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CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
TheCase
foraPHEV
P3for
Truck/SUV
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
WhyHybrid?
Regulation
Cost
Packaging
?Regulation–ZEV
HybridDriveline
?Packaging–EaseofIntegration
?Efficiency–EVDrive,Hybrid
Efficiency
Utility
?DrivingExperience–Performance
Driving
Experience
?Utility–GeneratorMode,4WDTractiveEffort,Towing
?CostComparison
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
Regulation
?ZEVRequirementsforPHEV2035
?50Milesallelectricrange“RealWorldDriving”
?35kWhBatteryStorage
?CompleteUS06inelectriconlymode
?>150kWofPeakEMPower
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
ParallelHybrid–MotorLocation
?P0,P1andP2Requires
TransmissionUpgradeforfullhybriddrive
?P3andP4onaxle,
Packaging/GeneratorIssue
?P3integratedintotransfercase:
?Enablesgeneratorfunction
P4Axle
?Enablesactivetorquedistribution
?Minimizespackagingdisruption
P3
TCase
P3Axle
P3
P1,P2P0
TCase
P3Axle
P4
Axle
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
Packaging
?EngineandTransmissionpositionunchanged
?PropshaftModificationsforlength
?BEVMotorre-use
?Packagingforbattery,inverterandon-boardcharger(OBC)reqd
A
Exhaust
Transmission
P3
FuelTank
SpareTire
150mm
P3TransferCaseActive
Clutch
GEN/Q
HYBRID
EM
ICE
FRONT
REAR
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
Comparison
?StudyperformedP3,P2,REEV,BEV
?BatteryandpropulsionsizedtomeetZEVrequirements(P3,
P2andREEV)
?400Vsystemusedforallvariants
Bat
35
kWh
OBC
P3
6500lb
EM
200kW*
Bat
35
kWh
OBC
P2*
6500lb
PE
EM
200kW
PE
Bat
35
kWh
OBC
PE
EM
200kW
REEV
6500lb
PE
EM
200kW
Battery
139kWh
EM
200kW
OBC
BEV
7000lb
PE
26Gal
PE
26Gal
GEN225kW
26Gal
D
EM
200kW
PE
*200kWNotCurrentlyCommerciallyAvailable
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
282.5
251.1
60.9
66.3
52.7
49.7
51.6
EV
EV
P3
P2
RE
BE
P3
P2
RE
BE
Regulation-EV
EVRange
?P3,P2andREEV-ZEV
?40milesonUS06
MILES
?50milescombinedEVrange(realworld)
?P3hasEVRangeHeadroomallowsfor30kWh(packaging
advantage)
300
250
70
60
50
40
30
20
10
0
57.2
V
V
US06(0.55xUDDS+0.45xHWFET)*.7
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
Efficiency-EV
?P3hasbettercombined
efficiencythanP2duetomoreefficientpowerflow
kWh/100km
?P2betterefficiencythanP3underconstantcruiseduetoabilitytofindmoreoptimumgearratio
?BEVandREEVhave4-8%
efficiencyadvantageoverP3dependingonconditions
50
40
30
20
10
0
!
EVPowerConsumption
44.5
43.0
42.2
42.7
BETTER
26.1
20.9
19.319.6
P3
P2
REEV
BEV
P3
P2
REEV
BEV
(0.55xUDDS+0.45xHWFET)Constant130kphCruise
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
Efficiency-Hybrid
?P3>P2BecauseofTransmissionLosses
MPG
?REEV>P3AxleLosses
45
38.3
34.033.9
32.1
31.3
30.5
BET
EV
EV
P3
P2
RE
P3
P2
RE
40
35
30
25
20
15
10
5
0
ChargeSustainingFuelEconomy
TER
UDDSCombined
1/(0.55/UDDS+0.45/HWFET)
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
Efficiency–Emissions
?P3betterthanP2duetobetter
EVrangeandchargesustainingfueleconomy
?REEVbetterthanP3
?AllPHEVsofferasignificant
improvementoverconventionalcombustion
400
350
EPAEmissions(gCO2/mile)
300
250
200
150
100
50
0
CO2EmissionsforEPAFleetCompliance
381.4
BETT
ER
83.4
70.6
59.4
ICE
P3
P2
0
!
V
V
REE
BE
Note:EmissionscalculatedassumingEPAapprovedfleetutilityfactorthrough2031
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
DrivingExperience
?PureEV≈EngineOnly
?0-60mphinunder5s,HybridMode
10.00
8.00
6.00
Time(s)
4.00
2.00
0.00
0-60mphAccelerationTime
8.78.68.78.5
7.7
5.0
4.74.7
4.5
P3
P2
P3
P2
REEV
BEV
P3
P2
REEV
EngineOnlyPureEVHybrid
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
Utility
?TowingRangeP3,P2
comparable,bothbetterthanREEV
?LowRangeinTransferCaseisreplacedbyEMwithreductiongearset
253.0
257.5
246.6
229.9
224.1
99.5
20.821.2
22.0
ICE
P3
P2
REEV
P3
P2
REEV
BEV
P3
P2
REEV
350
250
150
MILES
50
30
20
10
0
80mphTowing,10,000lbTrailer,0%Grade
235.2232.7
CombustionRangeEVRangeHybridRange
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
Cost
?P3≈P2componentdelta
?P3wouldhaveacost
advantageoverP2ifbatterywasreducedtoprovide
equivalentEPAEVrange
?REEVcosteffective,newvehicleplatform
?BEVdominatedbyBatterycost
58,650
51,800
50,75050,750
Costdifferenceusing30kWhbattery
36,000
P3
P2
REEV
BEV
$60,000
$55,000
$50,000
$45,000
$40,000
$35,000
$30,000
ModeledRepresentativeVehicleCost
BasedonUSDepartmentofEnergy12/22Study
$550
ICE
2022IncrementalPurchaseCostMethodologyandResultsforCleanVehicles()
CTISymposiumUSA15-16May2024,LarryPritchard,BorgWarnerDBS
PreferredArchitectureforAddingHybrids?
2035ZEVCO2FleetHighTowingCustomer
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