This document discusses trends in electrification of vehicle powertrains and HAN's activities related to sustainable mobility. Some key points: - International automakers are developing hybrid, electric, and fuel cell vehicles in response to factors like rising oil prices and emissions regulations. - HAN is creating strategic alliances and participating in projects related to electrified powertrains. It incorporates sustainable mobility topics into its curriculum. - One example project is Hymotive, which developed a fuel cell power pack and controller for a forklift truck. - HAN plans to open an electric powertrain laboratory to allow hardware-in-the-loop testing and controller development for electrified vehicles.

1. The electrification of the
vehicle driveline
The HAN perspective
HAN Automotive op weg in
duurzaamheid
Bram Veenhuizen
May 28, 2009

2. JP Balkenende
(Autorai, 1 april ’09)
“Ik vind het doel wat u heeft, 1 miljoen auto’s in
2020 ontzettend goed. En je hebt zo’n stip
aan de horizon nodig. Ik ben er volstrekt van
overtuigd dat we die kant op moeten.”
In Zeist opent Elipo, een nieuwe
dealer in elektrische voertuigen,
op woensdag 27 mei officieel zijn
deuren. Herman Wijffels verzorgt
de openingsspeech.

3. Contents
Hybrid, electric and fuel cell drive trains:
trends and developments
– International automotive
– National automotive
– National energy companies
Consequences for Han University of applied
science
Where are we now? Hymotive project. See
also parallel session and student exposition
Future plans
Conclusions

4. HAN R&D activities on sustainable
mobility (visit afternoon sessions)
Alternative fuels
– Ethanol
– LPG
– …
Light weight vehicle design
Sustainable manufacturing, efficient use of
resources (C2C)
Hybrid, electric and fuel cell vehicles, electric
power components in the vehicle driveline

5. Trends and developments
Macro developments
– Oil resources are deminishing, demand increases
– Unstable oil price, political unstability in oil/gas supplying
countries
– Emissions have increasing influence on public health and
global warming
Consequences:
– CO2 legislation/ Euro 6
– Strict regulations for inner city emissions
– Tax incentives for cleaner vehicles
– Trend for smaller vehicles
Trends
– Niche players emerging for E-mobility
– Test pilots by OEM’s
– Major investments in battery and e-drive components

6. Mercedes / Daimlers’ view

7. Toyota’s view

8. The ICE – EM continuum

9. Honda Clarity Fuel cell vehicle
Proton exchange membrane stack
100 kW
3.9 kg H2 @350 bar
400 km range

10. Daimler – Mercedes
collaborates with Evonik, Tesla Motors en RWE
Blue Zero
E-cell: 200 km (Li-ion)
E-cell plus: 600 km with
1.0 l ICE from Smart
Fortwo
F-cell: 400 km with fuel
cell

11. GM-Opel prototype
Opel Ampera
(Chevy Volt)
Series hybrid with 1.4
l gasoline engine
60 km e-range
Over 500 km with
range extender

12. BMW
Collaborates with E.on
Pure electric vehicle
150 mi range
260 kg lithium-ion
battery pack, 35 kWh
95 mph
500+ on the road

13. Tesla Model S
300 mi range
Battery swap option
190 kph top
65 kWh
45 min. charge
option (480 V outlet)

14. Mitsubishi
with Peugeot/Citroën
i-MiEV
47 kW
RWD
16 kWh
130 km
130 kph

15. The Plug-In Hybrid, Toyota
Source:Toyota

16. Toyota Plug in Prius

17. Gemco
Series hybrid w/o batteries
Separate motors at each rear wheel

18. Superbus motors by E2M
Direct Drive
Two identical
motors, back
to back on
test rig

19. Drive Train Innovations
Hybrid power shift module

20. E-traction
Wheel hub motors

21. Duracar
Battery electric vehicle

22. Hytruck: fuel cell
range extender
Nedstack
Fuel Cell System
H2 tank: 400 km
Batteries, also charged from the grid
Electronics
E-traction in-wheel motors

23. Source: ATC

25. HAN automotive strategy towards
electrified powertrain engineering
Create strategic alliances with (regional) stakeholders:
HTAS, ATC, TNO, TU/e, PDE, Exendis, SMC, Nedstack,
E-traction, E2M, ECE, Duracar, Evisol, KEMA, TU/e,
TUD, HRo, authorities, Epyon, Friend, Essent, DTI,
Alphatron, Centurion, ECN, AGV,…
Participate in technology projects (example later)
Create own HIL testing environment (example later)
Research: modeling, power electronics, control,
electric machines, drive train, batteries, fuel cells.
Collaborate with electric engineering dept. on vehicle
to grid R&D.
Incorporate R&D in BaMa education: projects, lecture
examples, practical exercises, etc.

26. Sustainable Mobility Innovations;
a Learning Experience - SMILE
On top of regular education
emphasis on aspects like:
– C2C, w2w analysis, Recyclability,
Emissions regulations, etc.
– Sustainable Mobility projects
– Starting with first grade 25
students in 09-’09

27. PHBO power electronics
for hybrids/EV’s
onderwerp
Inleiding management systemen
Inleiding Hybride Systemen
Inleiding wisselstroom theorie
Inleiding filtertheorie met decibels etc.
Inleiding theorie 3 fasen systemen
Vermogenstransistoren (Bipolair, MOS, IGBT)
DC-DC conversie (choppers etc)
Practicum opdracht 1 Wisselstroom systemen en filters met
Multisim
DC-motoren met H-brug en PWM sturing theorie +
berekeningen
Practicum opdracht 2 Choppers etc.
AC-motoren/generatoren (Hoofdzaak synchroon, kort
asynchroom)
Practicum opdracht 3 DC-motoren
Frequentie omvormers, Inverters
Practicum opdracht 4 AC-motoren
Accu’s en Supercaps
Brandstofcellen
CAN en Flexray
Energie management
Casus of Simulatie

28. Some Results
Hymotive project (parallel session 1)
Hymotive: “hydrogen
implementation projects for
automotive SME’s”.
Fuel cell power pack for fork
lift truck
Controller hard- and
software for power pack
Hydrogen hardware in the
loop test facility
…

29. Fork lift power train layout proposal

30. Component sizing by simulation
0.08442
kg H 2
P P_EM P_in_FC P_in P_out P_in P_FC P_fuel kg H2
1.198 e+007
I Energy
Electrical power link Fuel Cell
U U _SC P_in_SC Energy [J]
Energy Consumption
E
PI control
Duty Cycle 1 FC + SC parallel
Battery
load U_SC P_SC
Detailed loss modeling
profile Scope 1 Supercapacitor • Resistive losses in the
supercapacitor modules
• Compressor losses
• Hydrogen pump losses
• Water circulation pump
losses
• Cooling fan losses
For more info: visit parallel session 1

31. Outlook
Electric Power Train laboratory

32. V-Cycle Product Development
System System
definition testing
ePT-LAB Scope
Data
acquisition, HIL testing,
Modeling and Controller
Simulation, testing
prototyping
Targeting &
Detailed design

33. HAN ePT-LAB
Consortium
Programmateam HAN Adviesbureau
Subsidies
Fuel Cell systems, Chargers, Converters, Motors, Transmissions
Batteries and Inverters, Chargers and
Energy Management Mechanical Systems
Projects Projects Projects

34. Conclusions
Electrification will play a major role in drive
train research, development, design, testing,
production, sales
Automotive engineers (mbo, hbo, wo) should
become knowledgeable about drive trains
with electric components and systems
HAN incorporates the electrified drive train in
its curriculum (Smile, PHBO electronics, etc.)
HAN carries out applied R&D in this field
Thanks for your attention