Nevio Di Giusto, AD Centro Ricerche Fiat

Mobilità sostenibile: la trazione elettrica, un’opportunità?
Nevio Di Giusto
Centro Ricerche Fiat & ELASIS
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Environment generates Changes
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Technology generates changes
FIAT mod. 3 1/2 HP (1899)
Delta (2008)
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500 (2007)
Bravo (2007)
Mobilità sostenibile: la trazione elettrica, un’opportunità?
Mito (2008)
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Adaptation to survive
It is not the strongest of the species that survives, nor the most
intelligent … but the one most responsive to change
Charles Darwin
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Global Warming
Source: IPCC Fourth Assessment Report, Climate Change 2007 (AR4)
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Carbon Dioxide Concentration
Source: IPCC Fourth Assessment Report, Climate Change 2007 (AR4)
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Perception and Reality on CO2 Emissions
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Critical Factors for the Automotive Industry
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Expectations from Technology
Technology Acceleration
Technology Level
Threat
Perceived Risk
Time
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Fiat Brand Positioning in CO2 Emissions
Brand
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Average CO2
(g/km) 2008
FIAT
133.7
PEUGEOT
138.1
CITROEN
142.4
RENAULT
142.7
TOYOTA
144.9
FORD
147.8
OPEL/VAUXHALL
151.1
VOLKSWAGEN
158.8
BMW
160.6
MERCEDES
185.0
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Important international acknowledgements
“Recently, Chrysler reached out and found what could be a potential partner -- the
international car company Fiat, where the current management team has executed an
impressive turnaround. Fiat is prepared to transfer its cutting-edge technology to Chrysler
and, after working closely with my team, has committed to build -- building new fuelefficient cars and engines right here in the United States.”
Source: The White House
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Ecological manifestos
Gasoline or a Methane-Hydrogen mixture powered
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Diesel powered
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Engine Technologies
THERMAL MANAGEMENT
ADVANCED HIGH PRESSURE
MULTIPLE DIESEL INJECTION
ENGINE DOWNSIZING
ELECTRONIC VALVE
CONTROL
ADVANCED ENGINE CONTROL
NEW GEN. TURBOCHARGING
DIRECT GASOLINE
INJECTION
HIGH EFFICIENCY
AUTOMATED & DCT TRANSMISSION
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ELECTRICALLY
ASSISTED
HYBRID PROPULSION
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Electric Vehicle Evolution
Pure electric:
• battery (BEV)
• fuel cell (FCEV)
Pel/Ptot [%]
100
EV
50
Hybrid Vehicle
ICE /
electric plug-in
Hybrid Vehicle
ICE /
electric assisted
PHEV
HEV
Improved
ICE - aux
ICEV
0
Today
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Short term
Mobilità sostenibile: la trazione elettrica, un’opportunità?
Medium term
Long term
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Fiat Hybrid Systems
ADVANCED CNG
HYBRID
GASOLINE
HYBRID
DIESEL
HYBRID
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Electric Vehicle Prototypes
Vanzic
Qubo elettrico
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Multipla Hybrid Power
Panda Elettra
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Enabling Technologies for the clean forthcoming Electrical Mobility
Batteries
And Supercaps
Smart Silicon and Thin Film solar panels
Fuel based
Catalytic
Range extenders
Electrical
Motors
Power electronics
Green low rolling
resistance tyres
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Lightweight and flexible
lighting
systems
with
integrated PV, Batteries, RF
link and Photodiode.
Thermoeletric materials for
heating and cooling
All other sensors
and electronics
Light weight and fire
resistant composites
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IVECO Hybrid Technology
MISSION:
ƒ
ƒ
Urban Freight Transport (3,5 ÷ 12 t)
Urban Passenger Transport (5,5 t)
SYSTEM:
ƒ
ƒ
ƒ
ƒ
Reduced Displacement Internal Combustion Engine
Automatic transmission
Hybrid Architecture Parallel Diesel-Elettric in-line
Configuration “mild hybrid”
MAIN FEATURES:
ƒ
ƒ
ƒ
ƒ
Stop & Start
Electric Mode in Traffic Queues
Regenerative Braking
Electric Launch
OBJECTIVES:
ƒ
ƒ
Consumption & CO2 Reduction: up to 30%
Zero Emission Mode: available
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Daily Hybrid and Eurocargo Hybrid
DAILY HYBRID
GVW:
3,5 t (van) - 5,5 t (minibus)
Internal Combustion Engine: Iveco F1A 4cil/2,3l
Power: 85 kW
Torque: 270 Nm
Electric Motor:
Power: 32 kW
Torque: 280 Nm
Transmission:
Automatic ZF 6 AS400
Batteries:
NiMH
EUROCARGO HYBRID
GVW:
Internal Combustion Engine:
Electric Motor:
Transmission :
Batteries:
7,5 ÷ 12 t (urban missions)
Iveco Tector 4cil/3,9l - 6cil/5,8l
Power: 118 ÷ 160 kW
Torque: 530 ÷ 680 Nm
Power: 44 kW
Torque: 420 Nm
Automatic Eaton
Lithium-Ion
Daily Van 3.5 t
Daily Minibus 5.5 t
Eurocargo 7.5÷12 t
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Field-test with customers
Daily Hybrid FedEx
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Eurocargo Hybrid Coca Cola
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Daily Electric: lay-out
High Energy Density
Batteries
Drive Motor
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Reduction Gear
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21
Daily Electric: performances
Vehicle Range
Full load – Urban Mission
DAILY 35 S
90 km
DAILY 50 C
2 BATTERIES
120 km
100 km
130 km
Gradeability
3 BATTERIES
4 BATTERIES
16%
Max Speed
70 km/h
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Technology Roadmap for BEV’s
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Batteries
600
Energy density [Wh/kg]
500
400
300
Li-ions
Li-ions
Co
phosphate
Li-Mn2O4
NiMeH
200
100
Pb
0
1970
1980
NiCd
1990
2000
2010
2020
2030
2040
2050
years
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Batteries
Source: SAFT
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Supercapacitors
Source: Maxwell
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Solar Cells
Source: NREL 2007
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High-Priority Challanges In Europe
Greening of surface transport
Encouraging modal shift and decongesting transport corridors
Ensuring sustainable urban mobility
Improving safety and security
To promote safe, efficient and environmentally friendly mobility
BUT WHAT ABOUT THE FUTURE ?
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NETWORKED PRODUCT DEVELOPMENT
INSIDE ORGANIZATION
THROUGH ORGANIZATION
Performance
Requirements
Constraints
PROJECT LEADER
Add-on Function
Trade-offs
Needs
People
Components
System
Complexity adds on top of Complexity
with the risk of loosing the control
HIERARCHICAL ACTIVATION AND EXECUTION
LOCAL OPTIMISATION
DIRECT ACTIVATION AND EXECUTION
GLOBAL OPTIMISATION
Distributed intelligence
Complexity is pervasive
and becomes manageable
PROJECT LEADER
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Synchronising Product and Technology Evolution
By completely re-engineering
the whole product it is possible
to anticipate the adoption of
the ultimate technologies
Product Re-Engineering
Product Evolution
Technology Performance
Technology Acceleration
Time
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Energy used and dissipated
Vehicle Energy Demand
4% through higher efficency
Auxiliaries 3%
Useable Energy ~ 16%
Brake Energy 3%
Aerodynamic Resistance 3%
Drive Train 3%
Rolling Friction 4%
Loss of Energy ~ 84%
EE-VERT Concept:
- Higher efficiency
- Smart components
- Overall energy management
6% more useable energy through
an overall energy management
Average values for a
medium-class passenger
car in urban areas
Wasted Energy
EE-VERT Benefit:
Reduction of CO2 emissions and
fuel consumption by 10%
Engine Heat and Exhaust Gases 84%
Source: EUCAR EE-VERT Project
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Hypothesis of BEV Evolution
Today
Regenerative
Braking
Aerodynamics
Rolling Efficiency
Weight Reduction
PV Cells
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Power Supply
TODAY: Energy from Fuel pump
FUTURE: Energy recover from the vehicle,
from the infrastructure,
from the environment
(solar, wind, ….)
BATTERY
Electric
INVERTER Engine
Generator
ENERGY
CAPTURE
SYSTEMS
Tank
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ICE
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Vehicle Handling
Siemens eCorner
Energy Recovery Damper
Source: Tuft University
TODAY: Passive and active solutions, energy absorbing
FUTURE: New active systems, to maximise efficiency and recover energy
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Wheels
Max Knight
Walking Bike
TODAY: passive solutions, compromise rolling resistance/handling/comfort
FUTURE: active solutions, to zeroing the rolling resistance
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New vehicles: new Issues but also new Opportunities
New Green Vehicles will have a lower Carbon Footprint through:
ƒ Eco-design
ƒ Green Manufacturing
ƒ Lean logistics
Use of natural
and recycled
Natural
materials
Resources
Reuse,
Recycling
Recovery
NEW
GREEN
VEHICLES
Collection
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Eco-design,
Design for Recycling
Design for Recovery
Design
Mobilità sostenibile: la trazione elettrica, un’opportunità?
Manufacturing/
Green
Product
Manufacturing
Use
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Breakthrough Concepts and Prototypes
Source: MIT
Source: Bombardier BRP
Source: PSA
Enable the possibility to design and develop
new mobility solutions
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Multi-stakeholders Integrated approach
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THE NETWORK
PUBLIC ADM.
CONSORTIUM
RESEARCH
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ENTERPRISE
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TECHNOLOGICAL LAB
This project is a sort of “Technological Lab” for testing innovative solutions for a sustainable
urban mobility, endowed with the following technical and technological characteristics:
@
ELECTRIC
@
EFFICIENT AND TOTALLY RECYCLABLE
@
FLEXIBLE
@
MULTI-USE, FLEXIBLE IN USE AND CUSTOMIZATION
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TECHNOLOGICAL SCOUTING AND BENCHMARKING
CO2
ENERGY
OIL
CONSUMPTION DEPENDENCY
NOISE
POLLUTION
TRAFFIC
CONGESTION
1. MICRO & NANO TECHNOLOGIES
2. TELEMATICS
3. BIONICS
4. BIO-MATERIALS
5. PHOTOVOLTAIC
6. MECCATRONICS
7. HYDROGEN
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VEHICLE ARCHITECTURE
Upper body
Split-frame architecture
Aluminium Chassis and body construction in metal-plastic hybrid
Powertrain
Propulsion: Electric
Transmission: 4WD
Nominal Output: 27 kW
Peak output: 54 kW
Chassis
Suspension Front/Rear: Double Wishbone push rod
Breaking System: 4 discs regenerative breaking
Stability active control: 4 independent wheels
Differential: Electronic
Tyres
Front: 175/55/R15 ultra green
Rear: 195/50/R15 ultra green
Technologies
Photovoltaic cells:
340W (on-board generated power)
Fuel Cell system:
1kW (on-board generated power)
Batteries:
Lithium Ion or Lithium Polymers
Headlamps:
Chip-led
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The name Phylla - meaning “leaf” in ancient Greek - aims to communicate the capacity to convert
solar light into energy, and is the synthesis of all the different skills and competences, the result of
the synergic cooperation of all the partners involved
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THANK YOU
6 maggio 2009