Global Powertrain Development at Ricardo

Global Powertrain Development at Ricardo
Powertrain Strategies for the 21st Century: Designing Global Powertrains
July 2012
www.ricardo.com
© Ricardo plc 2012
Agenda

Introduction to Ricardo

Advanced Technology Development and Market Entry

Engine Development Examples

Competitive Cost Management

Driveline and Hybridization
© Ricardo plc 2012
2
Introduction to Ricardo
Ricardo is one of the world's leading management &
engineering consulting firms
Established Success Factors






International Presence
Focused on value-adding services
Solving key industry issues
Programme delivery as a core competence
Investment in people and technology
Critical mass with revenues exceeding £190m
and over 1800 people
Independent and long established (1915)
Value-Adding Capabilities
UK
Germany
USA
Japan
China
India
Global Client Base (selection)
Strategy
Consulting
Strategy development
Efficiency
M&A support
Improvement
Cost Optimization
Procurement strategy
Product development
Technical
support service
Manufacturing &
supply chain
Product
R&D, Industry
and Technology Strategy
Know-How
Vehicles
Engines
Product
Engineering
Transmissions
Motor sport
& drivelines
Control &
Electronics
High performance
exhaust systems
Software
Products/
Production
© Ricardo plc 2012
3
Introduction to Ricardo
Ricardo’s contribution to some key developments in the
history of transportation
1915 Engine Patents Ltd.

Harry Ricardo formed Engine Patents Ltd, the precursor of today’s Ricardo Plc becoming famous
for the design of a revolutionary engine which was utilised in tanks, trains and generators
1930 Fundamental Fuel Research

Development of a variable compression engine which was used to quantify the performance of
different fuels. This was the forerunner of today’s Octane rating scale (RON)
1935 Citroën Rosalie

The world’s first diesel production passenger car, the Citroën Rosalie, was introduced
featuring a Comet Mk III combustion chamber. Derivatives of this design are still used
1951 Fell Locomotive

The 2,000bhp Fell Locomotive was the world’s first diesel mechanical locomotive, with a novel
transmission invented by Lt. Col Fell. It was powered by four Paxman-Ricardo engines.
1966 Jensen FF

The 4WD system of the Jensen FF, the world’s first 4WD passenger car, was developed by
Ferguson Research Ltd (which later became part of Ricardo) launched at British Motor Show
1986 Voyager

Voyager was the first aircraft to fly around the world non-stop without refuelling. Ricardo
redesigned the Teledyne Continental engine, improving fuel economy and reducing drag
1999 Le Mans Successes

Advanced technology helped Audi to secure its special place in motorsport history with a novel
transmission to win 5 races out of 6 entries at the 24-hour race of Le Mans
2005 Bugatti Veyron

Development and manufacturing of the DCT (dual clutch transmission) for the fastest road going
car in the world , the Bugatti Veyron
2006 Record Breaking Year

2011 NHTSA/CAFÉ Fuel Economy

Development of the world's fastest diesel engine for JCB. The DieselMax set the diesel land
speed record at Bonneville with a speed of 350 mph (563 kph)
Ricardo helped shape future North American CAFE Fuel Economy Ruling
© Ricardo plc 2012
4
Introduction to Ricardo
Ricardo’s world wide footprint allows us to support clients in
their local markets
Ricardo UK Ltd
Ricardo GmbH
Ricardo Sweden
Ricardo Prague
Ricardo Japan
Schwäbisch
Gmünd
Shoreham
Munich
Prague
+ Aachen
+ Wolfsburg
Tokyo
Cambridge
Leamington
Ricardo Korea
Ricardo Inc.
Detroit
Ricardo India
Ricardo France
Seoul
Ricardo China
Ricardo Italia
Delhi
Chicago
Ricardo Strategic Consulting Offices
Main Engineering Facilities
Ricardo Corporate Offices
Ricardo Representative Offices
1800+ people based in main
automotive centres around the world
Shanghai
© Ricardo plc 2012
5
Advanced Technology Development and Market Entry
Ricardo’s advanced propulsion technology market strategy
development process
Growth Options
Define Opportunity
Define Strategy
Growth Option 1: Bus market Entry
2015
2020
USD (M) PowerGenix Opportunity
Growth Option
Overview
Share of
Total
Segment
Scenarios
Sales
Volume
Market Definition

2020
13%
2,936
Optimistic
2015
10%
2020

874
9%
1,958
5%
477
Target two market entry points:
– Bus Integrators; no BMS required
as integrators have development
capability
–Bus VMs; likely to require BMS and
integrated battery pack
Develop battery suitable for mild and
full bus applications
– Mild Hybrid: ~1kWh energy; 7 kW
power
–Full Hybrid: ~37 kWh energy; 170
kW power

Primary targets: Yuchai, Weichai as
integrators; Xiamen Jinlong, Yutong
and Suzhou Jinlong as bus VMs

Typical Battery Requirement
Target Bus VM and Integrator Customer Programs
1
Huanghai, DD6129HES11
Charge Voltage:
800V
Peak Discharge Power:
170-200kW
HEV Segment
Vehicle
Type

Value Proposition

Dual approach:
– Drive-train integrators, who integrate and sell solutions to bus VMs; sell
the same drive-train to multiple bus VMs
– Bus VMs, who integrate the drive-train into a chassis and may also
build the bus body
Bus drive-train are used across multiple bus chassis, creating a strong
market entry opportunity for PowerGenix with a single product
Bus power-train integrators not likely to require BMS capability; giving
PowerGenix the opportunity to target the segment while developing
internal competence
Bus VMs are likely to require a fully integrated pack
– Likely secondary target, to enable PowerGenix time to develop suitable
BMS
Lower cost alternative to Li-Ion
Higher specific power than NiMH should reduce pack weight, creating
more opportunity for passenger pay-load, critical for operator TCO
Filter Target Customer
Selection Criterion
Program
Planned Vehicle Program SOP
Time

2011
2012
2013
2014
2015
2020

Vehicle Volume

170-200kW
Bus
Xiamen Jinlong
HEV Bus
X
0.2
0.5
1.5
430A
Bus
Yutong
11m Bus
X
0.1
0.5
1.5

Kerb weight 13.2 Tonnes
132kW DFM Cummins Diesel
Peak Charge Current:
210A
Bus
Yutong
HEV Bus
0.3
0.7
24-50 Seats, 73 passengers
SOC Range:
40-60%
0.5
1.5
Instantaneous Charge Current:
210A
0.3
0.7
Continuous Charge Current:
105A
1.5
5
1.4 m Ohms
0.2
0.5
3.8
11.4
37kWh
Battery Capacity:
64Ah
Operating Temperature:
-20 to +55 Celsius
Cell Internal Resistance:
Battery Cell Cost (NiZn, China)
2015: 118,400RMB / $17,000
Target Battery Weight:
475-500kg
Life-cycle:
6 years
Target battery size:
800L
Bus
DFM
HEV Bus
X
X
Bus
DFM
HEV Bus
Integrator*
Yuchai
HEV Powertrain
X
Integrator*
Weichai
HEV Powertrain
X
TOTAL


Peak Discharge Current:
Battery Energy:

0.1
0.2
X
0.1
0.1
0.05

Bus VM

Target VM
Micro
576V
Full
400V
System Voltage:
Mild
Discharge Voltage:
Peak Charge Power:
S

1
11.9 Metres Long

Product Definition
INDICATIVE




Target Chinese Domestic Bus VMs and drive-train integrators (eg: Yuchai,
Weichai)
Key battery competitors include Chunlan, Forever, Shenzhou (NiMH);
ANX, ATL, Lishen (LiFePo4) MGL (LiMN04)
Long List of Potential Bus VM &
Integrator Customers
Full Hybrid Bus Vehicle Battery Requirements
Typical Vehicle

Identify Target Program
Technology Requirements

Sales Channel
Commence market activity with
prototype pack by end 2010 and target
market entry by 2012/13
–Relatively short programme lead
times due to integrator role in
development of drive systems

Baseline
2015

High Level Strategy



Xiamen Jinlong
Yutong
Chongqing Hengtong
Dandong Huanghai
Suzhou Jinlong
Jiangsu Youyi
Shanghai Sunwin
DFM Bus
Yangzhou Yaxing








BAIC
Zhongtong
Ankai
FAW Bus
GAIG Bus
CSR Times
Shenzhen
Wuzhoulong


Bus VM







Xiamen Jinlong
Yutong
DFM Bus
Bus Powertrain
Bus Powertrain

Target Customers
Product Fit
Non-captive battery supply
Vehicle/ HEV volume
Openness to Ni-Zn
Etc

Yuchai
DFM Cummins
Cummins
FAW
Weichai

21 VMs and
integrators
Yuchai
Weichai
5 Target VMs and
integrators
Source: Ricardo Analysis
© Ricardo plc 2012
6
Advanced Technology Development and Market Entry
Ricardo scientists and engineers continue to develop and
improve combustion engine technology
Advanced Combustion Technology for
Improved engine-Out NOx
Test
Data
Vehicle
Simulation
System
Optimisation
Code
System
Modelling
Analysis
Thermal / FE
© Ricardo plc 2012
7
Engine Development Examples
One of our latest accomplishments is the design and
manufacture of the McLaren supercar engine
McLaren MP4-12C Avoids Gas Guzzler Tax
3.8L Twin Turbo V8
592 Horsepower
443 ft-lbs peak torque
0-60 in 3.1 seconds
Redline 7000 RPM
22 MPG EPA Highway
© Ricardo plc 2012
8
Engine Development Examples
Our work for a regional OEM is a prime example of Ricardo’s
capabilities to support development from beginning to end
Projects Overview
R-UK
RSC
Powertrain Seminar
(3 days)


Long-term
Power-train
Strategy
( 5 months)
Product Group
conducted a three day
seminar at OEM
covering future engine
and transmission
technologies

This triggered a
discussion at OEM
about their future
engine strategy

Close collaboration
between RSC, RMalaysia and R-UK

Two phased approach
with RSC leading
Phase 1 but much
stronger R-UK
participation in Phase 2
(Phase 2)

Key recommendation
was to develop own
engine programme

OEM subsequently
asked Ricardo to assist
with development of its
future long term
powertrain strategy

R-UK handed over lead
for proposal
development to RSC
Asia
Source: Ricardo Strategic Consulting
Confidential
Ricardo Strategic
Consulting developed
the long term engine
and transmission
strategy over five
months
R-UK
Engine
Feasibility
Study
(6 months)
RSC
Procurement
and Quality
Support
(6 months)

Six months concept
feasibility study 3 years
prior to SOP

Procurement of first
wave of components
for new engine

Engine concept proven
and demonstrated

Very operational
approach with
emphasis on learning
to doing
RD.11/399001.01
© Ricardo plc 2011
9
Engine Development Examples
After the architecture is defined, design begins with emissions
and fuel economy targets
USA
Tier I
Tier II
CAFE (NHTSA)
California
LEV2
Approximate Comparison of EU and US Legislation
Euro 4 (2005)
Europe
Euro 5 (2010)
Predicted
NOx vs PM over FTP-75 cycle for various
applications with Euro 4 PC technology
0.12
140 g/km CO2
T1 - LDV
0.1
HVAC effects
Speculative
10
("real-world" effects)
Soot formation
2005area
Local Equivalence Ratio
9
8
2000
7
6
PM (g/mile)
0.08
Euro III
PM sizeT2
spectrum
Bin 10
(Max for HLDT)
Off-cycle Emissions?
0.06
2010
T2 Bin 9
(Max for LDV/
LLDT)
0.04
2015
~6L
Large
SUV
~4.5L
Mid SUV
~3L
Small
SUV
Euro IV
(2005)
5
NOx formation
area
4
3
T2 Bin 8
0.02
T2 Bin 5
2
0
1
1000
0
1400
1800
2200
Temperature /(K)
2600
3000
0.2V
Euro
(2010)
(Proposed)
0.4
0.6
0.8
NOx (g/mile)
1
1.2
1.4
Euro legislation represents
Diesel passenger car
© Ricardo plc 2012
10
Competitive Cost Management
Concurrent with design, supplier qualification, sourcing, and
component costs are established
2
15
5
6
7
8
16
3
5
4
3
27
32
18
5
2
3
61
6
4
1
2
6
2
© Ricardo plc 2012
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Competitive Cost Management
Powertrain components are sourced in successive waves
based on their cost and development lead time
Commodity Segmentation
Pumps
Development Lead Time Requirements
Throttle
Body
Piston
Cam
Conrod
Cyl.
Block
Pri Drive
High
VVT
Head Gskt
ECU
Wave 1
Fuel
System
Catalyst
Sensors
Vac. Pump
Turbo
Valves
Engine
Covers
Wave 2
Crankshaft
(if outsourced)
Composites
Alternator
Crit
Fasteners
Flexplate
Low
Sealing
excl. Head
Gskt
Starter
HPAS
A/C Compressor
Flywheel
Wave 3
Other
Turbo
Low
Source: Ricardo Strategic Consulting
Confidential
Medium
High
Cost Contribution
RD.11/399001.01
© Ricardo plc 2011
12
Driveline and Hybridization
Additional final drive ratios enable downsizing allowing engine
to operate in narrower peak power and efficiency bands
Technology Development
Automatic
• Increase in the number of
speeds offered by
conventional planetarytorque converter
automatics from the US
standard 4 speeds to 6/7
combined with adaptive
control strategies
+ Diesel engines with high torque
at low engine speeds can
capitalize on overdriven gears to
reduce engine speed during
cruising conditions and benefit
from low gearing to improve
launch feel
• Automatic transmissions
using a variator to offer
step-less ratio selection
+ Continuously variable ratios can
be used to ensure the
driveability of downsized /
boosted engines by keeping the
engine within its optimum
operating window
Market
DCT
MT
• Hydraulically actuated,
twin input shaft automated
manual transmissions
offering gear pre-selection
and shifting without torque
interrupt to optimize shift
speed and quality
+ Increased ratio spread and
control capabilities improve the
driveability of downsized /
boosted engines with
mechanical efficiency
approaching that of conventional
manual transmissions
78
CVT
%
AT
DCT
CVT / IVT
DCT
Benefits to Boosted
Vehicles
MT
7%
CVT
AT
DCT
MT
5%
CVT
AT
© Ricardo plc 2012
13
Driveline and Hybridization
Hybridization of heavy vehicles shows substantial
opportunities to reduce fuel consumption
© Ricardo plc 2012
14