Advanced Powertrain Forum Management Briefing Seminars Aug. 2, 2011 Doug Patton, Senior Vice President, Engineering Division DENSO International America.

Advanced Powertrain Forum

Management Briefing SeminarsAug. 2, 2011

Doug Patton, Senior Vice President, Engineering DivisionDENSO International America

Intro

Key Points• About DENSO • How do we get to 50+ mpg• Beyond Powertrain• Long-term: Electrification• Mid-term: Start/stop• Short-term: GDI• Conclusion

Anticipating Customer’s Needs

About DENSO

Beyond Powertrain

Have to Look at Entire Vehicle• Aerodynamics • Mass

Beyond Powertrain

Alternative Fuels• Diesel • Ethanol• Hydrogen• Bio-fuels

Beyond Powertrain

● Climate Control Products Automatic air conditioner, car heater,

rear cooling unit, compressor,

sensors, etc.

● Body Electronics Products Instrument cluster, windshield wiper

remote keyless entry system,

IC flasher, horn, etc.

● Powertrain Related Products Engine management system,

electronically-controlled diesel system,

starter, alternator, radiator, etc.

● Driving Control and Safety Cruise control system, airbag sensing system,

vehicle stability control, antilock braking system,

traction control system, etc.

Overall Systems Approach

How do all the pieces fit together?

• Collaboration is key• Technology tradeoffs• Weighing cost-benefits• Best systems

Beyond Powertrain

Long-term Powertrain Advancements

How do we achieve more than 50 mpg?

Electrification• Plug-in hybrids• Extended range vehicles• Advanced hybrids• Battery electric vehicles

Long-term: Electrification

How Will We Get There?

• Components• Cost-value• Integration

LV Battery

(12V)

e-Drive

Cooling fan

HV BatteryA/C ｲﾝﾊﾞｰﾀ

インバータ

HV ECUICE

Power SupplySystem

Bat. MonitorECU

Climate control system

w/e-compressorTransaxle

Motor/Generator

DC-DC Converter

HV

Rad

iato

r

ENG ECU

Accelerator pos. sensor

Signal

Energy

HV Relay

Current sensor

B-ISG

Charger

Long-term: Electrification

DENSO’s EV/HEV System Components

Traction Inverter

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.

Mid-term: Start/Stop Technology

35.5+ MPG 2016 and Beyond

Start/Stop Technology• Technical capability• Market acceptance

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

Fuel Consumption

(2L GDIMT & AT)

SystemConfiguration

AE starter AE starter

ＰｂBattery

ISG ECU

ISG ECU

Electric LoadAudio etc.

Electric LoadAudio etc. A/C

ECU

A/C ECU

ChargingControl

in Sensor

ChargingControl

in Sensor

VacuumSensor

VacuumSensor

AlternatorAlternator

Crank Angle sensor

Crank Angle sensor

Charging Control

MT

Engine stops when

vehicle stops

Charging Control

4%

3%5.5%

6.5%

AT

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%

Mid-term: Start/Stop Technology

Fuel Consumptio

n(2L GDI

MT & AT)

SystemConfiguratio

n

7.5%

5% 6.5%

Engine stopswhile Deceleration

Charging Control

PE or Tandem Starter

PE or Tandem Starter

Ｐｂ Battery Cold

Storage Cold

Storage

Electric A/TPump

Electric A/TPump

ECU

ECU

DDC DDC A/C ECU A/C

ECU

ChargingControl

in Sensor

ChargingControl

in Sensor

Brake System

ＥＰＳＥＰＳ

Crank Angle Sensor

(Both direction)

Crank Angle Sensor

(Both direction)

LINAlternator

LINAlternator

Ele

ctric

Lo

adA

udio

etc

.

Ele

ctric

Lo

adA

udio

etc

.

Electric W/P

Electric W/P

VacuumSensor

VacuumSensor

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%

Fuel Consumptio

n(2L GDI

MT & AT)

SystemConfiguratio

n

ChargingControl

10.5%

7.5%

PE or Tandem Starter

PE or Tandem Starter

LINAlternator

LINAlternator

Power source

Cold Storage Cold

Storage Electric

W/P

Electric W/P

Electric A/TPump

Electric A/TPump

ECU ECU

Ele

ctric

Lo

adA

udio

etc

.

Ele

ctric

Lo

adA

udio

etc

.

Brake SystemA/C

ECU

A/C ECU

ＥＰＳＥＰＳ

VacuumSensor

VacuumSensor

Crank Angle Sensor

(Both direction)

Crank Angle Sensor

(Both direction)

Ｐｂ Battery

ChargingControl

in Sensor

ChargingControl

in Sensor

Market Acceptance: Start/Stop TechnologyMarket Acceptance• Driving environment: Rural vs. City Driving • Fuel economy: Real world vs. Sticker

Market Acceptance: Start/Stop TechnologyMarket Perception

Physical • Restart time• Occupant Comfort• Noise, vibration, harshness (NVH)

Emotional• Green• Financial

Gasoline Direct Injection• High-pressure fuel pump• High-pressure fuel injectors• Advanced combustion

Other Improvements:• Down-sizing• Turbo-charging• Intercooler

Short-term: Fuel Efficiency

Year0.000

0.020

0.040

0.060

0.080

0.100

0.120

0.140

2005 2010 2015 2020 2025

NM

OG

+ N

Ox

(g/m

ile)

LEVII LEVIII

Short-term: Emissions

Emissions Requirements

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

THANK YOU