Conference on Future Automotive Technology

The small range of electric cars compared to cars with internal combustion engine is still one of the problems inhibiting the spread of these cars. Range extenders (RE) in general are the realistic possibility to increase the range of electric cars in the near future without the need to improve the technology of the main battery storage. This paper describes an alternative type of RE for electric cars. Its aim is to enlarge the range in special situations and not for the daily use. A stody [I] shows that a range of 100 km per dsy is suitable for 90 % of the dsily trips of a year in Germany. The electric car MUTE is designed to work as regional used car mainly for dtiving to work and for shopping. Range extension for a regional used car is necessary in special situations like dtiving around road works or traffic jams, which is the aim of this RE. Utilizing the zincair technology as RE makes a folly electric car with zero eruission feasible. This contribution shows that a zinc air RE with an energy content of 4 kWh and a peak power of 4 kW is feasible to increase the range of regional used electric cars even if the RE is activated at a state of charge (SOC) of the main battery which is below 10 %.

Since 2009 Heilbronn University has been investigating the specific needs of individual and commuter traffic for electric car operation in urbanregional areas. The plug-in battery-powered university research car has 26 lithium-based batteries, each with a capacity of 160 Ah and a voltage of 3.2 V. From approx. 11000 km of test drives with measurements and recordings of state variables like motor current or regenerative braking current it becomes clear that the available range allows reliable operation not only in urban, but also in mixed urban-regional areas. However, range remains an issue so that further research was started on additioual flywheel range-extending systems. The paper reports first resnlts of the flywheel system investigations. With a flywheel operation speed of 40 000 rpm basic effects of energy regeneration are investigated. Also, first resnlts of the investigations concerning flywheel dynamics on the vehicle dynamics are presented.

Mobility is a key challenge for sustainable development. Mobility can be blamed for an increasing world-wide oil demand, poor air quality in cities and accelerated CO₂ emissions. Electric vehicles seem to offer a way out of these problems, if electricity can be supplied in a sustainable fashion. What is the situation if the current German generation mix is assumed, what if the loading patterns are accounted for properly. In an extreme view a new electricity supply system only for cars is developed based on renewable energies.

A coming market segment of lightweight vehicles for urban mobility is bringing further challenges in terms of low weight and cost effectiveness. On system level, the usage of a low voltage system is desirable. A transverse flux permanent magnet motor design seems to be very well suited to provide high torque and power over a wide speed range at low weight, volume and production cost. A corresponding drive unit with integrated inverter has been developed for automotive application. The motors design and its operational behaviour will be discussed. A short description of the cost-effective manufacturing process is given.

Currently automotive technology is moving more and more from conventional combustion engines to hybrid and fully electrical power drives. The low battery capacity of conventional batteries causes small operating ranges and constrains electrical support in hybrid vehicles.

One possibility to increase the range of electric cars on top of energy recuperation during braking operations is to generate electric energy directly using a generator driven by a range-extender combustion engine. Continuous reduction of emissions and fuel consumption forces the application of supercharged combustion engines with low numbers of cylinders. However, this causes undesirable torsional vibrations even in hybrid and range extender concepts.

The pCPA-concept developed and engineered at the Technische Universitiit Miinchen (TUM) is a new type of pendulum-type absorber suitable for applications in highly downsized and downspeeded conventional powertrains as well as for hybrid and range extender combustion engines. The pCP A eularges the effective range of pendulum-type absorbers and improves the effectiveness and acoustical performance particularly in transient load states and in operational areas with low rotational speeds.

The developed powershift clutch system is electro mechanically actuated as required by using a ball ramp mechanism to transform rotational movement into axial load of the disc set. The integrated torque sensor allows control of the clutchs friction torque to realize start-up procedures or continuous slipping operations. By avoiding hydraulics as actuating media and so double energy conversion, it is predestinated for application in electro mobility applications. The developed system is the result of a joint project between the BMW AG, Kirstein GmbH Technische Systeme and the FZG.

Focus of this paper is on the advantages of additional transmission components in electric or hybrid drives for automotive applications. Having described the current challenges for electric mobility, the advantages of a more complex driveline topology are explained in detail by comparing first and second generation vehicles with regard to several customer relevant criteria. Some of the Schaeffler products for eMobility are highlighted with emphasis on their benefits for the global market.

The design of electric car concepts requires the development and integration of new components that have not been relevant in the design of conventional combustion-driven cars. High-voltage battery systems, electric powertrains, fuel cell systems and hydrogen storage systems for instance, are challenging with regard to an efficient package and design of constructed space. In addition, compromises between the functional and geometrical layout of these components, which determine the overall vehicle concept, are necessary. In respect of development of future electric vehicle concepts it is essential to know the interdependencies between the entire vehicle, its determining components and not least their underlying technologies. The first part of this paper presents the key components that determine the concepts for battery electric vehicles (BEV) and fuel cell electric vehicles (FCEV). Using the example of the BEV traction battery system, an approach for design and analysis of electric key components for a basic vehicle concept is introduced afterwards. In this context, a process model as well as dimensioning and construction tools based on MA TLABI Simulink and CATIA V5 have been developed and are to be explained in this paper.

This paper outlines the advantages of drive train architectures which allow free distribution of wheel torques on the rear wheel axle, so-called torque vectoring, with respect to driving dynamics. Electric cars open up new possibilities with regard to vehicle architectures. Utilization of the new degrees of freedom might lead to architectures with rear wheel drive and high rear axle loads. For conventional cars without counteractive measures, e.g. mixed tires, this would inevitably lead to inappropriate driving behavior. It is shown that such boundaries are no longer valid for electric cars with high rear axle load in com-bination with rear wheel drive and torque vectoring.

Changes in markets and technology of automobiles amplify the issue of fulfilling the requirements for as many customers as possible with a new vehicle concept. An increasing development of regional markets demands vehicle concepts or derivatives, which fit to the customer’s wishes and satisfy the regional specific needs.

The approach introduced in the present publication deals with the issue of regionally specific connections between the customer’s requirements and the technical concept’s characteristics and properties, especially in the early stages of the product development process. Because of spreads of requirements between several markets and thus varying technical solutions, goal conflicts in the conception occur. Therefore, different strategies are shown which enable a concept solution regarding complex product structores. In the area of conflicting interests between e.g. business relevant efficiency and customer relevant diversity, a way is shown how to develop successful products on several markets.