Opel Ampera − Extended-Range Electric Vehicle Concept with Future Roland Matthé Adam Opel AG

Automotive Propulsion Mobility Innovations 3 rd International AMI Congress 5th June 2012 Leipzig

Opel and GM Milestones in Electric Propulsion Electric Propulsion System Development 2000 HydroGen1

1987

1991

2007 HydroGen4

1996

2007 2000

1987 Sunraycer

1991 Impuls

1990 Impact (concept)

1996 EV1

1997 S10 Electric

2020 2012

2010 Volt 2011 Ampera

2-Mode Hybrids

2010/11

2012 RAK e (concept)

World Petroleum Production by Source 120

Uncertainty about availability

Million barrels per day

100

Unconventional oil

80

Natural gas liquids

60

Crude oil: fields yet to be found 3%

40

20

0 1990

Oil: $ 10 trillion cumulative investments required 2011 – 2035

1995

Crude oil: fields yet to be developed

10%

Crude oil: currently producing fields

Upstream

87%

Transport

Source: World Energy Outlook International Energy Agency, 2011

Refining

2000

2005

2010

2015

2020

2025

2030

2035

Year

Advanced Propulsion Technology Strategy Hydrogen fuel cell electric vehicles Improve vehicle fuel economy and emissions

Displace petroleum

Battery electric vehicles/E-REV Hybrid electric vehicles (including plug-in HEV)

IC engine and transmission improvements

Energy Diversity

Petroleum Alternative fuels (CNG, LPG) Electricity Hydrogen

Paradigm Shift: Tomorrow’s Vehicles are Powered Electrically Opel RAK e (BEV)

Opel Ampera (E-REV)

Opel HydroGen4 (FCEV)

Limiting Factors for Battery Development

Battery Range 100 km Eco drive style, no HVAC

80 km Eco drive style, with HVAC

60 km Sporty drive style, with HVAC

40 km Sporty drive style, with HVAC at extreme ambient temperatures

Future of Battery Electric Vehicles  Electric range will remain a limiting factor

150 km

Köln

 Time for recharging is significant

Marburg

80 km

Bonn

 Solution for city driving

Koblenz Wiesbaden Mainz

40 km Frankfurt

Rüsselsheim Darmstadt

Würzburg

Trier

Heidelberg Saarbrücken Karlsruhe Stuttgart

Comparison E-REV vs. BEV E-REV

Power

Gasoline

Electric energy Daily driving distance

60 km

Long distance

BEV

Power

Electric energy Daily driving distance

60 km

Long distance

Comparison E-REV vs. PHEV E-REV

Power

Gasoline

Electric energy Daily driving distance

60 km

Long distance

60 km

Long distance

PHEV

Power

Elec. energy

Gasoline

Daily driving distance

Battery System Energy Requirement Electric Vehicle Mode – Range, Useable Energy 25%

80% of daily driving  are 50 km or less  require about 8 kWh of useable energy

20%

15%

10%

5%

0% 0-1

2-4

5-10

11-20

21-50

51-100

> 100

km

Source: Mobilität in Deutschland, 2002

Opel Ampera Electric Drive System

Opel Ampera – Electric Vehicles with Extended Range Parking

Battery Mode

(Engine off) = Charge depletion

Extended Range Mode (Engine generator on) = Charge sustaining

Charge Mode

Electric on-board charger connected to grid

Parking

State of charge

100%

Regenerative braking

Engine will be off at certain times

Time

 Electric vehicle with 60 km electric range in urban driving  Full performance in battery mode: Top speed 160 km/h & 10 sec for 0 to 100 km/h

Opel Ampera Extended-Range Electric Vehicle (E-REV) Max. power: Max. torque: Top speed: Acceleration (0-100 km/h): Energy content (battery): Charging time: Range (battery-electric): (total):

111 kW 370 Nm 160 km/h < 10 s 16 kWh 4 – 6 h @ 230 V 40 – 80 km >500 km

Opel Ampera Drive System Electric drive unit Clutches

Generator Geared final drive

Traction motor

 Two electric motors

Traction: Generator:

111 kW, 370 Nm 54 kW

 Planetary gear  Geared final drive  Three clutches Planetary gear set Axle differential

Opel Ampera Drive System 1.4 Liter DOHC I-4 Engine

 Power:

63 kW @ 4800 rpm

 Max. engine speed:

4800 rpm

 Displacement:

1.4 L

 Compression ratio:

10.5 : 1

Opel Ampera Electric Drive System Battery Electric Driving (Low Speed) Electric energy flow High-voltage battery

Mechanical energy flow No energy flow Clutch open

Secondary electric motor/ generator

Power electronics

C3 Primary electric motor

C2 Internal C1 combustion engine

Planetary gearbox

Clutch closed

Opel Ampera Electric Drive System Battery Electric Driving (High Speed) Electric energy flow High-voltage battery

Mechanical energy flow No energy flow Clutch open

Secondary electric motor

Power electronics

C3 Primary electric motor

C2 Internal C1 combustion engine

Planetary gearbox

Clutch closed

Opel Ampera Electric Drive System Extended-Range Driving (Low Speed) Electric energy flow High-voltage battery

Mechanical energy flow No energy flow Clutch open

Generator

Power electronics

C3 Primary electric motor

C2 Internal C1 combustion engine

Planetary gearbox

Clutch closed

Opel Ampera Electric Drive System Extended-Range Driving (High Speed) Electric energy flow High-voltage battery

Mechanical energy flow No energy flow Clutch open

Secondary electric motor/ generator

Power electronics

C3 Primary electric motor

C2 Internal C1 combustion engine

Planetary gearbox

Clutch closed

Opel Ampera Electric Drive System Regenerative Braking Electric energy flow High-voltage battery

Mechanical energy flow No energy flow Clutch open

Secondary electric motor/ generator

Power electronics

C3 Generator

C2 Internal C1 combustion engine

Planetary gearbox

Clutch closed

Operation Modes for all Driving Conditions

Battery Mode Default

Extended-Range Mode

Normal Mode

Quick response

Sport Mode

Battery reserve

Mountain Mode

Reserve battery energy for EV-zone

Hold Mode

“Umweltzone”

Opel Ampera Drive System Li-ion Battery System

 No. of cells:

288

 Liquid thermal system  Energy content:

16 kWh (> 10 kWh useable)

 Power discharge: > 115 kW  Nominal voltage: 360 V

 Charging time:

4 – 6 h @ 230 V

 Warranty:

8 years / 160,000 km

 System weight:

198 kg

Electrical Architecture Rechargeable Energy Storage System Charge Cord Battery Disconnect Unit Including heater control

Charge Port

Voltage Current Temperature Module

Manual Service Disconnect and Fuse

Voltage Temp Sub Module

Traction Inverter

HVAC

Engine

Rechargeable Energy Storage System (RESS)

Gen erat or

Mot or

Battery Controller

Voltage Temp Sub Module

AC CM

Auxiliary Power Module VITM

Vehicle 12 V DC

Voltage Temp Sub Module

Voltage Temp Sub Module

On Board Charge Module

Battery Sections

Vehicle Development with Battery Focus

 Final calibration of battery control software  Mechanical verification of battery installed in vehicle

Driving Style Electric Range in real world operation Wiesbaden to Koblenz and return - 2 different drive styles 90

 Aggressive drive style  Rush hour @ highway A3  50 km in CD & 50 km in CS mode

140

70 speed

120

60

100

50

80

40

30 20

distance CS mode

160

120

60 Speed

100

50

80

40

60

30

40

20 Distance in CS mode

20

10

0

time [hh:mm:ss]

01:54:00

01:48:18

01:42:36

01:36:54

01:31:12

01:25:30

01:19:48

01:14:06

01:08:24

01:02:42

00:57:00

00:51:18

00:45:36

00:39:54

0 00:34:12

01:19:00

70

00:28:30

Moderate drive style Weekend traffic No grade (along river Rhine) 86 km in CD & 20 km in CS mode

140

00:22:48

time [hh:mm:ss]

01:15:03

01:11:06

01:07:09

01:03:12

00:59:15

00:55:18

00:51:21

00:47:24

00:43:27

00:39:30

00:35:33

00:31:36

00:27:39

00:23:42

00:19:45

00:15:48

00:11:51

00:07:54

00:03:57

0

Distance in CD mode

00:17:06

0

   

80

10

00:11:24

20

90

00:05:42

40

KO to WI - country road - relaxed driving style 180

00:00:00

distance CD mode

vehicle speed [km / h]

60

distance driven [km]

80

00:00:00

vehicle speed [km / h]

160

distance driven [km]

WI to KO - highway - dynamic driving style

180

Use Pattern of Extended-Range Electric Vehicles Average daily driving 1/3 range extender mode

2/3 electric mode

On average, the E-REV driver refuels gas every 1,500 km

Source: Data from Chevrolet Volt customer in the USA, via OnStarOn average

Summary  The Opel Ampera propulsion system provides the customer with all benefits of electric drive and overcomes “range anxiety”

 Electrification of automobile will play a major role to increase vehicle efficiency and energy diversity

 The Opel Ampera – Extended-Range Electric Vehicle – a concept for the future available today!