[Due to the increasing size of the archives, each topic page now contains only the prior 365 days of content. Access to older stories is now solely through the Monthly Archive pages or the site search function.]
Continental producing 48V hybrid drives at Nuremberg plant; in use in Renault diesels by end of year
December 16, 2016
Continental’s new 48V hybrid drives are making their first appearance in series production vehicles. (Earlier post.) Manufactured at Continental’s Nuremberg plant, these first series-production 48V hybrid drives will be applied in “Hybrid Assist” diesel variants of both the new Renault Scénic and Grand Scénic models from the end of this year.
Just three years after the start of the project, the Nuremberg location developed a modular manufacturing concept that it uses to manufacture efficiently and in line with the cost structures of the volume market. To do so, the supplier invested around €15 million (US$15.7 million) in new production equipment. Using the currently installed equipment, up to 200,000 vehicles can be furnished with 48-volt drives.
Honeywell Transportation Systems Forecast: turbocharged vehicles to account for 48% of annual global sales by 2021; electric boosting emerges
December 09, 2016
Honeywell’s Transportation Systems Forecast projects that turbocharged vehicles will acount for 48% of annual global sales by 2021, up 9 percentage points from 2016. This annual sales estimate, combining both passenger and commercial vehicles, would add more than 232 million turbocharged vehicles globally between 2017 and 2021—an increase of 35% from today.
This year’s forecast recognizes an industry trend for slightly bigger engine sizes in Europe and China as automakers adapt powertrain strategies to tackle updated emissions regulations developed for real-world driving conditions. In these regions, a typical powertrain is a three- or four-cylinder engine with a displacement size between 1.2 liters and 1.7 liters. By rightsizing engines with available technologies, automakers are able to continue applying the benefits of smaller turbocharged engines while fine-tuning powertrain systems to further optimize fuel economy, emissions and performance.
Some Volkswagen strategists see battery-electric, diesel cost lines crossing by 2023-2025; TRANSFORM 2025+
November 22, 2016
The increasing stringency of global emissions standards, both current and projected, is driving up the cost for internal combustion engines to meet those standards, although numerous technology pathways exist. (Earlier post.)
In a conversation with Green Car Congress at AutoMobility LA last week, Dr. Matthias Erb, Executive Vice President of the NA Engineering and Planning Center, Volkswagen Group of America, said that, as a result of those pressures, some strategists in the Volkswagen Group project that the cost lines between battery-electric vehicles and diesel will cross within the coming decade.
ICCT: 2025 target average of 70 g/km CO2 for new cars in EU feasible and economical; more so with electric drive
A 2025 CO2 target of an average 70 g/km for new cars in the EU could be met with very little electrification and with an average payback period of less than 4 years, according to a new study by the International Council on Clean Transportation (ICCT). However, transitioning soon to electric drive could lower manufacturers’ compliance costs by as much as €500 (US$532) per vehicle in 2025.
Under current European Union regulations, average new car CO2 emissions must decrease from the present 120 grams per kilometer (g/km) to 95 g/km by 2021. Although no further reductions are presently mandated, new targets for 2025 and 2030 are under discussion in Brussels. In 2013 the European Parliament recommended an “indicative range” of 68–78 g/km for 2025, while holding out the possibility that even lower targets should be considered if justified.
ICCT-led analysis of turbocharged, downsized engine tech finds lower costs and greater benefits than 2012 EPA/NHTSA analysis; 48V, e-boost, Miller
October 31, 2016
A new white paper published by the International Council on Clean Transportation (ICCT), in collaboration with Eaton, Ricardo, JCI, BorgWarner, Honeywell, and the ITB Group, analyzes current turbocharged, downsized gasoline engine technology developments and trends.
The assessment, which relies on data from publicly available sources and data and information from the participating automotive suppliers, provides an update to the technology assessments performed by US Environmental Protection Agency (EPA) and National Highway Traffic Safety Administration (NHTSA) to inform the 2017–2025 fuel economy and GHG rule.
Mercedes-Benz powering ahead with €3B strategic engine initiative; increasing electrification, 48V; diesel and gasoline; cylinder deactivation
October 30, 2016
Following the launch of the new Mercedes-Benz four-cylinder OM 654 diesel engine in spring 2016 in the E 220d (earlier post), 2017 will see the addition of four more members to the all-new family of engines: six-cylinder in-line engines in both diesel (OM 656) and gasoline (M 256) versions; a new four-cylinder gasoline engine (M 264); and a new biturbo V8 (M 176) with cylinder deactivation. Mercedes-Benz is investing a total of around €3 billion (US$3.3 billion) in its strategic engine initiative.
The scaling of state-of-the-art technologies and electrification options from 12 V to 48 V to high-voltage plug-in applications makes it possible to configure the appropriate powertrain for every vehicle. There will be world premieres for new advanced technologies, such as the Integrated Starter-Alternator (ISG); the 48 V electrical system; and the electric auxiliary compressor (eZV).
Daimler subsidiary ACCUMOTIVE begins construction of second Li-ion factory; batteries for 1st EQ model, 48V systems
October 24, 2016
Daimler subsidiary ACCUMOTIVE has begun construction of a second Li-ion battery factory at its site in Kamenz. With an investment of about €500 million (US$545 million), the site in Kamenz will be one of the biggest and most modern battery factories in Europe.
The new production facility is planned to start operations in the middle of 2018. The area of about 20 hectares is located in immediate proximity of the existing battery factory in Kamenz, about 50 kilometers from Dresden. With the construction of the second facility, the production and logistics area will be quadrupled to about 80,000 square meters. The workforce will double by the end of this decade.
Continental puts first 48V hybrid assist system into production with Renault diesels
October 21, 2016
From the end of 2016, diesel variants of the Renault Scénic and Grand Scénic models will be equipped with Continental’s 48-volt hybrid drive—the first application of the 48V “Hybrid Assist” in production vehicles.
The first production solution combines an efficient, water-cooled induction motor with an integrated inverter. The electric motor transmits power via a belt drive directly to the crankshaft of the combustion engine—an arrangement referred to as “P0 topology.” Further production ramp-ups are soon to be set in motion on the basis of a modular system for 48-volt drives.
BMW plans hydrogen fuel cell offering “early in next decade”
October 13, 2016
Speaking on the future of powertrains at the Aachen Colloquium, Klaus Fröhlich, Member of the Board of Management at BMW AG, Development, said that BMW will enter the fuel cell market early in the next decade, starting with very small production runs.
Fröhlich noted that at least until 2025 costs will remain too high and the hydrogen infrastructure too sparse to allow broad-based market penetration. However, he added, “by the time the fundamentals are in place, the BMW Group will also have marketable products ready that are attractive to customers.”
Testing confirms Torotrak V-Charge variable drive mechanical supercharger enables more ambitious downsizing; 1.0L demo at Aachen
October 10, 2016
Independent on-engine test results have verified the simulation predictions that a Torotrak V-Charge variable drive mechanical supercharger enables more ambitious levels of engine downsizing. Compared to a current 1.5L GTDI engine producing 240 N·m torque, a 1.0L GTDI engine of the same Ford EcoBoost family outperformed the 1.5L version when fitted with a V-Charge unit.
The tests were carried out by the University of Bath Powertrain and Vehicle Research Centre (PVRC), using a Ford 1.0L EcoBoost engine, in a part-government funded program. The 1.0L engine with V-Charge delivered 250 N·m (184 lb-ft) torque, corresponding to a BMEP (Brake Mean Effective Pressure) of 31 bar.
CPT showcases full range of 48V systems at Aachen
Controlled Power Technologies (CPT) is showcasing its range of 48V systems at the Aachen Colloquium this week: its Cobra electric compressor, SpeedStart belt-integrated starter-generator, SpeedTorq drivetrain motor-generator, and TIGERS exhaust energy recovery system.
Two of the technologies feature in the ADEPT (advanced diesel-electric powertrain) demonstrator vehicle (in which program CPT was a consortium partner), which makes its first appearance in Germany following its debut at the recent Cenex Low Carbon Vehicle event in the UK. (Earlier post.)
Schaeffler presents high-performance 48V concept mild hybrid vehicle at Aachen
As part of the 25th Aachen Colloquium this week in Germany, Schaeffler is unveiling the “Schaeffler High Performance 48 Volt” concept vehicle. The 48V mild hybrid, based on an Audi TT, features an electric rear axle equipped with a 20 kW motor complementing the internal combustion engine which drives the front axle (P4 architecture). In the demonstrator vehicle, the engine is connected to a 48V belt-driven starter generator.
The Schaeffler electric axle produces a starting torque of up to 2,000 N·m. This provides purely electric driving up to 35 km/h (21.75 mph) as well as active sailing at speeds of more than 70 km/h (43.5 mph).
Valeo introduces new 48V e4Sport hybrid system; all-wheel drive
October 04, 2016
At the Paris Motor Show, Valeo introduced another 48V hybrid system, the 48V e4Sport. The new system, which can be applied across all vehicle segments, to both gasoline and diesel engine models, recovers a maximum amount of braking energy and stores it in a 48V battery for various uses, such as increasing engine torque, via the starter-generator, or maximizing engine power during acceleration and boost phases, using the electric supercharger.
The system also supports driving in all-electric mode and, when on low-grip surfaces, improving performance by connecting the rear axle to the 48V eRAD electric rear axle drive, effectively transforming the vehicle into a four-wheel drive.
Final testing confirms ADEPT 48V diesel hybrid reduces fuel consumption 10-12% at low incremental cost
September 13, 2016
The three-year ADEPT (advanced diesel-electric powertrain) project (earlier post) in the UK set the target of developing and validating a range of advanced mild hybrid technologies with 48V “intelligent electrification” utilizing an advanced lead carbon battery. These have been applied to a Ford Focus project demonstrator which, for the first time, will be made available for public ride and drive evaluation by delegates at the Low Carbon Vehicle event (LCV2016), at Millbrook, UK.
Final testing has confirmed ADEPT’s key achievement of 10-12% reduction in fuel consumption (NEDC)—equivalent to sub-80g/km of CO2 emissions. According to the latest updated analysis of the potential cost of production implementation of ADEPT—conducted independently by Ricardo—the system would represent an incremental cost of in the region of €60 per gram/km of CO2 reduction. This is a result that makes the ADEPT powertrain architecture very competitive with other fuel economy solutions such as full hybridization, where costs of implementation can be significantly higher.
Audi developing electromechanical rotary dampers; potential for energy recuperation from suspension; 48V
August 10, 2016
Audi is developing a prototype electromechanical rotary dampening system called “eROT,” in which electromechanical rotary dampers replace the hydraulic dampers used today for an even more comfortable ride. The eROT system also offers the potential for energy recuperation from the suspension.
Every pothole, bump, and curve in the road induces kinetic energy during compression and rebound of the car’s suspension, observes Dr.-Ing. Stefan Knirsch, Board Member for Technical Development at AUDI AG. “Today’s dampers absorb this energy, which is lost in the form of heat. With the new electromechanical damper system in the 48-volt electrical system, we put this energy to use. It also presents us and our customers with entirely new possibilities for adjusting the suspension.”
Advanced ADEPT 48V affordable mild hybrid on path to meet future ultra-low vehicle emissions
June 29, 2016
Following almost three years of testing, development and validation of advanced mild hybrid technologies with 48V electrification applied to a Ford Focus project demonstrator, the ADEPT (advanced diesel-electric powertrain) (earlier post) consortium partners have announced that the project is on course to meet the stringent air quality and ultra-low emission requirements expected of near-term next-generation vehicles.
The ADEPT project is led by Ricardo in a research partnership including the Advanced Lead Acid Battery Consortium (ALABC); Controlled Power Technologies (CPT); Faurecia Emissions Control Technologies UK Ltd; Ford Motor Company and the University of Nottingham. The final results will be presented at the UK’s LCV2016 event on 14-15 September.
Daimler investing >€7B in next 2 years in green tech; fuel cell plug-in, BEV architecture; 48V
June 13, 2016
At its TecDay event in Stuttgart, Daimler said it will invest more than €7 billion (US$7.9 billion) in green technologies in the next two years alone. Shortly, smart will be the only automaker worldwide to offer its entire model range both powered by internal combustion engines or operating on battery power. Mercedes-Benz will put the first fuel-cell-powered vehicle with plug-in technology into series production: the GLC F-CELL. In addition, the company is developing a dedicated vehicle architecture for battery-electric motor cars.
Following the company’s recent introduction of the new OM 654 diesel family (earlier post), Daimler will introduce a new family of gasoline engines in 2017, which will again set efficiency standards and will be the first ever to be equipped with a particulate filter (earlier post). The 48-volt on-board power supply will be introduced at the same time and starter-generators will become part of the standard specification. The 48V system will make fuel savings possible that previously were the exclusive domain of the high-voltage hybrid technology.
Project FEVER to develop 48V through-the-road hybrid vehicle technology; SRM-based e-axle
May 09, 2016
Controlled Power Technologies, a developer of vehicle driveline electrification based on state-of-the-art switched-reluctance machines (SRMs), has partnered with Ricardo, Tata Motors European Technical Centre (TMETC) and Provector to develop a 48V through-the-road hybrid vehicle system and demonstrate it in a B-segment city car.
The Forty-Eight Volt Electrified Rear-axle (FEVER) project will apply CPT’s SpeedTorq technology to an ultra-lightweight rear axle module to significantly improve the fuel economy of the target car. The objective of the two-year project is to achieve a CO2 reduction of up to 15% over the regulatory cycle while offering significant savings (around $1,400) in manufacturing cost compared to a full HEV.
Study: Combination of active and passive engine-off coasting delivers optimal fuel savings with 48V hybrid systems
April 13, 2016
A study by Germany-based automotive supplier HELLA found that the combination of active and passive engine-off coasting and recuperation using a 48V mild hybrid system shows the best potential to reduce CO2 emissions for all car segments, with the highest potential in the larger car segments, for both NEDC and WLTP (especially true for real world driving).
On the other hand, passive engine-off coasting alone showed no CO2 reduction potential for NEDC and some in WLTP according to the paper presented at the 2016 SAE World Congress.
Delphi unveils new 48V mild hybrid system; working with two OEMs toward production within 18 months
Delphi Automotive PLC unveiled a 48-volt mild-hybrid vehicle solution; the company confirmed it is working with two global automakers and could see production within 18 months.
Showcased in a Honda Civic 1.6-liter diesel vehicle at the company’s annual investor update in London, Delphi’s 48-volt, mild hybrid technology uses the 48-volt electrification to minimize the demand on the engine, improving performance while lowering CO2 emissions by more than 10%.
FEV showcasing 48V technology at 2016 SAE World Congress
April 08, 2016
FEV will showcase some of its 48-Volt technology capabilities at the 2016 SAE World Congress next week in Detroit. FEV says it believes that 48V technology will be the next evolution in in-vehicle power.
The proliferation of components and systems that require electrical power in today’s vehicle are pushing the standard 12-Volt battery to its limits. Under idle conditions and especially under low-temperature conditions, current 12V electrical systems can account for the entire power output of a conventional alternator, FEV notes.
A123 Systems opening new manufacturing facility in Czech Republic; support for increasing volume of 12V and 48V Li-ion systems
March 21, 2016
Li-ion battery manufacturer A123 Systems is expanding its operations in Europe by opening a new manufacturing facility in the Czech Republic city of Ostrava. The opening of the new facility is the result of a substantial surge in European market demand for low-voltage automotive products, a strategic focus of A123.
This European location will establish regional assembly of A123’s advanced 12V Lithium-ion starter battery and next-generation 48V battery and cost effectively support the growing market demand.
Audi SQ7 features new V8 TDI, 48V system, electric compressor
March 03, 2016
Audi is introducing a diesel-engined S model to its Q7 model line. The newly developed 4.0-liter V8 diesel delivers 320 kW (435 hp) and 900 N·m (663.8 lb-ft), with estimated NEDC fuel consumption of 7.4 liters of fuel per 100 kilometers (31.8 mpg US), corresponding to CO2 emissions of 194 grams per kilometer (312.2 g/mi). The SQ7 accelerates from 0 to 100 km/h (62.1 mph) in 4.8 seconds; top speed is 250 km/h (155.3 mph) (governed).
Among its features are an electric compressor with a supporting 48V subsytem that augments the work of the two turbochargers. Audi engineers will present a paper on the new V8 TDI at the upcoming Vienna Motor Symposium in April.
Pierburg GmbH electric compressor for turbos
February 24, 2016
Pierburg GmbH, part of the KSPG Group, has developed an electric compressor for spontaneously boosting the charge pressure of engines fitted with an exhaust-gas turbocharger. This component allows pressure to be increased regardless of the exhaust-gas energy availability.
The compressor is compatible with both gasoline and diesel engines. Initial prototypes are now being tested by various customers. The electric compressor fits in well and without any constraints with the proven strategy of downsizing, the company said.
CPT invests £1M to industrialize switched-reluctance 48V mild hybrid technology; new durability test cells
February 16, 2016
UK-based Controlled Power Technologies, a developer of vehicle driveline electrification technology, has invested £1 million (US$1.4 million) to further industrialize its CO2 and NOx reduction capabilities for the global automotive and transport industries.
CPT specializes in the safe low-voltage application of switched-reluctance machines (SRMs) to a vehicle powertrain and driveline, providing intelligent electrification of the propulsion system with near full hybrid vehicle capability. (Earlier post.) The £1-million spend will support seven projects at the company’s new technical center in Coventry and at its headquarters in Laindon. A significant proportion of the funding targets product and manufacturing process maturity by capital expenditure in new durability test cells at Laindon and a low volume manufacturing facility in Coventry.
ALABC: 48V mild hybrids can meet emission targets with CO2 reductions of 15-20%
January 27, 2016
Current mild-hybrid vehicle projects, in partnership with Ford and Hyundai/Kia, that utilize advanced 48V lead-carbon batteries, can reduce CO2 emissions by 15-20%, according to the latest data from the Advanced Lead Acid Battery Consortium (ALABC), presented at the Advanced Automotive Battery Conference (25-28 January, Mainz).
The T-Hybrid (based on a Kia Optima) (earlier post) and the ADEPT (based on a Ford Focus) (earlier post) both utilize an advanced 48V lead-carbon battery system with bolt-on electrical components that allow for significant engine-downsizing without loss in performance.
Lux: micro-hybrids will provide the most economical path for automakers to meet 2025 fuel efficiency targets
January 06, 2016
While battery-electric vehicles, super-light carbon fiber composites, and hydrogen fuel cells will all be available, a new report from Lux Research has concluded that micro-hybrids will provide the most economical route—$1,700 additional average vehicle cost—to meet aggressive fuel efficiency targets in 2025: 54.5 miles per gallon (mpg) in the US and 95 g CO2/km in Europe.
The Lux report—Building the Car of 2025: How to Cost-Effectively Get to 54.5 MPG Using the Right Mix of Advanced Technologies—concluded that nearly half of the improvements required to meet the targets will come from improvements in micro-hybrid technology, notably through improved batteries, while lighter structural materials will contribute 39% and improved fuels will add 13%.
Lux: 48V microhybridization could prove to be cost-effective means of achieving 2025 CAFE targets
December 21, 2015
Lux Research has built a bottom-up model for automotive innovation for fuel economy improvements to analyze the cost-effectiveness of all the various pathways for meeting regulatory fuel consumption and emissions targets.
The roadmap to reducing fuel consumption and emissions from the automotive sector has many options—including lightweight materials, increasing electrification, autonomy, and alternative fuels—but picking the right mix of options is tricky.