ECOCHAMPS – European Competitiveness in Commercial Hybrid and AutoMotive PowertrainS

This project has received funding from the
European Union’s Horizon 2020 research and
innovation programme under grant agreement
No. 653468
ECOCHAMPS
Dr. Simon Edwards

This project has received funding from the European
Union’s Horizon 2020 research and innovation
programme under grant agreement No. 653468
ECOCHAMPS - European COmpetitiveness in Commercial Hybrid and AutoMotive
PowertrainS
Coordinator: DAF Trucks (Guus Arts)
Consortium: DAF Trucks (NL), CRF (I), Daimler (D), FIAT Powertrain (I),
IVECO (I), MAN (D), Renault (F),
Tier 1 Suppliers, Research Institutes, Academic
Call: H2020-GV-04-2014 Hybrid Light and Heavy Duty Vehicles
Budget / funding: 28.6 M€ / 21.1 M€
Type of project: Horizon 2020 Green Vehicle - Innovation Action
Project number: GA-653468

Project consortium
Suppliers &
Services
Research
Partners

Project motivation
§ Increase the competiveness of European vehicle manufacturers and
component suppliers by gaining a leading position in hybrid powertrain
technology
§ Enabling a future business case for hybrid light and heavy duty
vehicles
§ Reduce CO2 emissions and improve air quality

Call expected impacts
§ 20% powertrain efficiency improvement
§ 20% powertrain weight and volume reduction
§ Maximum of 10% cost premium
§ Compliant with Euro 6 / Euro VI regulations

Approach
Improved fuel
economy
Extended
functionality
Standardization &
modularization
Optimal
specification
Actions Benefit Result
Increased market
penetration of
hybrid vehicles
Reduced cost
premium

ECOCHAMPS targeted key results
1. Modular system and Standardization Framework (MSF) for
commercial vehicles
2. Development of (pre-selected) electric hybrid components
3. Development of optimized and integrated powertrains
4. Demonstrate key innovations in five vehicles
5. Assessment of technology

Modular system & Standardisation Framework
§ Cost reduction through standardization of interfaces
§ Initial industry standardisation framework for heavy duty hybrid
electric components
§ Use of passenger car technology and know-how in heavy duty vehicle
applications

Standardisation benefits
§ Battery
§ E-motor & Inverter
§ DC-DC Converter
§ Electric Air Compressor
§ Electro Steering Pump
Standardisation benefits:
ü Scalable battery energy content
ü Scalable power output
ü Use passenger car technology
ü Support for multiple applications
ü Component weight reduction
ü Compatible voltage levels

Standardisation benefits
Benefit for OEMs Benefit for suppliers Benefit for end-users
§ Reduce development
and testing efforts
§ Higher volume base:
economies of scale
§ Better planning basis
for development
§ Support competition
§ Improved offer for
products
§ Reduced cost premium
§ Supports competition
§ Reduce component
and (proprietary)
development cost
§ Transferability of
solutions
§ Support scalability
§ Reduced validation
efforts
§ Supports competition

MSF implementation
Steering Pump (ECS)
ü Multiple applications
Battery (Bosch)
ü Scalable energy content
ü PHEV2 cell format
Air Compressor (Gardner Denver)
ü Multiple applications
ü Weight reduction
DC-DC converter (Bosch)
ü Scalable power output
ü 12 and 24V use
Battery (Samsung)
ü Scalable energy content
ü PHEV2 cell format
ü Passenger car parts

ECOCHAMPS Demonstrator Vehicles
Five demonstrator vehicles at TRL7 will realise project objectives as
well show the impact from standardisation
§ Five different topologies
§ E-drive capabilities
§ Increases in other functionality

Class B Hybrid Powertrain
§ Plug-in hybrid
§ P1f + P4 configuration
§ Downsized engine
§ Electric range >30 km
§ Electric AWD
Electric motor-
generator in place of
the standard alternator
Automated
Transmission
Li-ion battery pack for
>30 km EV range
Downsized 3 cylinder
gasoline engine
Front e-machine
inverter
Rear e-axle for performance
improvement, e4WD & EV mode
Rear e-machine inverter with
integrated DC/DC converter for
vehicle auxiliaries

Class C Hybrid Powertrain
§ 48V mild hybrid
§ P2.5 configuration
§ Downsized engine
§ Electric driving possible
Lithium Titanate
Oxide battery
E motor, oil cooled
1,2l turbo charged direct injection
gasoline engine with specific front
end accessory drive (no alternator)
15kW 48V
inverter48V to 12V 3kW
DC/DC
Battery air
cooling
7 gears Dual
Clutch
Transmission

Medium-Duty Hybrid Powertrain
§ Plug-in hybrid
§ P3 configuration
§ High speed e-motor
§ Electric range 20 km
§ Plug-in for DC and AC
§ Includes MSF based
components
Manual Gear Box
modified for special
Gear Shifter
Traction Inverter
DC/DC Converter
Electric Motor
Transfer Box
Helicoidal cylindrical Gear
with electro mechanic actuator
HV Battery
HVPD and Socket Inlet On Board Charger
In green: MSF standardised components

City Bus Hybrid Powertrain
§ Series hybrid
§ Modular concept
§ Passenger car based
e-motor and battery
§ Electric range 15 km
§ Includes MSF based
components
Electric air
compressor
Electric steering pump
Battery system
(passenger car technology)
Traction drive and generator system
(heavy duty technology)
Electric Heating Ventilation
and Air Condition HVAC with
heat pump system
DC-DC converter Electric cooling for
drive E-components

Heavy-Duty Hybrid Powertrain
§ Plug-in hybrid
§ P2 configuration
§ Passenger car based
e-motor and battery
§ Electric feedback WHR
§ Including MSF based
components
Hybrid module
(passenger car
technology)
Electric Waste Heat
Recovery
Battery system
(passenger car technology)
Electric air
compressor
Electric
steeringpump
Optimized thermal
system
DC-DC converter

Mid-term conference
Aachen, November, 2017
§ Three of the
demonstrators on
show

EUCAR conference
Brussels, November, 2017
§ Demonstrator
vehicle and poster
presentation

Achievements of the project (status M30)
Technical Target
Call expected
impact
CRF
Renault/
Daimler
IVECO MAN DAF
Powertrain Efficiency
Improvement
+20% vs.
SotA
+20% vs.
SotA
+20% vs.
Megane gasoline
+20% vs.
DAILY Diesel
+10% vs.
SotA
+20% vs.
DAF XF Diesel
Powertrain Weight &
Volume reduction
-20% vs.
SotA
+5% vs.
SotA w/o battery
-20% vs
SotA
-20% vs.
DAILY Electric
-10% vs.
SotA
-5% vs.
FP7 CONVENIENT
Hybrid Cost Premium
+10 vs.
Conventional
15-20% 10% 40%
-10% vs.
SoA
10%
Emissions level Euro 6 < Euro 6b < Euro 6b < Euro VI < Euro VI < Euro VI

Achievements of the project (status M30)
WP3
FIAT 500X
WP6
MAN Lion‘s City
WP4
Renault Megane
WP7
DAF XF
WP5
IVECO Daily
under
discussion by
calculation

Expected Impact
Impact assessments are on-going
§ For the MSF: final assessment and inclusion of new findings (Q1 2018)
§ On vehicle level: final validation witnessed by Golden Engineers (Q4 2017-Q1
2018)
After the project
§ Validation of proposed standards through standardisation organisations, EUCAR,
CLEPA etc.
§ Re-use of MSF requirements and procedure for new component developments
§ Use of results in other (EU) research projects
§ Vehicle industrialisation

ECOCHAMPS Final Event
Date: 12-13th April, 2018
On show: Presenting all demonstrators:
- Class B passenger car
- Class C passenger car
- Medium-duty truck
- City bus
- Heavy-duty truck
Location: The Netherlands, RAI, Amsterdam

This project has received funding from the
European Union’s Horizon 2020 research and
innovation programme under grant agreement
No. 653468
Thank you
for your
attention

ECOCHAMPS – European Competitiveness in Commercial Hybrid and AutoMotive PowertrainS

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