eMobility –
Passing the baton from fossils to electrons
Octavio Vargas, PhD
Program Manager, eMobility
Historical perspective – late 19th century
FOSSIL FUELS
1885
1) High energy density
2) Cost
3) No air pollution concerns
1
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Octavio Vargas
ELECTRIC
1899
Megatrends in mobility
Society
Technology
"Mobility for Tomorrow"
Biosphere
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Economy
Powertrain electrification driven by CO2 legislations
Powertrain concepts
CO2 legislation worldwide
Light vehicles
in g CO2
Light vehicle production
2%
Proposed target
Enacted target
USA: incl. light duty vehicles
260
1%
9%
19%
240
220
35%
200
180
98%
160
140
80%
USA: 107 g
in 2025
China: 117 g
in 2020
56%
120
Japan: 105 g
in 2020
100
EU: 95 g
in 2020
80
60
2000
Combustion engines
2005
2010
2015
Schaeffler Symposium 2014
2020
2020
Hybrids
2025
Source: : IHS 2013; University of Duisburg-Essen 2012
Source: icct 2013
3
2013
EU: 68-78 g
in 2025
Octavio Vargas
2030
Electric
Powertrain electrification driven by CO2 legislations
Powertrain concepts
Light vehicle production
2%
1%
9%
19%
35%
98%
80%
56%
2013
Combustion engines
2020
2030
Hybrids
Source: : IHS 2013; University of Duisburg-Essen 2012
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Electric
44%
Powertrain electrification – Schaeffler's roadmap
Powertrain concepts
Light vehicle production
2%
1%
9%
19%
35%
98%
80%
56%
2013
Combustion engines
2020
2030
Hybrids
Source: : IHS 2013; University of Duisburg-Essen 2012
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Electric
P2 – hybrid module
Between engine and transmission
+
-
P2-hybrid module 1st generation
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Hybrid Module 2nd Gen with dry clutch
Hybrid module 2nd gen with integrated
electronics
P2 – hybrid module 2nd generation
Reduced axial space by 17 mm
Electrical sailing up to 100 miles/hr
Applicable to all types of transmissions
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Hybrid electric drivetrain architectures
Micro
Micro
Mild
Full electric
Plug-in
Range extender
*
Parallel
Serial
 Widest range of applications
 Based on known drivetrain technologies
 Only one E-Motor is needed
Power split
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*
Hybrid modules
Hybrid
Micro
Mild
Full
Plug-in
Range extender
Parallel
Hybrid – modules
Modular solutions for all levels of hybridization!
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Powertrain electrification – Schaeffler's roadmap
2%
1%
9%
19%
35%
98%
80%
56%
2020
2013
Combustion engines
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Octavio Vargas
2030
Hybrids
Electric
Product portfolio electric axle systems
48V
CO2 potential / functionality
HV
Low power
electric axle
2-speed
electric drive
2-speed electric
drive (parallel axis)
Mini hybrid vehicles (48V)
Regeneration
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Mechanical torque
vectoring
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Degree of electrification
48V axles – why 48volts?
Reduced safety
requirements
Higher power output
48V
12V
Smaller cable crosssections -> lower
current losses
Low cost system
HV
Up to 12 kW of traction power
~10-12% less fuel consumption
and CO2 emissions
New CO2 regulations
Low implementation costs
AFFORDABLE POWERTRAIN
ELECTRIFICATION
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48V axles – CO2 reduction potentials (e-segment car)
48 V Functions
12V Functions
1-speed
2-speed
CO2 Reduction [%]
-5
Start/Stop
-3
- 2.7
- 5.6
- 8%
+Smart
Alternator
(Delta between 12 V
and 48 V) = up to 7%
with additional
functionalities
-14.8%
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- 8.6
+eCreeping
(10 mph)
- 9.8
+eSailing
(ICE idle)
+eSailing
(ICE off)
Load point
shift
Front wheel drive
P2
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Rear wheel drive
P3
Octavio Vargas
eAWD
All wheel drive
P4 elect.
P0 – P3
All rights reserved to Schaeffler Technologies AG & Co. KG, in particular in case of grant of an IP right.
48V axles – vehicle architectures
Product portfolio electric axle systems
48V
CO2 potential / functionality
HV
Low power
electric axle
Mini hybrid vehicles (48V)
Regeneration
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Mechanical torque
vectoring
Octavio Vargas
2-speed electric
drive (parallel axis)
2-speed
electric drive
Degree of electrification
Hybrid vehicles
(HEV, PHEV)
Electric driving
Plug-in
charging
Mechanical TV
Electric vehicles
(BEV)
Zero emission
mobility
New vehicle
concepts
Electric axle drive gen III – HV system
Traction
motor
2 speed
transmission
Technical Data
Spur gear
differential
Weight
ca. 60 kg
Power output
65 kW
Dimensions
 230 x 423
Maximum torque
2000 Nm
Maximum speed of vehicle
> 260 km/h
Customer benefits
o Compact coaxial electric transaxle
o Modular system 1- or 2-speed
o Suitable for HEVs and BEVs as well
o Good scalability of power level
o Customer tailored scope of delivery
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Torque vectoring – basic configuration
TV-Transmission
Transmission
Differential
Traction Motor
TV-Motor
60 kW
6kW
Traction Unit
Traction
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+
TV-Unit
Torque Vectoring
Torque vectoring system
Traction [Nm]
60kW 6kW
2000 Nm
33kW 33kW
TV [Nm]
-2000 Nm
2000 Nm
-2000 Nm
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70kW 70kW

Torque vectoring – benefits
High comfort
Improved traction
Dynamics & safety
Steering support
AD
AD
AD
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AD
Electric axle drive gen III with torque vectoring
TV electric
motor
Gear shifting
actuator
Traction electric
motor
TV power electronics
Actuator control unit
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eAxle – modular concept
65 kW
Electric motor (scalable)
1 Planetary gear set
2 Planetary gear set
Spur gear differential
Transmission actuator with ECU
Torque vectoring unit
Other components
2 speed, TV
65 kW
1 speed, N
2 speed, N
1 speed
85 kW
1 speed, N
2 speed, N
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1 speed
Powertrain electrification – Schaeffler's roadmap
Powertrain concepts
Light vehicle production
2%
1%
9%
19%
35%
98%
80%
56%
2013
Combustion engines
2020
2030
Hybrids
Source: : IHS 2013; University of Duisburg-Essen 2012
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Electric
Customer benefits
Usable space
In-wheel drive train
Safety
High control quality
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Maneuverability
Extended steering angle
eWheel 2nd generation: prototype cross section
Power electronics
Friction brake
Motor
Liquid cooling system
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eWheel – exploded view
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Powertrain electrification
Schaeffler's solutions
2%
Combustion engines
Hybrids
Electric
1%
9%
19%
35%
98%
80%
56%
2013
26
2030
2020
HYBRID MODULE:
eAXLE:
eWHEEL:
• Modular Concept
• 15-30% FE
• P2 configuration
• 48V or HV variants w or w/o TV
• Coaxial / in-parallel design
•1-speed / 2-speed configuration
• Innovative product
• Integral compact design
• New vehicle configurations
Schaeffler Symposium 2014
Octavio Vargas
‟
It is not the strongest or the most
intelligent who will survive but those
who can best manage change.
”
Charles Darwin
1809 - 1882