전기자동차및전기구동부품기술동향 -...

14th . October. 2010

( , Sang-Yong Jung )

Applied Energy Mechatronic System Lab.

( [email protected] www.aems.kr )

Dept. of EE, Dong-A University

- Technical Trends and Perspective on EV and Electric Propulsion Parts -

IT KOREA 2010 - IT

2

Trend and Perspective on Environmental Vehicle1

Technical Trend on Electrical Vehicle Development2

Key Component Technologies in Electrical Vehicle3

R&D Strategy for EV & Electric Propulsion Parts4

Outline

3 Trend and Perspective on Environmental Vehicle

1

5

(1), (2), (3), (4), (5), (6)

, 5

4

Climate Change /

Global Warming

Trend and Perspective on Environmental Vehicle

2 Global Environmental Issue

5

3 Environmental Vehicle Classification

Cla

ss

Hybrid Electric

Vehicle( HEV )

Plug-in Hybrid Electric

Vehicle( Plug-in HEV )

Electric Vehicle( EV )

Fuel Cell

Electric Vehicle( FCEV )

Stru

ctu

re

Chara

cte

ristic

Improving the fuel

efficiency by optimal driving

with the best torque

combination of ICE and

Motor according to the

various types of operation

Chargeable battery through

external power, combined char

acteristics between the hybrid

vehicle and the electric

vehicles

Only using the charged electric

energy without the assistance

of an internal combustion

engine

Replacing the existing internal

combustion engine into the

fuel cell which converts

hydrogen to electric energy

Motorgenerator

battery

Fuel Tank

engine

power

Power

(No engine)

HydrogenTank

Fuel Cells

(No engine)

Environmental Vehicle : A vehicle reducing the exhaust by reducing the oil or using the new energy


Engine+Motor (assistance)

Battery 0.9 ~ 1.8 kwh Battery 4 ~ 16 kwh Battery 10 ~ 30 kwh Battery 0.9 ~1.8 kwh

Only motor drivingAvailable motor-only driving Electricity generationby Hydrogen / oxygen

Motorgenerator

engine

batterybattery

Motorgenerator

Motorgenerator

Assist.battery

Fuel Tank

6 Trend and Perspective on Environmental Vehicle

Classification HEV PHEV EV

Configuration

Driving Characteristics

Control

EV Limited EV Driving Optimal EV Driving Control Strategy

HEV Engine/Motor Optimal Power Blending Strategy -

BMS Sustaining (Within SOC Range)Charging + Depletion +

SustainingCharging + Depletion

H/W

Battery Batt. Batt. ~ Battery Battery

Charging w/o Vehicular Charging System

Battery

Engine

Motor

Gas

`

TM

Clutch

Wheel

Wheel

Wheel

Wheel

FD

Charger

Battery

Engine

Motor

Gas

`

TM

Clutch

Wheel

Wheel

Wheel

Wheel

FD

Charger

BatteryMotor`

Wheel

Wheel

Wheel

Wheel

FD

ReductionGear

SOC

Distance

Sustaining

modeDepleting

mode

RCD

SOC

Distance

SOC

Distance

Recharge

7

4 Paradigm Shift of Automobile Industry


8

EV1

FCHEV

ISG Soft Hybrid Full Hybrid Plug-In HybridPlug-In Range

Extender EVEV/FCHEV

- Engine start-

stop at idle

- Engine off on

deceleration

- Mild Regen.

Braking

- Electric power

assist

- Full Regen. Braking

- Engine cycle

optimization

- Electric launch

- Limited pure

electric drive

- Engine downsize

- Plug-in

rechargeable

- More electric

drive during

charge- depletion

- Reduced refueling

- Full-function

electric drive

- Initial pure

electric range

- Significantly

reduced refueling

- Plug-in recharge

only

- 100% pure

electric range

- No refueling

- +2~4% - +10~20% - +30~50% Cars

- +20~40% Trucks

- +100% in charge

depletion

- Same as full

hybrid afterward

- Electricity only

in EV range

- Same as full

hybrid afterward

- Electricity only

Functio

nality

Fuel Ec

onom

y

5 Classification of Environmental Vehicle


9





Outline

10

1 HEV (Hybrid Electric Vehicle)

Define HEV is using more than two kinds of power sources

(Engine + Electric Motor)

Config.

Series-Type Parallel-Type Series Parallel-Type

Features

Fuel Economy Implement Driving Performance

Idle StopEnergy

Recovery

High

Efficiency

Operation Control

Total

EfficiencyAccel.

Continuous

High Output

Series-type

Parallel-Type

Series Parallel-Type

: Excellent

: Superior

: Unfavorable

Technical Trend on Electrical Vehicle Development

11

2 PHEV (Plug-in Hybrid Electric Vehicle)

Define

Increased battery capacity Increased Driving distance

Improved operation time and high performance of EV (Electric Vehicle) mode

Reducing to emission, Improved fuel efficiency

Features

EV Drive : Engine stop, only motor operating by electric energy stored in battery

Plug-in : Plug installed for charging high capacity battery in vehicle

Extended Range : Expended EV drive range by external charging

Grid Connection State of Charge


12

3 EV (Electric Vehicle)

Define Operated only by electric energy stored in battery (pollution-free environmental car)

Features

Using a external (re)charge Store the energy in battery (Need high-capacity battery)

Driving range per once charge is an important performance index

(Operation until SOC depletion)

Charging time (normally or rapidly) & Expansion of infra-structure are important

Grid Connection Charging Technology


13

Mitsubishi - i-Miev Nissan Leaf

Renault Fluence Hyundai i-10

Overall Size : 3395*1475*1600 mm

Max.Speed : 130 km/h, Range(10-15 Japan) 160km

Motor(PMSM) : 47kW, Charging Time : 7hr(30min, Fast)

Battery : Li-PB, Voltage 330V, Energy 16kWh

Overall Size : 4,4451,7701,550 mm

Max.Speed : 130 km/h, Range(10-15 Japan) 160km


Battery : Li-PB, Voltage 330V

Overall Size : 4,8201,8821,520 mm

Range(10-15 Japan) 160km


Battery : Li-PB, Voltage 330V

Overall Size : 3565 X 1595 X 1550 mm

Max.Speed : 130 km/h, Range 130km


Battery : Li-PB


14

4 FCEV (Fuel Cell Electric Vehicle)

Define Operated by electrical power generated by chemical reaction of hydrogen and oxygen

Configuration of FCEV system Classification of FCEV

Pure Combined Reformer

Simple system

Following Load type

Fuel-Cell covers

full power operation

in all driving mode

Efficient driving

High efficiency operation of fuel cell

Regenerative braking by storing energy in Aux. battery

Available conventional fuel and infra-structure

Vehicle installation

and package problem

Features

Fuel Hydrogen, Methanol, Gasoline(Needing a reformer)

Energy Efficiency ~ 60% (Internal combustion engines : ~ 30%)

Emission Level ZEV(Hydrogen), Equivalent ZEV (Methanol, Gasoline)

Infra Hydrogen charging Infra need (Gasoline, Methanol uses established infra)


15 Technical Trend on Electrical Vehicle Development

5 EV System Configuration

16

6 Market Trends of Electric Vehicle

EV

- 09

-

- 10 10~200


: Lgeri

EV EV

17

7 World Leading Maker - Mitsubishi / Renault / Nissan

Mitsubishi Nissan Renault

i - Miev LEAF FLUENCE

460

( 3690)

376

( 3660)

'09 7 '10 '11

4 5 4

3,3951,4751,600 4,4451,7701,550 4,8201,8821,520

47kW 80kW 80kW

7

( 30, 80%)

8

( 30)

8

( 20)

160km

130km/h 140km/h


18

Government policies of Electric Vehicle Dissemination (10.8~)

- KEPCO signed the MOU for building-up EV Charging infrastructure

- Test drive is being held around capital area and Jeju island

Hyundai Motor Company

Vehicle Light car

Drive Distance 130 [km]

Charging

Time

Normal 7 [h]

Rapid 0.5 [h]

Maximum Speed 130 [km/h]

Motor 50 [kW]

Battery Li-PB

PrimaryTechnique

Infra.

Highly-efficientbattery

normal/RapidCharging-skill

Need charging infra.

8 Domestic Electric Vehicle Makers [1]


19

9 Domestic Electric Vehicle Makers [2]

Maker Model Image Performance Features Note

GM

DaewooVolt

- 111kW

64km

110V : 8

240V : 3

-55

(P-HEV)

1000km

2011

Renault

SamsungFluence

- 70kW

: 8

: 20

160km

4.8m

(EV)

, (3)

2011

Maker Model Image Performance Features Note

CT&T e-Zone

- 60km/h

70~110km

4(220v)

2

1000

,

AD-TECS AURORA

- 60km/h

60~70km

4~6(220v)

72v

5.5kW BLDC

2

,

SGK

- 50km/h

80~100km

4(220v)

2

1 2

PMDC

PMDC->ML( ) BLDC


http://cfs9.tistory.com/upload_control/download.blog?fhandle=YmxvZzY2Nzg4QGZzOS50aXN0b3J5LmNvbTovYXR0YWNoLzAvMDEwMDAwMDAwMDAwLmpwZw%3D%3D

20





Outline

21

1 Major Components and Technologies in EV

Key Component Technologies in Electrical Vehicle

High efficiency heating

and cooling technology

Regenerative braking

technology

Rapid charging

technology

High efficiency / Low price

inverter technology

High efficiency / Low price motor technology

High efficiency decelerator (1,2 step)

High energy / Low price

battery technology

Connection technology of

battery trays and platform

High efficiency / Low price

charging technology

Home power supply

[220V]

22

Motor / Battery / Inverter

key-component & technology

of electric vehicle

Hybrid

Motor,Inverter

High Performance

Battery

Battery

stack

charging,infra

Plug-inHybrid

Fuel Cell Electric Vehicle

Electric Vehicle


Internal

combustion engine

Rapid

Charging

Hybrid Plug-in Hybrid FCEV EV

Motor/

Inverter

Mass Production available




BatteryMass Production

availableHigh Performance

BatteryProduction available

High performance Battery and Rapid

charging technology

Infra Not necessary In-House charging infraHydrogen charging

StationsPlug-in infra and Rapid charging technology

Power -train

Existing internal combustion engines

technology

Existing internal combustion engines

technology

Stack Cost Reduction Technology

Not necessary

Practical Level middle A long time to achieve

Component Technology sharing

23

Electric Motor for Toyota RX400h (HEV)

- (Prius II) 2.4

= : 6000rpm 12400rpm

= : 500V 650V

- 2

RX400h HEV RX400h HEV

S

N

S

N

N

N

S

S

,

2


24

Electric Motor for Toyota Prius (HEV)

38km/l

- 2 6,500rpm 13,900rpm

- 50kW 60kW

- (30% ), 2 Segment ( )

Prius Prius


25

Electric Motor for Honda Insight (HEV)

- Side Member, Radiator Core Support, Toe Board Dash Upper

Civic HEV 15kW 10kW

- 22%, 15%

22%


26

/

1. .

2. .

3. .

4. .

5. .

, , ,

3


27

4

MCU

,

,


28

5

TOYOTA Mitsubishi, Infineon, TOYOTA

PRIUS

II

A

B

C

DC/DC (A) DC/DC

AC (B)(C)

DC/DC

DC/DC

IGBT , DC IGBT


29

PRIUS

III

DC/DC

PCU

Boost Voltage 650 V

Motor max rotation speed 13000 rpm

Motor max output 60 kW

Max Total Output 178 KVA

Generator max current 88 A

Motor max current 170 A

Weight 13.5 kg

Volume 11.2 L

PM DC


30

HONDA TOYOTA

Civic IPU Unit Intelligent Control Unit

,

Reliability

Power Control Unit Battery Unit

, 101V -> 158V

Inverter Block Diagram


31

Artwork

1. .

2. .

3. .

4. .

5. .

Firmware

, , ,

6


32

EV

2015 1.7, 2020 8.6

2020 2015 5

2010 2020 79.2%

< >< >

1980~1990 : 20~30%

- LS : 30~40%

- : , , , ABB, ,

- 2007 3,161 (2003 60% )

(2003~2007) 12.6%

2004(163 90), 2008(250 105)

0

50,000

100,000

150,000

200,000

250,000

300,000

350,000

2003 2004 2005 2006 2007

196,612209,796

226,945

274,008

316,111

0

500

1,000

1,500

2,000

2,500

3,000

2004 2005 2006 2007 2008

1,6351,609

1,9821,891

2,1112,015

2,4722,250

2,503

2,096

0

2000

4000

6000

8000

10000

2009E 2010E 2011E 2012E 2013E 2014E 2015E 2016E 2017E 2018E 2019E 2020E

2010-2015 CAGR 131.9%

2010-2020 CAGR 79.2%

< PHEV EV >

6 25 80 207533

1,137

2,601

1,697

3,8585,278

6,799

8,630

: , (2009. 12, )

: (2009.10, )


33

7 In-wheel System

System : ,

System : , ,

In-wheel System In-wheel System

Knuckle & Carrier

- Stator & Rotor

- ( )

-

-

Wheel & Tire

-

- A/S

-

&

-

- //

Brake

-

- / /

- (Rotor) Weight Balancing

Hub & Bearing

- ,

- A/S


34

8 Market Trends of Battery

Market

Forecast

Battery for hybrid will occupy 50% in 2013 , Estimated about 75% in 2020

Lithium battery market will be growing more than 3.6 million cell

- Market share rate of lithium battery will be increased according to the EV market


( : )`

2 ( : )

* 2014 LiB EV 80% ( : )

35

2020

(, )


36

1

(2010~2011)

2

(2015~2018)

3

(2025~2030)

(/kWh)500~1,000 150~250 20~80

(1) 80~200km 250~300km 500km

2 4

(KWH) (km) ()

56 374 700~1200

23 175 500~750

13 87 150~200

, , /, BMS

, , , 1 ,

( 375kg )


37





Outline

38

/

2013

- 7,500

- ( 5, 59, 16)

- ( 24) ( 80)

2020 1 - 5

- 2,500

2014 1 -

- 10,000

2012 10

-

- 1,000

-

15 - 6, 5 ,

25

90

(2010)

-

- 25, 139

(2011)

10% (2015)

2014 4000

- 50% ( 2

-

R&D Strategy for EV & Electric Propulsion Parts

1

39

- 3 2014

- 2020 1

BlueOn i-MiEV

(mm) 3585*1595*1540 3395*1475*1610

(kW) 61 47

100km/h () 13.1 16.3

(kWh) 16.4 16.4

1 (km) 140 130

/

(/)6/25 7/30

(km/h) 130 130

BlueOn i-MiEV

2009 10,

R&D BlueOn

, ,

- (15 ) : 1(PHEV), (20 ) : 1(EV/PHEV)

- (20 ) : 1(EV), (20 ) : 5()

BlueOn

(2014)

15 10%, 20

20% 100 (2020)

- 50% (2012)

-

- ,

-

- (2011 )

- , 220 (2020)

- (2012)

- (2013)

2 (10.9)


40

(2012)

- 17 3 14

-

(2011)

-

2

- 20 1 2 , 1/5 2

(2011~)

- : 2.8 3.2kW/l(15), 85 92%(15)

- :

(2011~)

-

(2011)

-

- ( )

(2011)

- (5.4), (91%) ,

EV EV

3


41

10 ~ 11 :

11 ~ 12 :

13 :

(10~11) : ,

(11~12) :

(13) :

:

(11) :

(11~12) :

(13) : ,

:

EV :

: , (2011)

4


42

5

(, )

/ 4

Catch up

Leading

(PHEV )

,

, ,

EV

Technology

Infrastructure

Policy

,

, /

,


43

, ,

( 10% )

, ,

,

2009 ()

- : 6~8

(220V )

-

- :

- : 30

-

-

-

- : 2~3

-


44

/

- , 2011

AD -

- 2

- ZAP 2

- 2

CT&T - ,

- ,

2/ : LG, SDI, SK

: , , ,

,

-

- 2 4

BMS , - BMS

, ,

S&T,

- 08

-

//

PCU/

, , ,

LS,

- LG CT&T PCU(Power Control Unit)

-

/ - , , CT&T

-


45

ICE () PHEV

Engine 2,357 1,370

Transmission 1,045 625

Accessory Power 210 300

Electric Traction 40 1,542

Starter Motor 40 -

Electric Motor () - 893

Power Inverter - 528

Electronics Thermal - 121

On-vehicle charging system - 460

Other battery/storage battery

30 809

Fuel Storage 10 10

Accessory battery 20 15

Pack tray - 170

Pack hardware - 500

Battery thermal - 114

Total 3,682 5,106

PHEV incremental cost - 1,424

2030 System Component

: , (2009. 12, )


Hitachi, Toyota

GM(10~)

Toshiba

PCU Toyota

VW EV

Toyota, Honda

Denso

Meidensha EV , MMC

Panasonic,

2 Toyota, Honda

Sanyo VW(09~)

TDKDC-DC ,

Toyota, Honda

Nichicon

Toyota

Mitsui Hightec Toyota

Toyota

Toyota, Honda

Furukawa Toyota, Honda

EV

46

EV

6


'20 '09

46 2,201 97.1% '20 ,

'09 20

: EV 9 74 95.1%

14

HEVEV / () / () / / DC-DC / / /

/ / ( ) / Idling Stop System / / /

: Fuji Chimera Research Institute, Inc.(10.8)

47

TDK,

()

1/2, 30% () 20~30%

(09 10) (10 )

Hitachi, HEV

HEV

: + 4~8% : 10nm

30~50%

2011

,

HEV

880 ,

, (11~) ,

2015

, 95%

- , 2009 3

1 7

- , 2010 8

( : USGS 2009)

: 70%, : 95%, : 18/

, , ,

10 2 7976 72%

7000/

7 ()


48

Cost Down

- (Cost)

/

(/)

Close Open

8 Cost Down


49

9

1

2

(BPRM)3

,

, ,


Applied Energy Mechatronic System Lab.

Prof. S-Y Jung / http://aems.kr / [email protected]

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