博格华纳P3混动-The Case for a PHEV P3 for Truck SUV

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

TheCase

foraPHEV

P3for

Truck/SUV

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

WhyHybrid?

Regulation

Cost

Packaging

►Regulation–ZEV

HybridDriveline

►Packaging–EaseofIntegration

►Efficiency–EVDrive,Hybrid

Efficiency

Utility

►DrivingExperience–Performance

Driving

Experience

►Utility–GeneratorMode,4WDTractiveEffort,Towing

►CostComparison

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

Regulation

►ZEVRequirementsforPHEV2035

►50Milesallelectricrange“RealWorldDriving”

►35kWhBatteryStorage

►CompleteUS06inelectriconlymode

►>150kWofPeakEMPower

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

ParallelHybrid–MotorLocation

►P0,P1andP2Requires

TransmissionUpgradeforfullhybriddrive

►P3andP4onaxle,

Packaging/GeneratorIssue

►P3integratedintotransfercase:

►Enablesgeneratorfunction

P4Axle

►Enablesactivetorquedistribution

►Minimizespackagingdisruption

P3

TCase

P3Axle

P3

P1,P2P0

TCase

P3Axle

P4

Axle

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

Packaging

►EngineandTransmissionpositionunchanged

►PropshaftModificationsforlength

►BEVMotorre-use

►Packagingforbattery,inverterandon-boardcharger(OBC)reqd

A

Exhaust

Transmission

P3

FuelTank

SpareTire

150mm

P3TransferCaseActive

Clutch

GEN/Q

HYBRID

EM

ICE

FRONT

REAR

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

Comparison

►StudyperformedP3,P2,REEV,BEV

►BatteryandpropulsionsizedtomeetZEVrequirements(P3,

P2andREEV)

►400Vsystemusedforallvariants

Bat

35

kWh

OBC

P3

6500lb

EM

200kW*

Bat

35

kWh

OBC

P2*

6500lb

PE

EM

200kW

PE

Bat

35

kWh

OBC

PE

EM

200kW

REEV

6500lb

PE

EM

200kW

Battery

139kWh

EM

200kW

OBC

BEV

7000lb

PE

26Gal

PE

26Gal

GEN225kW

26Gal

D

EM

200kW

PE

*200kWNotCurrentlyCommerciallyAvailable

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

282.5

251.1

60.9

66.3

52.7

49.7

51.6

EV

EV

P3

P2

RE

BE

P3

P2

RE

BE

Regulation-EV

EVRange

►P3,P2andREEV-ZEV

►40milesonUS06

MILES

►50milescombinedEVrange(realworld)

►P3hasEVRangeHeadroomallowsfor30kWh(packaging

advantage)

300

250

70

60

50

40

30

20

10

0

57.2

V

V

US06(0.55xUDDS+0.45xHWFET)*.7

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

Efficiency-EV

►P3hasbettercombined

efficiencythanP2duetomoreefficientpowerflow

kWh/100km

►P2betterefficiencythanP3underconstantcruiseduetoabilitytofindmoreoptimumgearratio

►BEVandREEVhave4-8%

efficiencyadvantageoverP3dependingonconditions

50

40

30

20

10

0

!

EVPowerConsumption

44.5

43.0

42.2

42.7

BETTER

26.1

20.9

19.319.6

P3

P2

REEV

BEV

P3

P2

REEV

BEV

(0.55xUDDS+0.45xHWFET)Constant130kphCruise

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

Efficiency-Hybrid

►P3>P2BecauseofTransmissionLosses

MPG

►REEV>P3AxleLosses

45

38.3

34.033.9

32.1

31.3

30.5

BET

EV

EV

P3

P2

RE

P3

P2

RE

40

35

30

25

20

15

10

5

0

ChargeSustainingFuelEconomy

TER

UDDSCombined

1/(0.55/UDDS+0.45/HWFET)

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

Efficiency–Emissions

►P3betterthanP2duetobetter

EVrangeandchargesustainingfueleconomy

►REEVbetterthanP3

►AllPHEVsofferasignificant

improvementoverconventionalcombustion

400

350

EPAEmissions(gCO2/mile)

300

250

200

150

100

50

0

CO2EmissionsforEPAFleetCompliance

381.4

BETT

ER

83.4

70.6

59.4

ICE

P3

P2

0

!

V

V

REE

BE

Note:EmissionscalculatedassumingEPAapprovedfleetutilityfactorthrough2031

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

DrivingExperience

►PureEV≈EngineOnly

►0-60mphinunder5s,HybridMode

10.00

8.00

6.00

Time(s)

4.00

2.00

0.00

0-60mphAccelerationTime

8.78.68.78.5

7.7

5.0

4.74.7

4.5

P3

P2

P3

P2

REEV

BEV

P3

P2

REEV

EngineOnlyPureEVHybrid

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

Utility

►TowingRangeP3,P2

comparable,bothbetterthanREEV

►LowRangeinTransferCaseisreplacedbyEMwithreductiongearset

253.0

257.5

246.6

229.9

224.1

99.5

20.821.2

22.0

ICE

P3

P2

REEV

P3

P2

REEV

BEV

P3

P2

REEV

350

250

150

MILES

50

30

20

10

0

80mphTowing,10,000lbTrailer,0%Grade

235.2232.7

CombustionRangeEVRangeHybridRange

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

Cost

►P3≈P2componentdelta

►P3wouldhaveacost

advantageoverP2ifbatterywasreducedtoprovide

equivalentEPAEVrange

►REEVcosteffective,newvehicleplatform

►BEVdominatedbyBatterycost

58,650

51,800

50,75050,750

Costdifferenceusing30kWhbattery

36,000

P3

P2

REEV

BEV

$60,000

$55,000

$50,000

$45,000

$40,000

$35,000

$30,000

ModeledRepresentativeVehicleCost

BasedonUSDepartmentofEnergy12/22Study

$550

ICE

2022IncrementalPurchaseCostMethodologyandResultsforCleanVehicles()

CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS

PreferredArchitectureforAddingHybrids?

2035ZEVCO2FleetHighTowingCustomer