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Advanced Powertrain Forum Management Briefing Seminars Aug. 2, 2011 Doug Patton, Senior Vice President, Engineering Division DENSO International America. Intro. Anticipating Customer’s Needs. Key Points About DENSO How do we get to 50+ mpg Beyond Powertrain Long-term: Electrification

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slide1
Advanced Powertrain ForumManagement Briefing SeminarsAug. 2, 2011

Doug Patton, Senior Vice President, Engineering DivisionDENSO International America

slide2
Intro

Anticipating Customer’s Needs

  • Key Points
  • About DENSO
  • How do we get to 50+ mpg
  • Beyond Powertrain
  • Long-term: Electrification
  • Mid-term: Start/stop
  • Short-term: GDI
  • Conclusion
slide4
Beyond Powertrain
  • Have to Look at Entire Vehicle
  • Aerodynamics
  • Mass
slide5
Beyond Powertrain
  • Alternative Fuels
  • Diesel
  • Ethanol
  • Hydrogen
  • Bio-fuels
slide6
● Climate Control Products

Automatic air conditioner, car heater, rear cooling unit, compressor, sensors, etc.

● Powertrain Related Products

Engine management system, electronically-controlled diesel system, starter, alternator, radiator, etc.

● Body Electronics Products

Instrument cluster, windshield wiper remote keyless entry system, IC flasher, horn, etc.

Beyond Powertrain

Overall Systems Approach

● Driving Control andSafety

Cruise control system, airbag sensing system,vehicle stability control, antilock braking system, traction control system,etc.

slide7
Beyond Powertrain
  • How do all the pieces fit together?
  • Collaboration is key
  • Technology tradeoffs
  • Weighing cost-benefits
  • Best systems
slide8
Long-term Powertrain Advancements
  • How do we achieve more than 50 mpg?
  • Electrification
  • Plug-in hybrids
  • Extended range vehicles
  • Advanced hybrids
  • Battery electric vehicles
slide9
Long-term: Electrification

How Will We Get There?

  • Components
  • Cost-value
  • Integration
slide10
Long-term: Electrification

DENSO’s EV/HEV System Components

Energy

Power SupplySystem

Accelerator pos. sensor

Cooling fan

B-ISG

Signal

Bat. MonitorECU

ICE

ENG ECU

HV ECU

HV Radiator

HV Battery

Charger

Climate control systemw/e-compressor

Transaxle

Motor/Generator

A/Cインバータ

Traction Inverter

Current sensor

インバータ

HV Relay

e-Drive

DC-DC

Converter

LV Battery

(12V)

slide11
Long-term: Electrification
  • Cost-value
  • Goal to reduce size and cost by 40 – 60 percent using our experience in thermal management, power electronic design and manufacturing.
  • Complex Component Integration
  • Marry or bundle technologies into a
  • single package or box.
slide12
Mid-term: Start/Stop Technology
  • 35.5+ MPG 2016 and Beyond
  • Start/Stop Technology
  • Technical capability
  • Market acceptance
slide13
ISG

ECU

AE starter

Crank

Angle

sensor

Alternator

Electric LoadAudio etc.

AT

A/C

ECU

Vacuum

Sensor

6.5%

Charging

Control

in Sensor

PbBattery

4%

5.5%

Charging Control

3%

Engine stops when

vehicle stops

Mid-term Start/Stop Technology

  • System 1:
  • Advanced Engagement (AE) Starter
  • Not “change of mind” capable as engine needs to be at zero rpm before restart
  • 3% to 5% fuel savings
  • Existing proven technology
  • Simple integration

MT

Charging Control

slide14
7.5%

5%

6.5%

Charging Control

Engine stops

while Deceleration

Mid-term: Start/Stop Technology

  • System 2:
  • “Change of mind” capable
  • Restart engine before zero rpm
  • Permanently Engaged (PE) and Tandem Solenoid (TS) starters
  • Integration
  • Increase fuel savings potential to more than 4%

ECU

PE or Tandem

Starter

EPS

Crank Angle

Sensor (Both direction)

Electric A/T

Pump

LIN

Alternator

Electric LoadAudio etc.

Brake

System

A/C

ECU

DDC

Vacuum

Sensor

Charging

Control

in Sensor

PbBattery

Electric

W/P

Cold

Storage

slide15
10.5%

Charging

Control

7.5%

Mid-term: Start/Stop Technology

  • System 3:
  • Electrical system tailored to repeated on/off cycling of start/stop systems
  • Overall fuel savings potential increases to more than 7%

ECU

PE or Tandem

Starter

EPS

Crank Angle

Sensor (Both direction)

Electric A/T

Pump

LIN

Alternator

Electric LoadAudio etc.

Brake

System

A/C

ECU

Vacuum

Sensor

Charging

Control

in Sensor

Electric

W/P

Cold

Storage

Power

source

PbBattery

slide16
Market Acceptance: Start/Stop Technology
  • Market Acceptance
  • Driving environment: Rural vs. City Driving
  • Fuel economy: Real world vs. Sticker
slide17
Market Acceptance: Start/Stop Technology
  • Market Perception
  • Physical
  • Restart time
  • Occupant Comfort
  • Noise, vibration, harshness (NVH)
  • Emotional
  • Green
  • Financial
slide18
Short-term: Fuel Efficiency
  • Gasoline Direct Injection
  • High-pressure fuel pump
  • High-pressure fuel injectors
  • Advanced combustion
  • Other Improvements:
  • Down-sizing
  • Turbo-charging
  • Intercooler
slide19
LEVIII

LEVII

NMOG + NOx (g/mile)

Short-term: Emissions

EmissionsRequirements

Year

slide20
Conclusion

Overall Strategy to Meet Future Requirements

  • Have to look at multiple solutions – under the hood and beyond the powertrain
    • Integration of technology
    • Maximize system efficiency - Cost
    • Quality
    • Manufacturing
  • Affordable and Appealing
  • Vehicles
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