L'evoluzione delle propulsioni elettriche
e ibride nei veicoli industriali
Il punto di vista di Iveco
Marco Aimo Boot
Alternative Traction & Electrification Manager
Turin, Italy
April 22th, 2015
Contains confidential proprietary and trade secrets information of CNH Industrial. Any use of this work without express written consent is strictly prohibited.
European Mobility
Key Figures
URBAN POPULATION
Population in urban areas in 2012: 76% of the global population in
EU-27.
ECONOMIC IMPACT
The transport industry represents an important part of the economy:
in the EU it directly employs around 10 million people and accounts
for about 5% of GDP.
ENERGY USE
The energy consumed by transport systems in the EU-25 is around 32% of the
overall energy consumption
CLEAN TRANSPORT
The transport sector contributes 23% of all CO2 emissions
C02 REDUCTION TARGET
Emissions of CO2 should be reduced by around 60% by 2050 compared to 1990.
TRAFFIC CONGESTION
The urban congestion accounts for about 1% of GDP.
April 22th, 2015
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Urban Mobility
Trend
2010 Turnover
2025 Turnover
+46%
+ $ 4,5 Trillions
Urban Logistic
+230%
2010 Split
2025 Split
30%
70%
45%
55%
URBAN
LOGISTIC
LONG
HAULAGE
Source Frost & Sullivan
April 22th, 2015
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CO2 Legislation
Current scope
NOT YET
COVERED
(VECTO
over 2020?)
CO2 LDV
(Reg. 510)
3,5
N1
CO2 HDV
(VECTO Expected 2018)
7,5
N2
April 22th, 2015
GVW
(t)
12
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industriali
N3
4
Urban goods delivery
Electric Vehicles
The electric delivery service is not new…
1903 - Geo. Ehret's Hell Gate Brewery, N.Y.C Electric
April 22th, 2015
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Urban goods delivery
Electric Vehicles
Today, what is new?...
2014 – New Iveco Daily Electric MY’14 (3,5 – 5 tons)
April 22th, 2015
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Daily Electric MY’14
New components: design & validation
Gearshift
lever
Low voltage / High
voltage wiring
Human
Machine
Interface
Vehicle
Management
Unit
Recharge
Inlet
Chargers
Electric
Heater
Management
Battery
System
April 22th, 2015
Inverter
Pedestrian
Acoustic
Alerting
System
Traction
Batteries
Supercap
Electric
Braking/Steering
Pump
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industriali
Hybrid and Electric powertrain
Key elements
HV battery
pack
DC/DC
converter
ICE
Electric
motor
Transmission
Vehicle
Management
Unit (VMU)
April 22th, 2015
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industriali
Daily Electric MY’14
Line-up
Line-up
& Range
CAB
NEW DAILY ELECTRIC
35S
1/2/3 BATTERY + SUPERCAP
WHEELBASE 3000 – 3450 – 3750 – 4100
RANGE 70/150/200 km
VAN
1/2/3 BATTERY + SUPERCAP
WHEELBASE 3000 – 3520 – 3520L – 4100
RANGE 70/150/200 km
NEW
DAILY ELECTRIC
CAB
35C
1/2/3 BATTERY + SUPERCAP
WHEELBASE 3450 – 3750 – 4100
RANGE 70/150/200 km
CAB
2/3 BATTERY + SUPERCAP
WHEELBASE 3450 – 3750 – 4100
RANGE 130/180 km
NEW DAILY ELECTRIC
50C
VAN
2/3 BATTERY + SUPERCAP
WHEELBASE 4100 – 4100L
RANGE 130/180 km
MINIBUS
2/3 BATTERY + SUPERCAP
WHEELBASE 4100L
RANGE 110/160 km
April 22th, 2015
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Daily Electric MY’14
The Energy Storage System evolution…
NEW MY’ 2014
MY’ 2009
MY’ 2012
MY’ 2014
New Energy Storage with Supercap and
Battery (Z5)
April 22th, 2015
Battery (Z5)
Custom Sodium Battery (EV36)
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HV Battery development
Pack bench testing
BMS integration and SW application
Cell
April 22th, 2015
BMS
Vehicle testing
Battery packaging
Safety and durability testing
Multi-stage process
Cells bench testing
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Energy Storage System
Technological Roadmap
Source: Automotive Council Technology Group 2013
April 22th, 2015
L'evoluzione delle propulsioni elettriche e ibride nei veicoli industriali
HV Battery development
Electrical testing
Reliability & durability
Performance
Performance
Electrical performance of the
battery pack under different
electrical loads:
Energy and capacity
Power, internal resistance
Energy efficiency
April 22th, 2015
Functional
Reliability and
robustness
Life time testing and
estimation
Electrical functions:
Reliability and robustness: Accelerated test to estimate
standard and safety functions
deriving warranty concept:
the battery life:
Electric shock protection
Failure prediction
(statistic)
Overcurrent protection
On-board diagnosis
Environmental influence
Degradation
High power high
frequency cycling impact
Cycle life
Isolation resistance
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HV Battery development
Environmental Testing
Mechanical & thermal
effects
Mechanical Testing
Mechanical effect:
Random and SinusoidalVibration
Testing (proving ground and
benches)
Vibration of electronic devices
Climatic Testing
Climatic effect:
temperature, humidity cycle
Deep fording test
Chemical Testing
Chemical effect:
Salt corrosion
Temperature cycling tests
Chemical agents used for washing
and cleaning
Enclosure protection level (IP
degree)
Substances used for operating the
vehicle (oils, fuel…)
Humid heat, cyclic test
April 22th, 2015
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HV Battery development
Abuse testing
Mechanical & thermal
influence
Mechanical Abuse
Mechanical overload leading to
destruction of test sample
Thermal Abuse
Thermal overload leading to
destruction of test sample
Electrical Abuse
Electrical overload leading to
destruction of test sample
Crush and nail penetration test
Ramp and thermal stability
Overcharge / overvoltage
Drop test
Fire exposure
Short circuit
Salt water Immersion
Storage temperature
Overdischarge (forced discharge)
Roll-over simulation
Rapid charge/discharge
Partial short circuit
Mechanical shock
Thermal shock cycling
April 22th, 2015
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E-motor development
Characterization & validation
Isolated Machine
Checks
Phase resistance at known
temperature
Machine
Characterization
Torque control map
Efficiency map
Insulation breakdown voltage
(phases and sensors)
Max power performances
Assembly and component masses
Deflux map calibration
Cooling system flow rate
Spin & endurance
Test
Phase rotation and position / speed
sensor feedback
Phase balancing
Friction losses up
Rotor inertia (dynamic acceleration /
deceleration conditions) and integrity
at high speed
Torque against speed and ripple
Heat rejection to coolant system
April 22th, 2015
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Acoustic Vehicle Alerting System (AVAS)
Design – testing – validation
Manufacturers shall install AVAS in new types of
hybrid electric and pure electric vehicles by 1 July
2019 (New Homologation 1 July 2021).
Function
requirements
AVAS on-vehicle
characterization
April 22th, 2015
Sound design
Sound
application &
tuning
Measurement
and jury test
Final
assessement &
validation
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EV-HEV Simulation
Modeling & design
Key benefits:
Design logic for supervisory control in line with the product requirements, task
scheduling and fault management
Improve the realiability of the system by simulation before to launch the code
generation
April 22th, 2015
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Model-based Development
ISO 26262
Development of embedded systems is a time
and cost consuming procedure under
growing time-to-market and new quality and
the incoming safety Standards.
Requirements
Model-Based Development and autocoding of
safety relevant software is widely applied for
gaining efficiency.
Validation
Specifications
System test
Design
ISO 26262 specifically addresses Modelbased development and testing with
Autocoding to improve quality and ensure the
safety needs.
Model in the loop validation: Its aim is to
validate the specification before to autocoding
( the same test plan is assured on MIL and
HIL)
April 22th, 2015
ECU test
Implementation
CODE GENERATION
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Vehicle Management Unit (VMU)
Hardware-in-the-loop (HIL)
Programmable test bench used to verify the
control logics and algorithms executed in realtime in the Vehicle Management Unit (VMU).
The major benefits are:
• Test repeatability
• Test automation
• Possibility to simulate some dangerous
and complex vehicle manouvres
• Automatic reporting
• Fault injection analysis
• HW scalability
• Easy SW upgrade and modularity
April 22th, 2015
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Iveco solution for urban mobility
Dual Energy
A light commercial vehicle capable of selfadapting selectively to the more suitable energy
source, depending on the specific mission.
System includes two kinds of
traction:
electric mode, to ensure
zero emissions and low
noise pollution;
hybrid mode, (dieselelectric) suitable for longrange travel and suburban
missions.
April 22th, 2015
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Iveco solution for urban mobility
Dual Energy
pure
electric
mobility
April 22th, 2015
hybrid
mode
mobility
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Urban mobility evolution
Iveco «Vision» of the future
April 22th, 2015
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