1. The Electrification of Powertrain
ICAT - Istanbul
The Electrification of Powertrain
Dr. Jan Lichtermann Director Hybrid Systems
Gasoline Systems
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

2. ICAT - Istanbul 13.11.08 1 Introduction 2 Market 3 Systems
4 Components
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

3. Worldwide Environmental Challenges
ICAT - Istanbul
Worldwide Environmental Challenges
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4. Hybrid Drives are the latest technology milestone for CO2 reduction
ICAT - Istanbul
Development in Powertrain Technology (Examples)
Electronic Gasoline Injection
Lambda Sensor for three-way Catalytic Converter
Electronic Diesel Injection
Gasoline Direct Injection
3rd Gen. CR with Piezo Injectors
GDI with Piezo Injectors
Start/Stop System
Hybrid Drives
1967
1976
1986
2000
2003
2006
2007
2008ff …
Hybrid Drives are the latest technology milestone for CO2 reduction
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

5. 35 years Experience in Hybrid Technology
ICAT - Istanbul
35 years Experience in Hybrid Technology
1973
Ford-Escort, DC-Motor
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6. Hybrid Engineering Center in Tamm
ICAT - Istanbul
Hybrid Engineering Center in Tamm
T o t a l S t a f f 320
Electrical-Drive,
Development
Hybrid Systems,
Teams
Software,
Braking Systems
Europe
Korea,
Customer
Teams
Japan,
China,
USA
Management,
Marketing,
Administrative
Controlling,
Teams
Quality-Management,
Purchasing,
Administration
Test Center
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

7. ICAT - Istanbul 13.11.08 1 Introduction 2 Market 3 Systems
4 Components
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

8. Drivers Powertrain Electrification
ICAT - Istanbul
Drivers Powertrain Electrification
Convent. ICE: increasing
penetration of 14 V
Start/Stop Systems
HEV: Affirmation of trend
PHEV: increasing
importance in US
and Japan
EV: pushes EV
technology
e.g. battery
Green-Image
Business models:
Agassi, Think Global
City restrictions: Paris, London,…
EU CO2-
Legislations
Drivers
Oil reserves &
Fuel prices
California
ZEV-credits
Country-Taxes
CARB 35mpg
Base: progress in battery technology
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9. Market development alternative drives world-wide
ICAT - Istanbul
Market development alternative drives world-wide
2.000
4.000
6.000
8.000
10.000
12.000
14.000
2008
2015
12.000
Electro vehicle, Plug-in hybrid
Liquefied gas (Liquefied Petroleum
gas, LPG )
Natural gas (Compressed Natural Gas, CNG)
Hybrid
Flex-Fuel
volumes (1000) vehicles
350
3.000
7.450
5.000 2
3.850
650
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

10. ICAT - Istanbul 13.11.08 1 Introduction 2 Market 3 Systems
4 Components
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

11. System strategy HEV, PHEV, EV
ICAT - Istanbul
System strategy HEV, PHEV, EV
Convent. ICE
HEV
PHEV 1
PHEV 2
w./ r.e. EV
Inverter
20kW
Inverter
85kW
Inverter
60kW
Inverter
60kW
12 V Gen  HV-GEN
S/S + 12 V Gen.  HV-BSG
Charger
Charger
Charger - + HV
12kWh - + HV
12kWh - + HV
12kWh HV
1.3kWh - + - +
12V
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

12. Powertrain Electrification (Subcompact class)
ICAT - Istanbul
Powertrain Electrification (Subcompact class)
Convent. ICE
HEV
PHEV 1
PHEV 2
w./ r.e. EV
2010
CO2 [g/km] (Well to Wheel) 1
140
120
80 (EU)
El.Range [km] - 2 50
802
120
Vehicle Weight [kg]
1100
1250
target 800
1453
target 1000
EV gets attractive, if:
Battery available with sufficient energy density
Lightweight design of vehicles realized
Electric energy cost does not increase dramatically
Max. El. Power. [kW] - 20
603
853
Energy Batt. [kWh] -
1,34
125
Cons.. [€/km]
0,11
0, , , ,026
1 – El. Mix 2006, 2 – ECE R(101), 3 - a <0,3g, vmax 130km/h, 4 – SoC Swing 20%, 5 – SoC Swing 70%, >20Ah/cell
6 – Tax of el. Energy as today, Battery cost included in vehicle price
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13. Hybrid Architectures with Parallel Energy Flow
ICAT - Istanbul
Hybrid Architectures with Parallel Energy Flow
P2 Parallel Hybrid (AT w/ 2 clutches)
AT with clutch as launch element
AS Axle Split (eAD) Conventional drive train plus
electric axle drive (eAD)
IMG
clutch 1
clutch 2
engine
motor AT
TS Torque Split Hybrid (eDCT)
DCT w/ integrated electric drive
EV Electric vehicle
Electric axle drive
SMG
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

14. ICAT - Istanbul 13.11.08 1 Introduction 2 Market 3 Systems
4 Components
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

15. Components for HEV, PHEV, EV
ICAT - Istanbul
Components for HEV, PHEV, EV
HEV
PHEV 1
PHEV 2
w./ r.e. EV
Convent. ICE
Engine Management
Charger
Integrated E-Machine incl. clutch
Inverter with DC/DC* Converter
Separated E-Machine
Li-Ion Battery
Brake Systems
Battery Management
Transmission Control
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16. Product Line IMG and SMG E- Machines
ICAT - Istanbul
Product Line IMG and SMG E- Machines
Le[mm] 22 55 77
100
200
150
Iron lengths scalable in steps of 11 (IMG) or 10 (SMG) mm
Do[mm]
250
300 Le
Peak torque
300Nm
SMG
IMG 300
IMG 290
Nmax=6800rpm
IMG 260
150Nm Le
170Nm
200Nm
SMG 180
IMG
Nmax=14.000rpm
15kW
70Nm
100Nm
SMG 138
Nmax=18.000rpm
Nmax: max. operational speed
Do: Outer stator diameter (active parts)
Mech. power 10-40kW, dep. on battery
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17. Axle parallel system with e-drive disconnection clutch
ICAT - Istanbul
Axle parallel system with e-drive disconnection clutch
# gears
Advantages
side mounted
coaxial 1
low complexity
Cost effective solution
no gear switching operation
Compact, low weight 2
High torque for driveaway / acceleration.
Enhanced regeneration capabilities.
Optimization of efficiency.
Cooperation Bosch – Getrag in development of Electric Double Clutch Transmission and Electric Axle Drive for Parallel Hybrid Systems.
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18. ICAT - Istanbul 13.11.08 control unit HW & SW E-Machine 300Nm/34kW
Functional overview – Power Electronics
control unit
HW & SW
power supply
communication lines (CAN, LIN, Flexray)
control signals / vehicle functions
E-Machine 300Nm/34kW
HV-Battery
Inverter
300 Aeff
=/~
PSM
UN=288 V
DC/DC-Converter
=/=
12V; 3kW
(~200A)
12V-Battery
12V-Powernet
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19. Power Electronics ICAT - Istanbul 13.11.08 Voltage range up to 400VDC
DC/DC-converter (Integrated; bidirectional)
Water cooling 85°C
MED17-control technology
Double inverter option
Cooler with DC capacitor and (DCDC-) inductances
Phase connections with current sensors
Mounting fixture
Pressing plate for power module
DC/DC and bottom housing
Housing cover with control board and gate drivers
Power module
Gen 1
Gen2 - SoP 2010
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20. Battery JV Bosch Samsung
ICAT - Istanbul
Battery JV Bosch Samsung
50%
SB LiMotive Co. Ltd.
50%
Scope of Business:
Li-ion battery technology for automotive power-train and board-net applications
OEM Customers
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21. Conclusion and Questions
ICAT - Istanbul
Conclusion and Questions
Thank you for your attention
GS/PJ-HT | 13/11/2008 | © Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.