CTI Symposium 2013, Berlin

DENSO’s contribution for the future

E-mobility through new technology
Max Nakagawa
Chief Technology Officer
DENSO AUTOMOTIVE Deutschland GmbH

Ulrich Schwarz
Senior Manager, EV/ HV Engineering
DENSO AUTOMOTIVE Deutschland GmbH

Jakob Andert
Project Manager, Electrics / Electronics
FEV GmbH

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
AGENDA 1 / 25

1. DENSO Company Profile

2. CO2 Reduction Activity
3. DENSO Long-Term Strategy
(Innovative approach for development)

4. New Proposal for Hybrid Transmission

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
AGENDA 2 / 25

1. DENSO Company Profile

2. CO2 Reduction Activity
3. DENSO Long-Term Strategy
(Innovative approach for development)

4. New Proposal for Hybrid Transmission

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
 3 / 25
DENSO Company Profile

Established December 16, 1949

Capital €1.44 billion

Net sales
Consolidated basis €27.55 billion

Non-consolidated basis €17.51 billion

Net income
Consolidated basis €1.40 billion
Non-consolidated basis €1.12 billion

Employees
Consolidated basis 132,276
Non-consolidated basis 38,385

Consolidated subsidiaries 183

(Japan 62, North America 28, Europe 34, Asia/Oceania 53, Others 6)

Affiliates under the equity method 32

(Japan 13, North America 4, Europe 2, Asia/Oceania 11, Others 2)

Notes:
Euro amounts are shown for convenience, at the rate of ¥130 = €1, the approximate exchange rate prevailing on July 10 2013.
Billion is used in the American sense of one thousand million. / as of March 31, 2013

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
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 4 / 25
DENSO Global Network
North America Europe Japan

Consolidated subsidiaries Consolidated subsidiaries Consolidated subsidiaries

Companies: 28 Companies: 34 Companies: 62

Employees: 14,205 Employees: 13,152 Employees: 25,542

Affiliates under the equity method Affiliates under the equity method Affiliates under the equity method

Companies: 4 Companies: 2 Companies: 13

Employees: 1,480 Employees: 645 Employees: 5,500

Others Asia-Oceania

Consolidated subsidiaries Consolidated subsidiaries

Companies: 6 Companies: 53

Employees: 3,427 Employees: 31,316

Affiliates under the equity method Affiliates under the equity method

Companies: 2 Companies: 11

Employees: 737 Employees: 3,319

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
DENSO Global Network (Europe Operation) 5 / 25

EU Technical Center
Core Center
Aachen Engineering Center TEC
Powertrain, Electric/Electronics,
EV/HV and Info&Safety Thermal/R&D

Thermal European Center

Engineering Center
Aachen(DE) Coventry(UK)

Munich(DE) Gothenburg(SE) Coventry

Gothenburg

U.K.
• Airconditioners
• Heaters
Munich
• Radiators GERMANY
Engineering Center
• Oil Coolers • Compressors
POLAND
• Intercoolers • Starters
Aachen • Small Motors
Engineering Center Czech (2003)
• Airconditioners
• Heat Exchangers

HUNGARY
• Common rail systems
• VCT Development- and Sales Center
ITALY
• ETC
• Airconditioners Headquarter
PORTUGAL
SPAIN • Heaters
• Intercoolers Production: A/C-Komponenten
• ECU • Radiators ITALY
• Heaters
Production: Powertrain, Electric, Elektronic
• Gasoline Coolers • Ignition Coils • Starters
• Stick Coils • Alternators Sales Offices
• Air Flow Meter • Small Motors
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
AGENDA 6 / 25

1. DENSO Company Profile

2. CO2 Reduction Activity
3. DENSO Long-Term Strategy
(Innovative approach for development)

4. New Proposal for Hybrid Transmission

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
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IEA 450ppm CO2 scenario 7 / 25

Source: World Energy Outlook 2010, IEA※

※International Energy Agency
42

40 Current Policies Scenario

[Gton]

38
Advanced
countries
Global CO2 emission

36 As it is 380ppm
(current)
34
Emergings
32

30

28 Developings
450 ppm Scenario
26 to hold the temperature rise
below 2deg.C
24
2010 2015 2020 2025 2030
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Roadmap for CO2 reduction 8 / 25

Improvement of engine efficiency

Improvement of Reduction of running losses,
fuel consumption Traffic flow control

Energy recovery Hybridization (ICE & Motor)

& reuse Energy recovery

CNG, Bio-fuels,
Energy diversity Hydrogen, and Electric energy

CO2 capture & storage

Renewable
energy Use of natural energy
Smart grids, micro grids

CO2 Free Automobile

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
 9 / 25
Scenarios for achieving 95g/km CO2
Segments (Gasoline) A B C D E
(Diesel) A B C D E
Improvement Items
Lower driving
resistance
Vehicle
Lighter weight
Light + Power saving
Electric power saving
Auxiliary Drive power saving
Lower friction
Improve combustion Improved Stop & Start
ICE +
Stop & start ICE system
Down sizing
Electric management Energy
Control
Thermal management management

Electrifi
HV Hybrid
-cation Plug-in HV
EV Range
extender
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
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 10 / 25
CO2 Reduction Technologies in Powertrain

＠ Practical road mode 12.6%

15.4% Drive force
① Efficiency 8.7%
improvement
10.2%
Heater core for heating,
accessories load
 Gasoline DI system 34.6%
Friction, transmission
 Diesel CR system 18.5% losses
Pumping loss
 EGR system
Cooling loss
Exhaust loss ② Load reduction
 Stop & start system
 Energy saving air conditioner
③ Energy regeneration
 Electric power saving
 Hybridization  Power generation control
 Energy and heat called DENPI, NETUHI-control
generation/storage components

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
DENSO HV/EV System Product Line-up 11 / 25

E-Drive system Energy

Under mass production

Inverter 12V BSG 48V BSG Motor Generator 12V Li-Ion

(HV)
Under development

Battery Pack

Inverter 48V Li-ion

HV Batt. pack Battery Pack w/
Cooling fan DCDC
BSG
HEV radiator

HV ECU
Batt. ECU

ICE Main Batt.

ENG ECU TCU
Charger
MG HV relay
(PHV)
Pb. Batt Current
(12V) DCDC sensor

HEV-ECU Batt. monitor ECU DCDC Charger

Current Sensor

Control ECUs E-Power conversion system

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
Electrification Direction 12 / 25

Full-Hybrid/
System Start & Stop Mild-Hybrid BEV
Plug-in Hybrid
High V Batt.

12V Transmission
T/M High V T/M High V
T/M
(Transmission)
Batt. INV2
INV2 Batt INV
INV MG
MG
Batt. High V INV1
INV1
MG2
Config.
12V Batt. Clutch
Clutch Batt CL MG2 High V
Batt
MG Planetary Planetary
INV
INV MG
MG1
MG1 Gear High V
STA Engine Gear
Starter 12V Batt.
12V Batt.
Batt.
12V Batt. 12V Batt.
Engine 12V Batt.

12V Batt.

Direction Higher Electrical Power

DENSO CORP. understanding of key requirement of Electrification is

higher power density
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 Motor Generator for Hybrid & Electric Vehicles 13 / 25

DENSO CORP. MG technology:

Segment Conductor High producibility
Insert
Maximum output torque

Welding

High power density

Square wire Round wire
Benchmarking results
+7%
Diameter

MG volume
MG volume =πD2/4×L

Space factor:53%
Length

DENSO CORP. develops Motor Generators suitable for future E-mobility

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Technology for Low Voltage Systems 14 / 25

Target Focus point

・Fuel consumption reduction at conventional ・Output density / efficiency improvement by
vehicle environment / low voltage system press SC starter / rotor with magnet
・Cooling enhancement by water cooling and
high heat accumulation cooling fin

Conventional product: New product under development:

SC Alternator belt-driven Integrated Starter Generator (= BSG)
High output density growth
Stator Liquid cooling Low iron loss
Rotor stator core Press SC
bent SC Water cooled
Low coil end
Rotor with magnet
【Temp. details】Heat release fin
Air cooling Heat capacity up
Reduction of short term output time
(Maximal current)
Temp.
spec Water cooling
Short term output
Successive output (Maximal current)
base temperature

Air cooled Successive output

base temperature
*SC：Segment Conductor cooling fin Integrated inverter

DENSO CORP. develops efficient e-machines (<60V) for easy integration

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
AGENDA 15 / 25

1. DENSO Company Profile

2. CO2 Reduction Activity
3. DENSO Long-Term Strategy
(Innovative approach for development)

4. New Proposal for Hybrid Transmission

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
DENSO Long-term (2020) Policy 16 / 25

Protecting Lives, preserving the planet, and

preparing a brighter future for generations to come

Preserve the Planet Security and Safety

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
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 DENSO Roadmap Structure 17 / 25

1st layer : Society / Regulations 2025 future social

Social trend, regulations, automotive industry image activity
Backcasting:
1.5th layer : Automobile Realize the future social image
Future automobiles, future society (customer value)

2nd layer : System

System function that will be needed in the future
Engineering RM Approaches for
innovation
3rd layer : Product activities
DENSO products that meet future needs Forecasting:
Acting ahead of future trends
4th layer : Technology
Core technologies needed for product completion

2015 2020

DENSO CORP. Roadmap based on “back-casting concept”

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
AGENDA 18 / 25

1. DENSO Company Profile

2. CO2 Reduction Activity
3. DENSO Long-Term Strategy
(Innovative approach for development)

4. New Proposal for Hybrid Transmission

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
New Hybrid Transmission System Concept 19 / 25

DENSO CORP. new Hybrid Transmission System Concept

 The predicted increase of the market share of

hybrid vehicles has led to a variety of transmission hybrid
power
and powertrain solutions train

 Strong variety increases development costs and

parallel serial mixed-
variance complexity hybrid hybrid hybrid

 Still many solutions suffer from high production

power
costs and large package speed
addition
torque
traction
force combined distribution
addition addition hybrid hybrid

 DENSO started developing a simplified hybrid single

shaft two shaft
hybrid hybrid
transmission system that offers all hybrid features Over 1000 concept
possibilities
– 1st proof of concept demonstrator was built and
successfully tested
– Layout is being optimized with engineering support
from FEV GmbH

DENSO CORP. started development of a new Hybrid T/M System concept

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 20 / 25
New Hybrid Transmission System: Structure
Structure of DENSO CORP. Hybrid Transmission System

Two Shaft structure with 2 electric

machines and combustion engine
Two gear-sets (Low and Overdrive gear)
for combustion engine and MG1
Small number of gears:
 Reduction of friction/meshing losses
thereby improving efficiency
 Allows very short packaging
 Reduction of cost and weight

(under development)

Simplified structure for improving cost, weight, package and efficiency

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New Hybrid Transmission System: Functionality 21 / 25

Functionality of DENSO CORP. Hybrid Transmission System

E-Drive Series drive Parallel Drive

• MG1 and MG2 both • MG1 is used as an • Low and overdrive gear
are propelling the electric generator for combustion engine
vehicle • MG2 works as and MG1
• Decoupling of engine propulsion source • Load shift for MG
possible to avoid efficiency improvement
coasting

3 different drive modes

Full hybrid functionality with strongly simplified gear-set
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 22 / 25
Hybrid Transmission System: Simulation results
Simulation Results
 Simulations were carried out
by FEV out to investigate the
practical capability of Hybrid
T/M System Concept
 Hybrid T/M System layout
stands demanding driving
situations even with low-
power ICE and MG
– WLTC and traffic jam cycles
can be driven in E-Drive with
MG2 only
– Demands of WLTC can be
covered with potential for
charging in series drive

Demanding cycles like WLTC can be handled even in layouts with low-power ICE and MGs;
Sufficient performance in series drive  backup drive mode for discharged HV battery
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 Rolling Moment Compensation 23 / 25

Low Vibration Concept

 NVH is very challenging for engines with low
cylinder numbers
harmonized rotating mass moments of inertia
 Rolling moment can cause heavy shaking, esp.
engine start
 Smooth engine starting behavior is a major
challenge hybrid vehicles
 Compensation by FEVcom technology by FEV:
– Rolling moment compensation of engine and MG
 nearly vibration-free engine cranking reversion of rotation rigid gear drive

 Application in Hybrid-T/M System

– Counter rotation of engine and MG1 allows increase NVH-quality
FEVcom principle in series drive through FEVcom-concept
Full Engine Vibration Compensation
– No connection of combustion engine to wheels

High starting comfort of the combustion engine

Very low vibration in series drive
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 24 / 25
Degrees of Freedom
Global market share prediction by powertrain technology
slow scenario moderate scenario fast scenario

Source: McKinsey&Company, 2011

 Development of technological drivers for E-mobility is difficult to forecast

 Degree of market hybridization unknown
 Use of different power distributions for ICE and electric motor possible
 The new Hybrid T/M System concept suits various applications due to its
many degrees of freedom

New Hybrid Transmission System Concept can cover the

variety of future market scenarios
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 25 / 25
Summary

DENSO will contribute to a brighter future mobile society

by proposing new advanced technologies

We are confident that through effective collaboration between

OEMs/ TIER1s and DENSO New Products
and attractive cars can be brought to the future market.
Discussions for this approach are welcome.

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.