Powertrain 2020 - The Future Drives Electric (PDF ... - Roland Berger

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42 | Study Battery charger When an EV or PHEV is hooked up to the external grid, a battery charger converts the single or three-phase AC supply to the right voltage level necessary for charging the battery. The AC – now at the right voltage level – is rectified through diodes into DC and smoothed out via capacitors. Chargers vary significantly in terms of their system specifications, weight and cost. Small chargers can weigh as little as 2.5 kg, while large ones with more than 4.5 kW power can add as much as 11 kg to total vehicle weight. Depending on the maximum power levels required for charging the vehicle, chargers can thus add considerable weight and volume to the powertrain system. Efforts are currently underway to combine the charging capabilities of the traction inverter with the battery charger in a single component, thus saving both costs and packaging space. Once realized, this achievement would represent a significant step forward, especially as the higher power levels needed for quicker battery charging are likely to make bigger chargers a necessity in the future. DC/DC converter The high-power battery in EVs and PHEVs also supplies power to the standard electric system in the vehicle. The DC/DC converter uses semiconductor switches, similar to those in the traction inverter, to convert the battery DC into AC.
43 | "Powertrain 2020 – The Future Drives Electric" It then transforms the high voltage level down to the requested level. In the final stage, the AC is rectified through diodes into DC and smoothed out via capacitors. Ultimately the DC/DC converter will render a "normal" lead acid starter battery unnecessary, as it can supply appropriate power to start the engine and operate the vehicle's internal grid. Depending on the voltages and exact system specification, the weight of the DC/DC converter can vary from approximately 2 to 4 kg. Generator inverter EVs with an ICE-based range extender need a separate generator inverter to convert the AC produced by the generator into DC for recharging the battery during driving. Even so, the functionality is very similar to the traction inverter in energy recuperation mode. Because generator inverters only work one way, as it were, they offer weight and cost advantages over traction converters. To summarize, power electronics for automotive applications are still in their infancy. They still show significant room for improvement in terms of their performance, size, weight, integration and production costs. Most past developments in the field of electric motors have focused on other applications and not taken the specific requirements of the automotive industry into account. This will no doubt change as EVs and PHEVs become more common on the market. To achieve even greater penetration of EVs and PHEVs, important developments are needed in the third major component of electric powertrains, the battery system. It is to this core component that we now turn our attention. 2.2.3.3 Battery system A number of different battery technologies exist at present. The lead acid battery, currently the standard vehicle battery, has been used to supply vehicle electricity for a number of decades. With the introduction of the first modern EVs in the 1980s, the need for more powerful batteries arose. Nickel-cadmium batteries were originally used, later replaced in hybrid vehicles by nickel-metal hydride batteries. However, none of these battery technologies provide the energy density required for sufficient driving distance in pure electric mode. The successful launch of Li-Ion batteries for consumer electronic goods such as laptops and mobile phones opened the door to further developments. These batteries are powerful enough to make EVs and PHEVs a viable alternative to today's standard ICE vehicles.
Page 1: Michael Valentine-Urbschat, Dr. Wol
Page 4 and 5: 2 | Study Contents Executive summar
Page 6 and 7: 4 | Study 1. High-power and high-en
Page 8 and 9: 6 | Study Introduction There can be
Page 10 and 11: 8 | Study These developments have r
Page 12 and 13: 10 | Study To achieve this ambitiou
Page 14 and 15: 12 | Study 1.2 Regulatory framework
Page 16 and 17: 14 | Study The Chinese domestic aut
Page 18 and 19: 16 | Study 1.2.2 Support for resear
Page 20 and 21: 18 | Study 1.2.3 Steering demand In
Page 22 and 23: 20 | Study 1.2.4 Authorities and lo
Page 24 and 25: 22 | Study In Japan, Honda's new mi
Page 26 and 27: 24 | Study Full hybrid powertrains
Page 28 and 29: 26 | Study Most of the technologies
Page 30 and 31: 28 | Study
Page 32 and 33: 30 | Study If most of the powertrai
Page 34 and 35: 32 | Study OEMs selling in the Euro
Page 36 and 37: 34 | Study PHEVs can take a number
Page 38 and 39: 36 | Study The new versions will mo
Page 40 and 41: 38 | Study For high-end application
Page 42 and 43: 40 | Study To follow the path of le
Page 46 and 47: 44 | Study But Li-Ion batteries hav
Page 48 and 49: 46 | Study The exact chemical make-
Page 50 and 51: 48 | Study Battery costs will mainl
Page 52 and 53: 50 | Study To summarize, battery te
Page 54 and 55: 52 | Study 2.2.3.5 Conclusions As w
Page 56 and 57: 54 | Study 3. Scenarios for the dev
Page 58 and 59: 56 | Study 3.2.1 Meeting customers'
Page 60 and 61: 58 | Study Model 2: "Like gas stati
Page 62 and 63: 60 | Study The first generation of
Page 64 and 65: 62 | Study 3.2.2 Attractive pricing
Page 66 and 67: 64 | Study Driver 3b: Battery price
Page 68 and 69: 66 | Study For all intents and purp
Page 70 and 71: 68 | Study Given these uncertaintie
Page 72 and 73: 70 | Study 4. Impact on the mobilit
Page 74 and 75: 72 | Study 4.2.2 Raw materials for
Page 76 and 77: 74 | Study At the same time, key Eu
Page 78 and 79: 76 | Study 4.4.1 Financial burden a
Page 80 and 81: 78 | Study 4.5 Infrastructure and e
Page 82 and 83: 80 | Study 4.7 Summary The coming c
Page 84 and 85: 82 | Study What does the story of t
Page 86 and 87: 84 | Study But, in addition to all
Page 88 and 89: 86 | Study Synthesis: Define your g
Page 90 and 91: 88 | Study Step 3: Define your posi
Page 92 and 93: 90 | Study > In early phases, autom
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92 | Study Implementation and timin
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94 | Study Co-authors Ralf Kalmbach
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96 | Study Co-authors Jesus Salvado
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Powertrain 2020 - The Future Drives Electric (PDF ... - Roland Berger

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