RECENT TRENDS IN AUTOMOTIVE ELECTRICAL SYSTEMS

BY, Prof. M . Adimurthy BLDEAs college of Engg. And Technology Bijapur 586103
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AGENDA

Basic Electrical Terminology Different Electrical Loads in a Vehicle Battery Technology Today 42 V Technology Integrated Starter Generator Electromagnetic Valves

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BASIC ELECTRICAL TERMINOLOGY

CURRENT: The flow of electrons through a conductor caused by the application of a potential difference between its ends. VOLTAGE: It is the force or pressure that causes the electrons to flow through the conductor.

RESISTANCE: It is the factor that resists the flow of current through a conductor.
POWER: power is defined as the rate of doing work.

P=VxI

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WATER ANOLOGY OF ELECTRIC CIRCUIT

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WATER ANOLOGY OF ELECTRIC CIRCUIT

The rate of flow of water (current (I)) is measured by the flow meter (ammeter (A)). The rate at which water flows through the pipe depends on the pressure (voltage (V)), is indicated by pressure gauge (voltmeter). Power required to run the water motor (starter motor P=VI) is directly proportional to the rate of flow (voltage (V)) and the quantity of water in the pipe (current (I)).

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THE 12V ELECTRICAL SYSTEM

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ELECTRICAL LOADS - MARUTI 800

Head light
Indicator light Tail / Brake light Number plate light Room light Starter motor Parking light

12 V, 60/55 W
12 V, 21 W 12 V, 21 W 12 V, 5 W 12 V, 5W 300 400 Amps (starting) 12 V, 21 W

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ELECTRICAL LOADS MAX 100 R

Head light
Indicator light

12 V, 35 W
12 V, 10 W

Tail / Brake light

City lamp

12 V, 10/5 W
12 V, 3.4 W

Starter motor

12 V, 5 Amps.

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BATTERY - TYPES

(i)

Lead Acid Battery

(ii)

Nickel Cadmium Battery

(iii) Nickel Iron Battery (iv) Nickel Metal Hydroxide Battery

(v)

Zinc Bromine Battery

(vi) Sodium Sulfur Battery (vii) Sodium Nickel Chloride Battery

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BATTERY TYPES (Contd..)

The most successful battery in terms of reliability, life expectancy and cost is the lead acid battery. A 12 V battery which has 6 cells producing 2V each. Lead acid battery still being used in EVs, more researches are going on advanced lead acid batteries. Nickel cadmium battery longer life, good low temperature performance, high power capacity. Disadvantage - High cost and toxic nature of cadmium. Nickel iron battery longer cycle life than lead acid battery High Maintenance
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ELECTRIC VEHICLE BATTERY REQUIREMENTS

High specific energy High specific power High efficiency Longer cycle time Reasonable recharge time Recyclable material Low cost Safety Reliability and low maintenance

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BATTERY CHARACTERISTICS

Specific power (W/Kg) An indicator of the maximum power that the battery can deliver instantaneously (decides EVs acceleration and hill climbing) Specific energy (Wh/Kg) Energy capacity per unit weight of the battery (decides driving range) Energy density (Wh/m3) How much energy per unit volume of the battery can store (decides space on the vehicle)

Cycle life measured in number of cycles.

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COMPARISON OF BATTERY TECHNOLOGIES (RELATIVE TO LEAD-ACID)

Battery Technology Lead-acid Nickel-iron Nickelcadmium Nickel-metal Sodium sulfer Sodium nickel chloride Specific Energy Specific Power (W/Kg) Density Wh/l Energy Wh/Kg 35 300 70 130 100 200 140 200 90 120 150 50 90 60 100 60 100 100 210 75 110 160 15 45 35 60 30 60 55 80 80 120 100 Cycle life 300 600 400 1200 1000 1500 1000 250 500 500

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CHARGING SYSTEM

The alternator is a device which generates alternating current to charge the battery as well as to cater the various electrical loads when the engine is running. It works on induction. the principle of electromagnetic

The alternator takes its drive from the engine crankshaft.

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STARTING SYSTEM

The starter motor (self starter) converts the electrical energy stored in the battery into mechanical energy to crank the engine. The cranking motor consumes a very high current during cranking the engine.

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TECHNOLOGY TODAY

6 Volt systems were used till 1950 In the 1950s, The implementation of high power headlights, radios, and high compression V8 engines, which required higher ignition energy, created the need to move away from the 6-volt battery system to A 12-volt system. 12 to 14 volt systems are being used today Most, if not all of the accessories are currently depending upon on engine power. With the planned implementation of advanced electronic systems, a shift away from the current 14-volt electrical system to a new 42-volt electrical system is required.

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42 VOLT TECHNOLOGY HISTORY

Vehicle electrical demand has doubled over the last 20 years

On research from 1980s Rapidly emerging as the technical solution for improved fuel consumption and higher electrical power requirements Keeping wiring harnesses small and light weight are a definite advantage in manufacturing and long term fuel economy

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42 VOLT TECHNOLOGY HISTORY (contd..)

MERCEDES BENZ has been studying the feasibility from the early 1990s
MIT The mastermind for this technology 34 countries to introduce the technology soon JAPAN will be the first to introduce this technology 42 Volts and its resulting higher power will be the enabler for a range of new technologies like EPS, water pumps, door closes and advanced braking and suspension system
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CURRENT TECHNOLOGIES THAT WILL BENEFIT FROM 42-VOLT SYSTEM

Technology
Electric power steering

Benefits
More power, improved fuel economy

Heated catalytic converter

Mobile multimedia Fuel pumps

Lower emissions, quicker light off time

More power for video, navigation system, fax, amplifiers, cell phones Reduced size and increased performance

Heated seats
HVAC Power windows, seats, lift gates

More power, improved fuel economy

Smaller and lighter units, better packaging Reduced size of motors, more efficient operation

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42V - ADVANTAGES

Based on one of the basic laws of electricity i.e. the higher the voltage, the more current will flow through a conductor. So through a small size cable, it is able to conduct more current. So we moved from 6 V to 12 V in future 12 V to 42 V It supports more powerful electrical devices like micro contollers, mind blowing sound system, luxuries such as heated seats, heated steering wheels, heads-up displays and navigations systems.

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42V ADVANTAGES (Contd..)

Electrical power generation by charging system requires lot of fuel. It saves 15% of fuel for every 1 KW of power produced by the alternator.

It can significantly reduce vehicle wiring size and weight compared to existing 14-volt configurations.
In 12 V system the resistance in an electrical connector will cause change in current flow which cause computer to receive wrong inputs.

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42V ADVANTAGES (Contd..)

1.

2.

Since 42 V technology has the ability to overcome resistance in wire connections, ECMs receives right signals at right time. The improved performance that are possible under a 42-volt system Decrease of the amount of power drained off the power train by belt driven components and accessories. (fuel consumption is reduced) Flexibility to accommodate driver assistance technologies like collision avoidance systems, parking assistance etc.
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SINGLE 42 VOLT SYSTEM

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SINGLE 42 VOLT SYSTEM

The simplest design on paper, but its the hardest to put into production,
It requires that all of the electrical components in the vehicle be redesigned to operate on 42-volts. A single 42-volt system would avoid cost, weight and packaging problems created by a second battery. Because of the high initial costs of implementing a single 42-volt system, a dual-voltage architecture is preferred.

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INDUSTRIAL IMPACT

The list of 12-volt products and systems that will feel a direct impact by the shift to 42-volt standards is quite extensive.
More obvious are the mechanical devices and systems that can readily be replaced by electronic versions: water pumps, air conditioning compressors, and the like. Within 10 years we will see a move to 42-volt systems in an attempt to improve fuel consumption, decrease emissions and provide consumers with more options.

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INDUSTRIAL IMPACT

Falling revenue and a shrinking market will inevitably affect investment in new mechanically driven products and the processes that produce them. As the auto industry changes over to the 42 volt standard, and begins eliminating belt-driven components, companies that are not ready for radical changes in engine technology, will find themselves at a competitive disadvantage.

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HOW TO USE CURRENT 12 V SYSTEM COMPONENTS IN 42 V SYSTEM?

Modules will convert 42 V of charging system into 12 V, so 12 V system component can be used with 42 V technology.

A common module will be located at the centre of the vehicle powering several 12 V system components.
Advances in electronics may allow each 12 V device to have its own module.

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DISADVANTAGES

Safety is a concern with 42 V power systems. In 42 V, arcing effect can generate temperatures above 1000oC Fire hazard develops.

By mistake or accidentally a car owner disconnects a live wire or a switch becomes faulty - Fire hazard develops.
Costly.

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AUTO ANCILLARY MANUFACTURES CHALLENGES

Higher power relays, switches, standardized components such as connectors, fuses and semiconductor devices are need to be developed for this system. Due to the enormous 14-V component infrastructure, the first 42-volt systems will be dual voltage systems.
Manufacturers will also have to consider how to handle the aftermarket items that consumers add, like fog lamps, radar detectors, etc.

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INTEGRATED STARTER GENERATOR (ISG)

It replaces the conventional starter motor and alternator (generator). Apart from its two basic function (starter and alternator), an auxiliary one, as a convenient automatic vehicle start stop system for improved fuel efficiency. The electronic control system switches off the engine at zero load (when standing at traffic light) and automatically restarts using the ISG very rapidly when the accelerator pedal is pressed.

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INTEGRATED STARTER GENERATOR (ISG) (Contd..)

During braking the ISG can convert the Kinetic Energy (KE) into Electrical Energy (EE) and them feed this power back into electrical system. As it fully supports the stop and start operation, electric driveoff, acceleration and recycling of braking energy the ISG helps to reduce both fuel consumption and emissions. The compact dimensions of the ISG allow it to be placed directly on the crankshaft between the engine and the transmission. The ISG electro-magnetically transmits its force to the crankshaft when the key is turned and starts the engine at a fraction of the time it would take a conventional starter.

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INTEGRATED STARTER GENERATOR (ISG)

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INTEGRATED STARTER - GENERATOR

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ISG - NECESSITY

To eliminate starter which is only a passive component during engine operation. To replace belt and pulley coupling between the alternator and the crankshaft.

To eliminate slip rings and brushes used in alternators.

ISG acts as a bi-directional power converter, changing mechanical energy into electrical energy and vice versa.

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ADVANTAGES

Because of its start-stop and the recuperative braking capability and higher voltage makes the ISG more efficient than a conventional generator resulting in upto 20% reduced overall fuel consumptions. Because using ISG no fuel enrichment is necessary to start the engine lower start emissions can be achieved, especially during the cold start period. It can achieve noise and vibration reduced operation improving comfort. The components of the ISG system are not subject to wear and tear and are maintenance-free because of the systems brushless design. ISG Can be integrated with most of actual car models, therefore is no need to develop a new car model or significantly modify an existing car. Thus it is very cost-efficient system.
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CHALLENGES

High starting torque at most unfavorable operating conditions. Wide speed range in generator mode. High efficiency in wide speed range (600 8000 rpm). Vibrations of up to 20 g in crankshaft mounted systems. Cycle life over 250 000 stop/start cycles in 10 years. Good serviceability, high reliability, acceptable cost, etc.

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ELECTROMAGNETIC VALVES (EMV)

Used in camless valve actuation Electromagnetic valves (EMV) would be actuated by sending current pulses through spring-loaded solenoids with the valve stems as their cores

Therefore they could be opened and closed without regard to crankshaft position.
This would allow each valve to be controlled independently for timing, profile, and liftgiving far more flexibility than any crankshaft driven variable valve timing system.

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ELECTRICALLY HEATED CATALYTIC CONVERTER

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ELECTRICALLY HEATED CATALYTIC CONVERTER

The electrically heated catalytic converter is another new kind of load on the battery. The electric heater will get the catalytic converter up to temperature quickly, which is important because a converter can reduce nitrogen emissions (NOX) only when it is hot. Another proposal calls for preheating the catalytic converter from a dedicated battery before start-up. Such heaters could eliminate a large source of pollution--emissions from cold engines.

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ELECTRICAL ACTIVE SUSPENSION

Active suspension system, will keep the passenger compartment on a flat trajectory (constant ride height) as the car wheels encounters a bump, bounce over potholes and rough roads. The system senses a vehicle's vertical accelerations and energize electromechanical actuators to counter them. Although active suspension is available today on some highend luxury vehicles, it does not have the bandwidth of a fully electrical system and therefore does not achieve its full potential. Expensive, heavy, and power-intensive, an active suspension system will need very high voltages to operate efficiently.

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SUSPENSION BY WIRE

Hydraulically operated but electronically controlled Road profile is sensed Other method is calculating vertical wheel height Coil springs also present for more comfort

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ELECTRIC POWER STEERING

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ELECTRIC POWER STEERING

The current mechanical power steering system continually place a small load on the engine even when steering assist is not required. A small permanent-magnet motor powered by the vehicle battery supplies the effort necessary instead of a hydraulic jack powered by a pump. The systems steering effort is correlated to vehicle speed, steering torque and steering position. An advanced feature of EPS systems can actually help enhance the return ability characteristics of the steering with its assisted return-to-center feature.
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ELECTRIC POWER STEERING

Some manufacturers like Honda currently offers EPS on their niche products like the NSX, S2000, and the Insight hybrid. The disadvantage under the current 14-volt systems is their large current requirement during low speed maneuvers, which makes them only applicable in small to midsize vehicles. The move to 42-volt will allow the use of EPS on all cars, SUVs, and light commercial vehicles.

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ELECTROMECHANICAL BRAKES

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ELECTROMECHANICAL BRAKES (EMB)

Electromechanical Brakes (EMB) dispense with the master cylinder, vacuum servo, all hydraulic components, and hydraulic fluid found in a conventional brake system. With an EMB system, Functions such as Anti-lock Braking System (ABS), Traction Control System (TCS), vehicle stability, and Panic Brake Assistance also possible.

So this system demands a new 42V system to be implemented in the future cars.

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ELECTRIC WATER AND OIL PUMPS

To improve the mileage, the only solution is transition of engine driven water pump and oil pump to the systems run on electricity. With the implementation of 42-volt, the engine management system can be designed to control an independently driven electric water pump to efficiently provide cooling demand while allowing for improvements in fuel efficiency.

The electric load and speed variation needed to implement these electric pumps can only be provided by a 42-volt system.
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ELECTRIC AIR-CONDITIONING

In contemporary A/C configurations, the compressor is driven off of the accessory belt, via an electromagnetically clutched pulley on the compressor. When the engine is shut off at a stop there is an electro-magnetic clutch on the crankshaft instead of the compressor, which disengages. At this point the Starter/Generator spins the accessory belt. This system is only electrically driven when the engine is not running.

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MOTORS AND ACTUATORS

In a 12 V system, motors lose 15% of their energy in the brushes alone. Many automakers favor 42 V DC, which can readily be handled by power MOSFETs made by the standard 60-V process. 42V motors can be made comparatively smaller in size, which could mean thinner doors that offer more passenger room, or even additional storage space under seats.

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STEER BY WIRE TECHNOLOGY

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STEER BY WIRE TECHNOLOGY

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STEER BY WIRE TECHNOLOGY

EMBEDDED SYSTEMS play a impotant role. DELPHI and BMW are working together for years. Reaction time is much quicker than HYDRAULICS CIRCUIT

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THROTTLE BY WIRE TECHNOLOGY

Eliminates the mechanical elements of a throttle substituted with fast responding electronic circuits Greater accuracy of data improves the drivability of the vehicle

Reduces the number of moving parts

There is no possible wear in parts Thus less maintenance and more life

Reduces the drivers fatigue.

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BRAKE BY WIRE TECHNOLOGY

Dry electrical components systems replaces conventional actuators with electrical motor-driven units

ADVANTAGES

Connects with emerging systems, such as ABS and Adaptive Cruise Control (ACC) Reduces system weight to provide improved vehicle performance requirements Supports better control over the brake even in hill roads also Removes mechanical components for freedom of design

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SAFETY IMPROVEMENT USE OF ADVANCED ELECRICAL TECHNOLOGIES

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PROPOSED SYSTEM ARCHITECTURE

Single 42-volt systems Dual Alternator Dual voltage o Dual Alternator o Dual starter o DC/DC Converter

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ON GOING PROJECTS IN ELECTRICALS AND ELECTRONICS

Investigate the design and control of high-power alternators incorporating power electronic controls. Investigate the application of a new composite magnetic material to the development of new permanent magnet machines that can achieve higher performance at lower cost for automotive applications. Modelling and controlling energy flow in advanced automotive electrical system.

Investigate advanced topics in fault detection and correction in dual-voltage systems.

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THANK YOU

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