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Punch Powertrain

The leading independent provider of innovative clean powertrain technologies

Mechatronics in Automotive
From the first electric intermittent windscreen wiper to the self driving electric car

 2014 Punch Powertrain Strictly confidential. All rights such as copying and passing on to third parties reserved by Punch Powertrain.
300k

 2014 Punch Powertrain Strictly confidential. All rights such as copying and passing on to third parties reserved by Punch Powertrain.
Product Portfolio

HT1 Hybrid transmission / Hybrid powertrain

VT4 CVT for RWD or AWD

DT1 180Nm Dual Clutch Transmission


Development

VT5 300Nm

VT5 190Nm Torque converter CVT

VT5 250Nm Torque converter CVT

VT2/VT3 CVT transmission

Time
Development
Advanced

EV powertrains
Twinspeed EV gearbox
emKERS rear axle flywheel solution
MecHybrid flywheel hybrid CVT

2015 2016 2017 2018 2019


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Mechatronics in Automotive

Agenda
• Historic (incomplete) overview of Automotive mechatronics
• Power steering and robotized gearboxes
• Hybrid and the electric car
• 48V and the self driving car
• Conclusion & Outlook

Mechatronics ≠
electro-mechanical designs

Mechatronics =
multidisciplinary engineering

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Historic overview – icons in time
Start century of the mechatronic power 48V platform
mass market petrol steering (1990s- (2017-
car (T-Ford,1914)
revival electric
electronic engine car (2010-
controls (1980s-
today
electric power
Toyota Prius • autonomous
window (1950s-
hybrid car (1997) car (2020-
• hydrogen car
• solar car
• ….

robotized gear-
electric car electronic windscreen boxes (2000-
(1880-1920) wiper (late 1960s-

 2014 Punch Powertrain 5


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electric power steering –
early enabler of the autonomous car

rack mounted
EPS

column mounted EPS

pinion mounted EPS

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electric power steering –
mechatronic system layout

• vehicle speed
• emergency
• parking assist
• lane keeping
• ….
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Self parking thanks to EPS

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Next generation self parking…?

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Toyota Prius – first mass market hybrid

I/B
1997,
5.6 L/100 km
(US-EPA)

2004,
5.1 L/100 km
(US-EPA)

2010,
4.8 L/100 km
(US-EPA)

Toyota has sold to date: Plug-in Prius 2012


• over 7 million hybrid cars… 4.4kWh Li-ion, 650V
• of which over 4 million Prius 2.5 L/100km (US-city, partly EV)
4.7 L/100km (US-highway) 10
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Robotized gearboxes – CO2 and comfort

Dual Clutch
Transmission
(DCT)

Automated Manual
Transmission (AMT)
DCT
AMT

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Robotized gearboxes – CO2 and comfort

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Revival electric car – now to stay

• Do you think they stay because now, EVs look better than ever?

• Why did they disappear the first time (1910s)?


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Revival electric car – now to stay

Birth of the mass gasoline car market, like any good product it is

CONVENIENCE for a FAIR PRICE!!

• Gasonline engines took smaller EV motors to use it as an electric starter


• Gasoline cars had greater range
• Gasoline cars had much quicker refueling times
• Rapid expansion of petroleum infrastructure initiated BY THE GOVERNMENT!
• So much convenience steps in such a short time, the choice for gasoline was a
NO-BRAINER at that time!
• Market growth cuts the prices and accelerates further growth, etc. etc.

…and everybody took the noisy, shaky and stinky engine for granted
…being completely unaware about the future environmental impact

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Revival electric car – now to stay
100 years later….
(Re)birth of the mass EV car market, like any good product it should be

CONVENIENCE for a FAIR PRICE!!

• EV cars take a small internal combustion to use it as a range extender


• Nobody uses full (800km) gasoline range in a no-stop continuous trip
• SuperChargers refill the battery in less than 20 minutes (300+ km range)
• Rapid expansion of (super)charger network initiated BY THE GOVERNMENT,
bold ENTREPENEURS and everybody’s electric HOME!
• After 100 years of fiddling with exhaust, dampers, noise, vibration and
harshness engineering and 50 years of emission law enforcement, the electric
car seems a silent, clean and convenient miracle that you can actually buy.
• …and because mechatronics are there anyway, EVs better drive themselves!
• So much convenience steps exactly at the right point in time, the choice for EV
is a SMART-BRAINER!

• Market growth cuts the prices and accelerates further growth, etc. etc. 15
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48V platform –
CO2 and expansion of mechatronics
• Let’s not completely rule out the engine for the next 20 yrs or so, as the
price of battery technology is still (too) high and the energy density (too) low
• However, use the engine and other appliances only when necessary and
with great efficiency.
• This requires far-going advances in mechatronics boosted by 48V board net
• These 48V mechatronics can stay when the engine finally leaves the car...

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48V platform –
CO2 and expansion of mechatronics

(Courtesy BMW)
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48V platform –
CO2 and expansion of mechatronics

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48V platform –
CO2 and expansion of mechatronics
48V machine + flywheel
≈ full hybrid

fair cost high cost

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Autonomous car –
logical step for the connected consumer
• Why is the autonomous car coming so fast into the market (<2020)?
• Safety, fuel efficiency, transport efficiency, convenience, etc. etc.

• However, most important trigger/accelerators


from outside incumbent automotive industry:
• The next generation “drivers” are rather occupied
with connectivity than with the task of car driving.
• Consumer tech driven giants like Google, Samsung, Apple and Tesla are
boosting this trend
• The CES(!) shows how highly interaction technology and automotive
technology are colliding into a whole new product experience!

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Autonomous car –
full reliance on mechatronics
4 Levels of autonomy defined by NHTSA (excluding level 5)
(Level 0 - no autonomous functions, warnings at most)
Level 1 - one autonomous function such as ACC, LKA, CMBS
Level 2 - partial autonomy: multiple automations, driver still “watchdog”
Level 3 - limited self-driving: Autopilot in certain conditions
Level 4 - full self-driving: Autopilot for entire trip, car may be manually
controllable in case of Autopilot-disfunctionality.
(Level 5 – same as Level 4, however no means for manual control)

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Conclusion & Outlook
 100 years ago, the mass market petrol car market “ignited” the
disappearance of the electric car, but not the electric domain
 Since then electro-mechanical solutions and “mechatronics” later on has
been offering an ever increasing amount of innovative car functions
 Before the end of this decade, this will be further boosted by the introduction
of the 48V board net platform
 After 100 years of car mass market, the revival of the electric car changes the
automotive industry and many other industries in unexplored directions
 The (electric) car is finally becoming a real “automobile” through consecutive
stages of autonomy, mechatronics is the key enabling art for this
 Regardless of its maturity, the automotive industry has just begun to get truly
smart, clean and exciting!

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 2014 Punch Powertrain Strictly confidential. All rights such as copying and passing on to third parties reserved by Punch Powertrain.
Thank you for your attention!
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