Hybrids

Porsche Cayenne, VW Touareg hybrids to use Bosch motor
In a wide ranging interview Bosch's Bernd Bohr mentions that their first hybrid vehicles, the VW Touareg and Porsche Cayenne, will use Bosch developed electric motors. Sanyo will likely produce the nickel metal hydride batteries. Overall Bosch forecasts 2.5 to 3 million hybrid vehicles in 2015, and 800,000 all electric vehicles, compared to 80 million new vehicles overall, a 5% market share.
July 19, 2008

Tesla to build electric sedan in California
Tesla Motors decided to build their next generation electric sedan in California, due to incentives extended to in-state production of zero emission vehicles. A video of the announcement was posted on Office of the Governor. Tesla's Model S will be a fully electric, five passenger, multi-use sport sedan with a driving range of approximately 225 miles on one charge. The projected cost of the Model S is $60,000 and it is expected in late 2010. A lower cost electric auto for under $30,000 was mentioned as well, to debut in less than 4 years.
June 30, 2008

Daimler plans two electric autos by 2010
In addition to the electric smart fortwo expected in 2010, Daimler plans an electric Mercedes-Benz. In an interview with Wirtschaftswoche Mercedes chief of development Dr. Weber revealed that one possibility is the current A-Class or B-Class, whose sandwich floor is well suited to house alternative drivetrains. This is similar to the arrangement in the 1998 A-Class EV shown at left or the F-Cells.
June 28, 2008

Tesla Motors, Daimler in deal
Tesla Motors and Daimler agreed on a small technology cooperation, according to Elon Musk, which may lead to a potentially large deal. Potential areas of cooperation could be advanced lithium ion battery technology, electric drive systems, or Tesla's next generation electric sedan, project WhiteStar. Last September Mercedes was thinking about a cooperation with Tesla Motors as mentioned earlier.
June 14, 2008

UPS Places Largest Order for Hybrid Electric Trucks
UPS ordered 200 diesel electric walk in distribution trucks. The architecture of the van's drive system follows the familiar parallel hybrid principle, and is based on a 900-series (US designation: MBE 900) four-cylinder diesel engine with a displacement of 4.25 liters and an output of 125 kW (170 hp) in a joint venture with an Eaton 44 kW electric hybrid drive. Hybrids are well suited for urban delivery routes with frequent stop-and-gos. UPS also ordered 300 compressed natural gas vans, and 1500 turbodiesel vans, which are well suited for longer distribution routes.
June 5, 2008

Continental invests in ENAX
Continental invests in ENAX, which has been developing large format lithium ion cells since 1996. ENAX partners with EVonik as mentioned earlier. Here is an ENAX Europe company profile.
June 3, 2008

Researchers elucidate how lithium ion cells work
MIT researchers Kisuk Kang and Gerbrand Ceder found how the lithium ions inside the battery work. The ions are stored in highly ordered octahedral sites inside the layered oxide of the cell electrode. When charging the cell these ions then hop via intermediate tetrahedral sites into adjacent octahedral sites. The intermediate elevated energy tetrahedral transition state was found to be rate limiting, one factor limiting the cell's performance.
May 24, 2008

Bosch set up lithium ion battery development unit
During the annual press conference Franz Fehrenbach mentioned Bosch set up a second project unit in addition to its hybrid unit. This project unit will develop high-performance lithium-ion batteries, and focus the company's efforts on further developing the core competence it needs for the increased use of electrical motors in drive systems. Bosch already develops lithium iron phosphate cells for its power tools with Phostech as mentioned earlier.
May 10, 2008

ZF Sachs to produce S-Class hybrid module
ZF Friedrichshafen officially inaugurated a new production facility for electric drives in Schweinfurt. The first volume production contract is for the Mercedes-Benz S 400 BlueHYBRID. At the present time pilot production has started for release samples. Volume production is to begin in the fourth quarter of 2008. ZF is working on eight series production projects for four manufacturers, with planned launch between 2008 to 2012. BMW's 7-series is likely among them.

The DynaStart hybrid drive modules have from 10 to 100 kW as well as a maximum torque of 100 to 1000 Nm, depending on the requirements. Electric drive modules for passenger vehicles, buses and delivery vans can be built. ZF Sachs also built the electric drive for the Sprinter hybrid and plug-in hybrid program as mentioned earlier, and codeveloped with the EPRI.
May 7, 2008

Orion VII New Generation Hybrid Bus update
Daimler Buses North America announces the next leap in diesel-electric hybrid bus technology with the release of an improved driveline configuration in 2010, and the electrification of accessories for deliveries in 2011. The picture shows an Orion VII New Generation bus, an attractive European inspired, redefined city bus operated by MTA New York City.
May 4, 2008

Mercedes unveils Vision GLK BlueTEC HYBRID
In Geneva Daimler presented a sleek Vision GLK BlueTEC HYRBID concept in alubeam blue. It's powered by a four cylinder turbodiesel and 15 kW electric motor sandwiched between automatic and engine. With a combined hybrid system power of 165 kW / 224 hp and combined torque of 560 Nm / 413 lb-ft the GLK rockets to 100 km/h in 7.3 seconds while consuming just 5.9 liters per 100 kilometers, or 40 MPG in US numbers. Market introduction will not be before 2011.
March 1, 2008


S 400 BlueHYBRID lithium ion battery announced at the 2008 Motorshow in Geneva

Continental Launches Production of Lithium-Ion Battery

  • The Powertrain division supplies complete battery and other hybrid components for Mercedes S 400 BlueHYBRID

Hanover/Regensburg. Continental will launch volume production of a high-performance lithium-ion battery for hybrid vehicles at the end of the present year. It will be used in the Mercedes S 400 BlueHYBRID. "This marks an important breakthrough for Continental as supplier of battery systems. In the next few years we will be launching production of further lithium-ion energy storage devices for mild- and full-hybrid and electric-powered vehicles," says Continental Executive Board member Dr. Karl-Thomas Neumann (far left).
Lithium-ion technology is viewed as the key to the success of the hybrid and electric drive systems in motor vehicles. Lithium-ion batteries have a higher energy density, and thus a wider range, than those based on conventional nickel metal hydride technology. The power output of the battery determines the overall performance of the vehicle as well as the potential for lower emissions and for possible fuel savings.
Aside from the lithium-ion battery, Continental also supplies the inverter and the DC/DC converter for the Mercedes S 400 BlueHYBRID. The inverter controls the flow of energy between the electric motor and the hybrid battery. The DC/DC converter is the link between the hybrid battery and the vehicle's standard electric system and thus permits the elimination of the conventional generator.
February 29, 2008

Breakthrough in Battery Technology by Daimler

  • First patented integration of a lithium-ion battery into a series- produced passenger car

  • Available in Mercedes-Benz S 400 BlueHYBRID starting in 2009

  • 25 patents for top technology 'made in Germany'

Daimler AG has achieved a crucial breakthrough in battery technology. The Stuttgart-based automaker is the world's first manufacturer to have succeeded in adapting lithium-ion technology to the demanding requirements of automotive applications. Until now, the technology has been used primarily in consumer electronics. The new battery will be used in the series-production S 400 BlueHYBRID beginning next year. This important technology was possible thanks to 25 patents held by Daimler.
Dr. Thomas Weber, member of the Daimler AG Board of Management and responsible for Group Research and Mercedes-Benz Cars Development, says: "What we have here is a groundbreaking key technology that is going to be a decisive factor for the future success of the automotive industry. That is a tribute to our intensive research efforts, which we have been conducting in this area since 1992."
The engineers' success is above all a result of the Daimler-developed integration of the lithium-ion battery into the vehicle's climate control system. This ensures that the battery always works at optimal system temperatures of between 15 and 35°C, which in turn makes it possible for the battery to provide long service life and maximum performance.
The main advantages offered by the newly developed lithium-ion battery are its very compact dimensions and its far superior performance compared to conventional nickel-metal hydride batteries. The weight/power ratio of the entire battery is 1,900 watts per liter (W/L). What's more, the battery stands out by virtue of its high ampere-hour efficiency, long service life, and great reliability, even at very low temperatures. Its high level of safety is the equal of that provided by today's auto batteries.
Lithium-ion batteries are ideally suited for use in hybrid vehicles to help reducing fuel consumption. At the same time, the Daimler engineers are investigating to what degree this technology can be applied to other vehicle concepts, such as electric and fuel cell-powered cars.

S 400 BlueHYBRID -- the world's most economical luxury sedan

The S 400 BlueHYBRID consumes only 7.9 liters of gasoline per 100 km in the NEDC, a very low value for this vehicle class and power class, making the S 400 BlueHYBRID the world's most economical luxury sedan -- unrivaled by any gasoline, diesel, or hybrid drive system offered by any competitor. And S 400 BlueHYBRID drivers will still enjoy impressive performance: combined with the hybrid module, the maximum output is 220 kW/299 hp, and the corresponding maximum torque is 375 Nm. The S 400 BlueHYBRID accelerates from zero to 100 km/h in 7.3 seconds on its way to an electronically limited top speed of 250 km/h.
Even more potential is offered by the combination of clean BlueTEC diesel technology with a hybrid module, a duo that is featured in the S 300 BlueTEC HYBRID, for example.
February 29, 2008

Lithium Ion Factory for Mercedes-Benz S 400 Hybrid Opens
Johnson Controls Saft opened the new factory in Western France to produce lithium ion cells for the Mercedes S 400 Hybrid. Initially 5000 units are planned per year, and this can be expanded lateron, for example to include other automakers, like BMW.

"We are the first company to produce the batteries for the automotive industry," said Mary Ann Wright who is general manager of Johnson Controls' hybrid battery business. The joint venture also supplies the cells for the Sprinter Hybrid vans mentioned earlier.

Top picture: Quality check at the end of the coating line where the positive and negative ink are applied.

Middle upper: Cathode, separation and anode foils are wound together in the joint ventures' new plant in Nersac.

Middle lower: This machine, part of the automatic production line, welds the cover to the can to close the cell.

Bottom picture: The automatic assembly line inserts the coil into the can and closes the cell.

© JCI, photo credits Saft
February 2, 2008

Continental selects Maxwell BOOSTCAPS for boardnet
Maxwell announced that Continental selected their BOOSTCAP ultracapacitors for a bordnet stabilisation program for a major automaker. Boardnet stabilisation enables localised load levelling of pulse loads like electric boosters, regenerative braking, electric heaters, door actuators or electric transmission shifting, and thus smooths voltage fluctuations or spikes and thus also enhances electric circuit reliability. Series production should start late in 2009 for a 2010 model year vehicle. Mercedes-Benz announced a BOOSTCAP development cooperation with Maxwell as mentioned earlier.
January 8, 2008

Li-Tec develops large format lithium ion cell production
Li-Tec in Kamenz is working on large format manganese lithium ion cells. They use the LITARION® electrodes produced by Evonik, described below, and the SEPARION® ceramic separation foils for enhanced safety. Prototype cells were tested successfully in a Honda Civic IMA as mentioned earlier.
December 12, 2007

Updated LITARION® specs online
Evonik made data sheets for their ready to use LITARION® lithium ion materials available. The cathodes are based on a Li-Ni-Mn-Co oxide chemistry offering enhanced safety and long-term stability. In addition, a cathode solution based on Mn spinel oxide chemistry is also offered. The table gives an overview of the basic characteristics of Evonik's current product portfolio. Besides these standard types, custom-made electrode designs are also available. Evonik partners with ENAX.
December 12, 2007

Daimler Plug-In Hybrid Vehicles need more R&D
At the electric vehicle symposium in Anaheim California Daimler researchers Dr. Christian Mohrdieck, Dr. Andreas Truckenbrodt and Prof. Karl E. Noreika presented a paper titled: "Plug-In Hybrids - Promise, Hype or the Solution?". They summarised the status of Plug-In Hybrids thusly:

  • The key component for the success of Plug-In Technology is the Li-Ion battery. Lifetime, cost and safety are the main critical areas which need substantial improvement.

  • Operation of a PHEV can reduce fuel consumption and hence save costs. However these savings are outweighed by the initial costs of the battery.

  • Batteries that fulfill the special requirement of high energy and high power density for Plug-In vehicles are not yet available. Further research and development is required and will take several years.

  • Daimler's Plug-In-Hybrid Sprinters are in normal operation in a test fleet with customers and help evaluate the technical and the market feasibility for Plug-In-Hybrid vehicles.
    December 5, 2007

Daimler Trucks and Buses Update
Daimler Trucks and Buses issued an extensive update on their commercial trucks and buses. Their focus is on BlueTEC Hybrids.
From left to right: Canter BlueTEC Hybrid, Atego BlueTEC Hybrid, Econic NGT, Freightliner M2 hybrid and Mercedes Citaro G BlueTEC Hybrid Bus
November 12, 2007

Industry consortium to research and develop high performance batteries
BASF, Bosch, Evonik, Li-Tec and VW formed a research and development partnership for high performance batteries. Evonik (formerly Degussa) makes the ceramic SEPARION separation foils mentioned earlier. In addition Evonik produces electrodes under the trademark LITARION. Its 50-50 joint venture with ENAX of Japan has produced customized electrodes since 2005 as mentioned earlier.
November 6, 2007

Mercedes-Benz may cooperate with Tesla Motors
Wirtschaftswoche. Mercedes head of development Dr. Thomas Weber is thinking about a cooperation with Tesla Motors. Mercedes-Benz is planning to bring a hybrid with Lithium Ion batteries to market and is working with Continental and A123 Systems. Tesla's pioneering lithium ion battery pack has a high energy density, about 55 kWh and 450 kg, using 6831 cells. In the picture Tesla chief engineer Martin Eberhard chats with customer Arnold Schwarzenegger.
September 22, 2007

Saft confirms Lithium Ion batteries for S 400 Hybrid
Johnson Controls Saft in Paris confirmed that it has been selected to supply lithium ion batteries for the Mercedes S 400 HYBRID. The batteries are to be supplied from a new plant in Nersac, France as mentioned earlier. "I am very pleased that the combining of Saft's and Johnson Controls' know-how has led to a first programme of this importance" said John Searle, Chairman of Saft's Management Board.
September 12, 2007

Mercedes-Benz Hybrid Fleet @ IAA 2007
Top row: S 400 BLUETEC HYBRID, E 300 BLUETEC HYBRID
Middle: F 700 DiesOtto HYBRID, S 400 HYBRID, ML 450 HYBRID
Bottom: C 300 BLUETEC HYBRID, S 300 BLUETEC HYBRID
September 11, 2007


when

combustion
engine

combined hybrid system
power + torque

consumption

ML450 BlueHYBRID

2009

M272 (V6)

250 kW/340 hp 480 Nm

7.7 l/100 km

NiMH, two-mode

S400 BlueHYBRID

2009

M272 (V6)

220 kW/299 hp 375 Nm

7.9 l/100 km

Li-Ion

E300 BlueTEC HYBRID

2010

OM651 (I4)

165 kW/224 hp 560 Nm

5.1 l/100 km

new E-Class (W212)

S300 BlueTEC HYBRID

2010

OM651 (I4)

165 kW/224 hp 560 Nm

5.4 l/100 km

AdBlue SCR

C300 BlueTEC HYBRID

2011

OM651 (I4)

165 kW/224 hp 560 Nm

4.6 l/100 km

NSK Advanced

S400 BlueTEC HYBRID

after 2010

OM642 (V6)

195 kW/265 hp 630 Nm

5.8 l/100 km

AdBlue SCR

BMW Concept X6 ActiveHybrid unveiled
BMW unveils their first hybrid, the Concept X6 ActiveHybrid. In electric mode it automatically closes the exhaust pipes with a flap integrated into the rear bumper.
September 11, 2007

Maxwell to design ULTRACAPS for Mercedes-Benz Cars
David Schramm, Maxwell's CEO, said the new contract provides for funding from Mercedes to develop a new BOOSTCAP(R) ultracapacitor cell specifically designed to meet the energy storage and power delivery requirements of one of Mercedes' torque assist and recuperative braking systems. BMW has been researching an X5 with ultracap powered active transmission as mentioned earlier.
September 10, 2007

ML 450 HYBRID: Mercedes two-mode hybrid introduced
As one of the seven hybrid models at the IAA 2007 Mercedes-Benz is presenting the ML 450 HYBRID, due to be launched on the market in 2009. Its innovative two-mode hybrid system (earlier mention) enables electric driving and satisfies the highest comfort demands. With a combined system output of 250 kW (340 hp) and a combined maximum torque of 480 Nm, the ML 450 HYBRID consumes just 7.7 litres per 100 kilometres, or 31 MPG.
September 6, 2007

Behr develops storage evaporator for stop-start hybrids
From Behr's recent annual press conference: For air conditioning in the stop-start mode of mild hybrids, we are working on so-called storage air conditioning. This involves a cooling battery filled with a latent medium, which is cooled by the refrigerant from the evaporator. For example, if the vehicle is stationary at a red light, the air conditioning compressor is also inactive. The latent medium melts and thus cools the vehicle interior for up to 50 seconds - long enough for an average red-light phase. Behr and BHTC make the PHYSIO CONTROL® shown at left.
August 1, 2007

IAV paper: Dieselhybrid compelling for large vehicles
At the Motor Symposium in Vienna IAV said full hybrids are compelling for large diesel offroaders. The additional costs are justified by a 15% efficiency gain and enhanced agility. The hybrid levels the load on the diesel. As an example a typical 3 liter SUV diesel engine would be replaced by a 2 liter 4 cylinder in combination with a 50 kW electric motor. With changed engine control, phlegmatising the diesel, not only the consumption can be reduced but nitrogen oxide emissions as well, by 40%, facilitating exhaust cleanup. While electric boosting handles quick dynamic torque requests.
July 31, 2007

Porsche/Audi announce Hybrid SUVs with 9.8 liters/100 km
The new Porsche Cayenne hybrid is a parallel hybrid consisting of a high-strength clutch and a electric disc motor sandwiched between the engine's flywheel and the automatic transmission, similar to the Mercedes M-Class HYPER concept built in 2002 as mentioned earlier and the Sprinter hybrid introduced in 2004 mentioned earlier.
In electric mode the Cayenne hybrid can drive up to 50 km/h, and 'sail' without combustion engine up to 120 km/h. It uses a 34 kW electric motor, a 69 kg NiMH battery in the spare wheel well and an advanced "Hybrid Manager" power controller. A month later Audi unveiled the Q7 hybrid with similar technology.
July 30, 2007 (Cayenne)
August 30, 2007 (Q7)

BMW extends Efficient Dynamics to 3-, 6-, X3 and X5
Starting this fall 40% of BMW models sold in Europe in the 2008 model year are to attain a CO2 emission of under 140 g/km as BMW introduces more powerfull and efficient gasoline and diesel engines across a range of vehicles, also utilising automatic stop-start (1-, 3-) and brake energy regeneration (3-, 5-, 6-, X3, X5) thus enhancing efficiency and agility. For example the BMW 318d diesel sedan pictured on the left burns only 4.7 liter per 100 kilometers in the EU test cycle which translates to 50 MPG in US numbers.
June 26, 2007

smart fortwo to introduce automatic stop-start
The Hightech Report 2007/1 mentions an automatic stop-start system will first launch on the new smart fortwo by the end of the year and is to be spread to Mercedes models lateron starting with the A- and B-Class. Mercedes studied a belt driven stop-start generator in cooperation with Valeo on the previous generation smart fortwo cdi. The automatic stop start is planned for the gasoline powered smart fortwo models and stops the engine when waiting at a red light to reduce emissions and to enhance efficiency. The system restarts the engine automatically once the foot is taken off the brake pedal. The Citroėn C3 uses a similar system since 2004.
smart fortwo info page
June 21, 2007

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