Volvo car Malaysia

Tech Talk

CO2-reduction EU / average new vehicles

CO2 curve *IPCC 450 ppm

g/km CO2
200
180
160

140
120
100
*Intergovernmental Panel on Climate Change

80
2006

2008 2010 2012 2014 2016 2018 2020

Drive Towards Zero

Efficiency

Alt. fuel

Electrification

Best Volvo Fuel consumption l/100km

6,5

5,9
3,8
1,9
0,0

2000

2006

2009

2012

201X

Why electrification?
Uncertain future oil availability
Higher total efficiency than fossil
fuel
No pollution/less noise in the local
traffic environment

40 years of electrification at Volvo Cars

Volvo cars Global approach

Region

Current
Market
China via e.g. the NEV
definition
(New Energy Vehicle)

T8
Twin
Engine

Future Market
Wide range of market forecasts
due to uncertainties

(Aiming for 5 Million vehicles on the road 2020)

US via the e.g. ZEV credit

legislation (Zero Emission
Vehicle)

EU via the CO2 legislation

Will transform into a normal

competitive market

The key to adapt to the future

is to develop a range of
opportunities / options

Studies

Mild
HEV

PHEV
AWD

Studies

T5
Twin
Engine

PHEV

BEV

A true safe Volvo with No compromises!

Safety Driving experience Comfort Versatility

Vehicle with zero CO2 emission

Volvo C30 Electric - city commuter

Certified 163 km range (NEDC)
Practical range 120-140 km
90% of all commuters drive a
shorter distance per day

Main learnings from project

Li-Io Chemistry assessments

Design Li-IO HV batteries
Control and protect safety
Electrical Machines
Gearbox technology
Integration including NVH
Inverters and other HV components
Fast charging
Control software incl. Functional safety (ISO 26262)
Optimize Complete vehicle properties
Customer reactions range anxiety

Volvo Car Corporation Electrification strategy

95g
CO2 / km

130g
CO2 / km

2009

2012

2015

2020

2025
Large Cars

Plug In
Hybrid
Product portfolio
prepared for
Plug in Hybrid
BEV

VCC
Product
portfolio

Small cars

Different Hybrid architectures

Electrifications Topologies

Engine

Battery
Electric
Motor

Transmission
Final Drive

Engine

Engine

Gearing

Electric
Generator

Battery
Battery

Electric
Motor
Battery
Electric
Motor

Electric
Motor

Electric
Motor

Final Drive

Final Drive

Final Drive

Parallel Hybrid

Split Hybrid

Series Hybrid

Full Electric

Electrification level
Electrification Level
Type

Battery
Voltage
V DC

Prop.
Power
kW

Electric Range
km

BEV

400-600

>80

>150

REV

350-450

>80

70-150

PHEV

350-450

40-80

20-70

HEV

250-450

40-80

1-2

Mild
HEV

36-120

10-20

--

Micro
HEV

12

3-5

--

2016-09-29

Parallel
Honda, Volvo,
BMW, Audi
Mitsubishi,
PSA, Daimler,
..

Split
Toyota
Ford, GM

Serial

EV

BMW

Tesla, Nissan
Renault

Vcc hybrid architectures

2010

2013

2015

2018

Gen 3 CMA 2018

Gen 2 SPA 2015 Q2

Gen 1 EUCD 2013 Q1

2020

BISG+ERAD (15+50kW)

CISG+ERAD(35+60kW)

Electric motor 55 kW integrated in 7DCT

5 Cyl. Diesel Engine (158kW)

VEA HP(237kW)

GEP3 (132kW)

HV battery between rear wheels

HV battery in tunnel

HV battery in tunnel

3.5 kW OBC

CIDD=Inverter+DC/DC

CIDD=Inverter+DC/DC

3.5kW OBC

3.5kW OBC

New Volvo XC90 t8

7 seater Phev

Shift by Wire

Drive mode selection

START ENGINE

PHEV Powertrain architecture in XC90

Twin Engine Technical principle

Twin Engine PHEVs:
Combine ICE power with electric power
3 cars in one: Pure/ Hybrid/ Power
Battery positioned for optimal safety and
driving experience
No compromise in interior space or
flexibility
Four Volvo models offered today:
XC90T8, S60L T6(China), V60 D5 and
V60 D6

Demand on XC90 Plug-in Hybrid

Top of the Line Powertrain based on
Drive-E Powertrains
No compromise; high performance
& low CO2
Future proof
Need to match / beat competitors 6- and 8cylinder powertrains in customer attributes
Realize electric AWD
Designed around you three cars
in one you decide

Mastering the technologies of electrification

XC90 T8 Competitiveness
9

Power/C02 [hp/(g/km]

XC90 T8

Competitor Z (Diesel)

Competitor X (Petrol)

Competitor Y (Petrol)

3
3

3.5

4.5

E-Range/ Installed Battery Capacity [km/kWh]

Note: NEDC cycle data

SPA architecture T8 Twin Engine powertrain

Electric Rear
Axle Drive

Internal Combustion
Engine

Electric A/C
compressor

Crank-Integrated
Starter Generator

High Voltage
Li-Ion Battery

Power
Electronics

Engine and Automatic Transmission

Electric vacuum pump

Shift by wire actuator

Simplified FEAD

Transmission electric oil pump

Bearings

CISG integration

polymer coated
bigger diameter

24 mm increased length
Integrated cooling ISG & engine
Modified housing and block

CRANK-Shaft Integrated STARTER Generator

Function
HV Generator
HV Starter
Power boost
Specification
180 Nm
34 kW
Water cooled

electric drive Components - LOCATION IN SPA

ERAD

CIDD

IEM

C-ISG

HV SYSTEM ELECTRIC CONNECTION

Spa hv battery-overview
HV battery main functions:
Store, receive and deliver energy

Battery Status
Monitoring and
Calculating

HMI Indication

HV Battery

Electric Motor

HV Battery

On Board Charger

Battery Charging
Control

SPA HV battery basic parameters:

Total Energy

Usable Energy

Nominal Voltage

Battery Weight

Supplier

10kWh

7.5kWh

345V

114kg

LG Chem

Battery Cooling
Control

Spa hv battery-cell technology

Battery Cell Construction

Different Battery Cathode Material Comparison

Power
10
8
6
Cost

Energy

LFP
LMO
NCM

NCA

Cylindrical

Pouch

LCO

Prismatic

Safety

Life

HIGH Voltage Battery

96 Li-ion cells
270 400 V
65 kW
9.3 kWh
Lithium Manganese Oxide
Nickel Manganese Cobalt / Graphite
6 modules
water cooled
manual service disconnect

Spa hv battery- Safety Design

HV Battery Safety

Crash
Safety

Fire
Safety

Electrical
Safety

Packaging
Battery disconnect

Material requirement
Cell abuse test
Battery pack fire test

Isolation detection
High Voltage Interlock
Manual Service
Disconnect

Spa hv battery-pack structure

Enclosure

Battery
Disconnect
Unit

Modules
Battery
Management
System

Thermal
Management

Enclosure
Main structure to provide protection and
water/dust tightness for components inside
Modules
Single unit, consist of 16 cells
BDU
Consist of fuses and relays, switches of the
battery pack
BMS
Monitor battery voltage, current,
temperature;
Calculate SOC/SOH etc.
Control the battery switch on/off
Thermal Management
Coolant loop inside the battery pack, to
keep battery working in efficient
temperature zone (room temperature)

Spa hv battery-MODULE Structure

Module
Controller

Battery Cell

Plastic
Frame

Cooling Plate

Coolant Pipe

Module Controller
Monitor each cell voltage, module temperature
Battery Cell
Li-ion pouch cell, nominal voltage 3.7V
Plastic Frame
Support structure for battery cell
Cooling Plate
Heat exchange with battery cell, every two
cells share one cooling plate
Coolant pipe
Main pipe for the coolant

Electric Drive system overview

2

DC Current

AC Current

-2
0

V
0.005 0.01

0.02

U
q
Is

N
s

S
W

HV Battery

Inverter

Motor

ELECTRIC REAR AXLE DRIVE

Function
Electric drive
Power boost
Regeneration (brake)

Specification
240 Nm
60 kW
10 gear ratio
Max rpm 12500 (120 km/h)
Disconnect clutch
Water cooled

Electric Machines
ERAD (Electric Rear Axle Drive)

Propulsion of the car at the rear wheels and regeneration of energy

Peak torque / power : 240 Nm / 60 kW

Water cooled

Transmission &
differential

Max speed: 12500 rpm(120km/h)

Disconnect clutch

Supplier: Siemens

CISG (Crank Integrated Starter Generator)

HV Starter motor, Charging HV Battery, power boost

Peak torque / power : 180 Nm / 34 kW

Water cooled

Max speed: 8000 rpm

Supplier: ZF

Electric Machine

POWER ELECTRONICS
CIDD - Combined Inverter and DCDC ( IGM)
Max Current: 285 A rms (for C-ISG motor)
DCDC maximum output current: 260 A DC
Max Voltage: 420V
Water cooled
In Engine bay
Supplier: Delphi

IGM in CIDD

POWER ELECTRONICS
IEM - Rear inverter
Max Current: 375 A rms (for ERAD motor)
Max Voltage: 420V
Water cooled
Under the rear floor on bracket with OBC
Supplier: Siemens

Charging technology
Charger

1-phase AC

3-phase AC

DC

Charger location

In Car

In Car

Charging station

Power

3.3kW(SPA)

22kW(C30)

120kW

AC input voltage

220V

380V

380V

AC Input current

16A

63A

192A

Charging time

2.5h

23 minutes

248 seconds

Battery

SPA HV battery, 10kWh

Charging is easy

Wallbox & charging cable

Mode 3: Wallbox and its cable/ connector

Mode 2:
Charging cable:
Length=6.65m
Can adjust charging current
3-wire red cable and 5 wire yellow Cable
Connector can be changed according to application in
different country.

ON BOARD CHARGER
The OBC converts AC voltage from Grid(220V 50 Hz) to DC
Voltage (300-420V) for charging the HV Battery.
The SPA OBC is mounted on the bottom of luggage bay.
Key OBC Features: OBC
Single phase AC Charger
Isolated design
Water cooling (sharing circuit with DCDC, ERAD and inverter)
Maximum power: 3.3 kW (assuming 16 A input current)
Charging time: 3.5-7 h for full charge depending on current
High efficiency: >92% in main operation window.

High and Medium Temperature cooling

Integrated cooling ISG and engine
Medium temperature cooling for
ERAD and power electronics (50 - 65
C)
Thermostatically controlled bypass to
assure minimum coolant flow in cold
climate (~ -30C)

Battery cooling
Low temperature cooling
Chiller allows cooling with assist
from Air Condition system for
efficient cooling in driving and
parked conditions

FUEL System
Non vented tank
Canister adsorbs fuel vapor in
combination with refuel or high tank
pressure
Canister is purged from adsorbed
fuel when engine is running

Spa hv control system-propulsion control

Driver input
Phev mode buttons
Gear lever

The propulsion software

controls the different
subsystems based on
driver input and system
states/limitations

High voltage
Battery

Propulsion control
Mode
Management

DCDC

Acc/Brake-pedal

Active safety

Torque
Management

Energy Management

HMI

Stability
limitation

Electric AC

Reconfiguration
strategy
Clutch

Transmission

Engine

Integrated Starter
Generator

Electric Rear Axle

Motor

SPA Electrical architecture

VDDM
Vehicle Dynamics
Domain Master
VDDM
Backbone
FlexRay

Vehicle
Dynamics
Domain
Master

0x1601

AGM

BCM
Brake
Control
Module
0x1631

PSCM
0x1612

ASSM

ECPM

GPCM

ACM

ACCM

EDCP

optional

optional

optional

optional

optionall

optionall

LIN
PSCR4
0x1613
optional

LIN
6
SUM
0x1614

SCL
0x1615

optional

SAS
0x1616

RML
0x1416

RMR
0x1417

PreSideNT_L

PreSideNT_R

0x1413

0x1414

optional

optional

optional

Safety CAN
Protected SODL
WAM
0x1431
0x1432
optional

ASDM
Active Safety
Domain Master
0x1401

CCSM

optional

CPM
optional

DIM

HUD
0x1841

SWM
0x1A91

ASWM

Propulsion CAN HS

SWSM

optional

LIN20
TVM
0x1211

AUD
0x1212

optional

optional

CCSM

DMSM
optional

Int. WLAN

USB
Diagnostics
Ethernet

RDMR
0x1215

Optical
Media Drive

SHRR

optional

TDMR
0x1639

optional

optional

BECM
0x1635

IGM
0x1636

DEM
0x1638

optional

optional

optional

optional

optional

DDS
LIN
5 CCM

Propulsion CAN HS
IDM
IDM
RPDM
Driver Rear
Passenger
0x1AC1
optional
optional

RDDM
0x1AB1

IDM
Driver

DDM
0x1A12

POT
0x1A15

TRM
0x1A17

optional

optional

optional

IDM
Pass. Rear
optional

LIN
9

RBCM
0x1A19

PDM
0x1A13

optional

Body CAN HS

HUS

BBS
0x1A51

IMS
0x1A52

PSMP
0x1A1A

optional

optional

optional

LIN2

CEM
Central Electronic Module
0x1A01
LIN
1

WMM

LIN12
BLML

LIN0
(K-line)

PSMD
0x1A14

SCMR
optional

SCML

PSRL

optional

optional

SFM3

SFM2

PSRR

optional

optional

optional

optional

LIN22
MAM
0x1A31

LIN21
PAS

Hard-Wire

LIN13
BLMR

optional

optional

AHML

AHMR

optional

optional

FFML

FFMR

LIN3
OHC

OHCR

OHCRL

OHCRR

OHCTR

IDM

optionall

optional

optional

optional

optional

optional

RLSM

MOST
150
LIN19
RCSM
optional

USB
OMD

SHMR

SUS

RDML
0x1214

optional

Connectivity
Ethernet

SHRL

LIN14

WLAN

IHU
Infotainment
Head Unit
0x1201

SHML

optional

IEM
0x1637

optional

Safety CAN
Exposed

Driver
Imformation
Module

HBMF

optional

AEMM
0x163B

OBC
0x1634

0x1A11
HVCH

Backbone
FlexRay

Ext. WLAN/3G/4G

Stepper Motors
& Sensors

LIN18

SODR
0x1433

AND

ESM
0x163A

TACM
0x163C

LIN/Cooling
LIN17

optional

VCM
Vehicle
Connectivity
Module
0x1001

Shift by Wire

EGSM
0x1633
optional

HBMR

LIN10
OWS

0x1801

XOR

ECM
0x1630

DMM
0x1415

TCM
0x1632

optional

Chassis
CAN HS

SRS
Supplementary
Restraint System
0x1C01

LIN
7

GSM
0x1661

IRMM

optional

optional

TEM
0x1011

HIRL

HIRR

optional

optional

optional

FMDM

BCSM
BMS
0x1A61

LIN
CAN
USB
MOST 150
FlexRay
Ethernet
WLAN

30, Battery feed

Note:
LVDS connections
not shown

Spa hv control system-overview

Main PHEV Propulsion system components and their main functions
IEM

BECM

TCM

El. motor Control

Actuator torque arbitration Transmission control
Clutch Control
Motor torque actuation
Gear ratio/shift contr.
Torque monitoring

Battery Control
Calculate Battery SOC, SOH, ..
Calculate Battery capability
Control Contactor status
Monitor Battery Status

Actuator for Engine

Process Driver Request
Produce Engine Torque
Command

Charger Control
Charger activation
Charger current control

IGM (CIDD)

ECM
Engine control

OBC

Vehicle Control

System mode control

Propulsion Energy Management
Torque distribution
HV Battery SOC control
LOS control

El. motor Control

Actuator torque arbitration
Motor torque actuation
Torque monitoring

Power conversion
Supply 12V net

Modified from
Conventional
SPA
SPA PHEV
Unique
component

Spa hv control system- Charge modes

Charge depletion

SOC
If possible, electric driving (engine off) shall be used.
Full
engine shall start when
Electric traction is not sufficient to implement driver traction request

Charge sustain

Over a drive cycle, the battery SOC shall be sustained

The engine shall start when
more efficient to use engine than battery energy
Too low SOC
Electric traction is not sufficient to implement driver traction request

SocChargeModeThreshold
SocTarget

Empty

Charge
Depletion
EV

Charge

Sustain
full hybrid

time

Spa hv control system-operation during driving

Charge Depletion mode (EV-mode, engine off)

Electric Propulsion
Energy recuperation

Charge Sustain mode (Hybrid mode)

Battery charging
With front electric drive system (CISG)
Electric Power assist
Electric propulsion system adds electric traction power to engine
When extra torque needed

Energy recuperation

Charging the HV battery using electric rear axle

Request to recuperate when
Coasting (no pedal pressed) (depending on accelerator pedal map setting)
When brake pedal is pressed through true brake blending system (electric braking will be prioritized)

Spa hv control system-Engine start/stop conditions

Engine start/stop conditions depends on PHEV mode
Engine start when

Too low battery SOC

EV performance is not sufficient
When HEV-mode is more optimal
Other systems request
Climate
Transmission
At faults in the High Voltage system

Engine stop

Vice versa

The Driving modes

How the power flows through the system in the different driving modes
PURE .. HYBRID .. POWER .. SAVE .. AWD
Electric Propulsion
Propulsion using the combustion engine
Energy recuperation

PHEV DRIVE MODE: PURE

Pure electrical drive vehicle like BEV, with recuperation
Engine start when battery SOC* lower than
~17%

Engine off

*/ SOC = State of Charge

ERAD propulsion
only

PHEV DRIVE MODE: HYBRID

HYBRID mode is economy mode (Default mode)
split power between the engine and E-motor, to
get the best fuel economy

Selective Engine running

ERAD propulsion, boost or

recuperation

PHEV DRIVE MODE: POWER

Support high driving performance
Engine always on for best response

Engine running

ERAD boost

PHEV DRIVE MODE: SAVE (for later use of battery)

C-ISG may charge the HV battery to maintain a high SOC level
Reserve the electric power for possible later electric driving

Engine running & charge the

battery (if below target SOC)

ERAD Driving & Regeneration

PHEV DRIVE MODE: AWD

Provide best possible traction eg. in slippery
conditions
Always four wheel drive both engine and ERAD

Engine running

ERAD boost for best traction

Summary
The new PHEV powertrain is a modular
concept built on Volvos new Drive-E
powertrains
High performance 406 hp and 640 Nm
Low emissions that complies with
Euro6 and TZEV standards
Low CO2 : 49 g/100km
and fuel consumption 2,0 l/100 km

Twin Engine powertrain on CMA

High Voltage
Li-Ion Battery

Power Electronics

SPA and CMA

55 kW motor
Electric Motor

9.7 kWh battery

Over 50 km range

Conclusions

Electrification is a logical solution to reduce CO2 emissions, it matches the Volvo Brand profile, and PHEVs
complement our Combustion Engine program perfectly. Currently 4 models offered.

In the next years, PHEVs will likely be the strongest offer among the different variants of Electrified cars

Volvo cars were early on the PHEV market and have leading offers, now expanding to FWD Twin Engine
variants

Battery technology will continue to develop rapidly - Energy density, Power, Cyclebility and Cost

For Convenience, additional functions such as wireless charging and extended driver support will be important

BEV concepts will continue to evolve over the next decade. Assuming growth of charging infrastructure, we
believe that affordable, fully worthy and in all ways competitive BEVs are likely to increase their market share
from year 2020-2025.

Volvo will offer a highly competitive BEV with long driving range and strong power level

Thank Thanks
you forfor
your
attention!
your attention !