthermalmanagementsystemcanpre-heatbatterywhiledriving(e.g.whendestinationisfastcharger)

?Balancebetweenremainingdrivingrangeandenergyneededforconditioningrequirescalibration

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

24

ElectricDriveUnit(EDU)heatgenerationcanbeusedforbatterythermal

conditioning

Power[kW]

Temperature[。C]

14

12

10

8

6

4

2

0

Batt

eryPower

·······Fron

tHeatPower、

·······Rear

HeatPower

·······Syst

emHeatPower

350

300

250

200

150

100

50

0

60

50

40

30

20

10

0

-10

BatteryC

ellTemp.

——EndWind

ingTemp

——BatteryC——HVBatte

oolant-inTempyCurrent

r

VEHICLEISSTARTEDAFTERCOLDSOAKANDVEHICLEREMAINEDINPARK

FCV

>BothfrontandrearEDUsshowhigh

currentflow,althoughvehicleremainsatstandstill

Current[A]

>Convertertopologyallows400V

nominalbatteryvoltagetooperateatlowervoltageandconsequentlyboostthebatterycurrenttogenerateheatinthemotor

>Twophaseexcitationisusedtomaketherotorlockintomagmaticnorthwithnotorquegenerated

0120240360480600

time[s]

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

25

FCV

AGENDA

INTRODUCTION(MARKETTRENDS)THERMALMANAGEMENTOVERVIEW

ENERGYCONSUMPTIONOFCLIMATESYSTEMSANDTHEIRINFLUENCEONTHEDRIVINGRANGEBATTERYCONDITIONINGCONSIDERATIONSFORTHERMALMANAGEMENTSYSTEM

THERMALMANAGEMENTCALIBRATIONSTRATEGIESTOINCREASEENERGYEFFICIENCY

SUMMARY

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

26

Vehiclecontrols&calibrationcomplexityhaveincreasedsignificantlydue

totopologytrends(e.g.,numberofmachines,gearratios,etc.)

VEHICLECONTROLFUNCTIONANDCALIBRATIONDEVELOPMENT

FCV

20002010201520202025

Calibrationtaskswith

directconnectionto

Driver

PedalInputthermalmanagement

StabilityControls

Battery

Thermal

Management

PredictiveStrategies

Conditioning

ADAS/ADFeatures

Driver

PedalInput

Regenerative

Braking

CloudIntegration&Services

Multiple

ElectricMotors

Stability

Controls

Disconnects

Electric

Accessories

HighPower&

Bi-Directional

Charging

?

Howarethesecomponentsandcontrollerswiththeirindividualoperationandsafetyaspectstobecoordinatedandcalibrated?

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

27

EDUefficiencyisimpactedbytemperature;suchimpactsneedtobe

consideredduringvehiclecalibrationtooptimizeoverallsystemefficiency

LOADEDEFFICIENCYMAP–DIFFERENCEBETWEENWARMANDCOLDOPERATINGTEMPERATURE

BaselineFluid80°C-minus40°CEfficiencymap

8500

8000

7500

7000

6500

5000

4500

4000

3500

3000

2500

2000

1500

50100150200

250

300

350

MotorSpeed[rpm]

500

0

60005500

1000

MotorTorque[Nm]

CTISymposiumUSA15-16May2024,TomD'Anna,FEVNorthAmerica,Inc.

>EfficiencyoftheEDUdependsonoperatingtemperature

?Variouslosscontributors(churning,meshing,electricmotor,etc.),impactlossesatgivenoperatingpointseachwithtemperatureinfluences

>Thermalmanagementtogetherwithconsiderationofoperatingpointsrelativetocomponent

efficiencycanenhancecalibration

XUDDSHWFT

HigherefficiencyatLowerefficiencyat

80°C80°C

28

Calibrationofkeysystems(e.g.,lowvoltageconsumers,TMS,regen,charge

system)enabledarangeincreaseof15%alongwithMPGelabelimprovement

MCTTESTING,DYNAMICPART1&2

Current[A]

CoolantFlow[l/min]

Speed[k