23 MAY 2023
Pre-Check-In and Reception
Pre-Evening Reception for Delegates, Speakers, Exhibitors, Advisory Board Members Hyatt Place Novi, Fireside Lounge
24 MAY 2023
Check-in & Welcome Coffee in the CTI SYMPOSIUM EXPO
Welcome Address by the Chairman and CTI
Where is the Industry Moving?
Electrification, connectivity, new mobility concepts, upskilling the workforce … how OEMs deal with a multifaceted transformation.
Networking Coffee in the Exhibition
Plenary Speeches
Challenges Arise – Innovation Overcomes!
The Battery Challenge: Meeting the Safety and Performance Requirements for All Levels of Electrification
Systematic Enhancement of the Battery Electric Vehicle Supply Chain
Joint Discussion with Plenary Speakers
Short Break
Transformation of the automotive industry from the suppliers’ point of view
In the transition towards electrification, powertrain suppliers rebuild their product portfolios. Business fields and relationships are changing.
Lunch Break in the Exhibition
Presentations during Lunch Break
Session D
Compatibilities of Elastomer Sealing Materials in Dielectric E-Fluids for Direct Contact, Immersive Cooling Technologies in EVs
- Water-glycol and dielectric e-fluids
- Elastomer use in EV thermal management systems and electric drive units
- Chemical compatibilities of elastomers in sealing and transport of dielectric e-fluids
Mark Nevitt, Senior Applications Development Chemist, Zeon Chemicals L.P., USA
Session E
Introducing Glulock Bonding Process for Improved E-Motor Cores
- Increased efficiency in laminations for e-motor cores
- Energy efficiency, stack stability, and impermeability to cooling fluids
- Thinner sheets. Greater performance. Glulock.
Markus Lock, Head of R&D and Engineering, Feintool System Parts Sachsenheim GmbH, Germany
DEEP DIVE SESSIONS
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Electric Drives Units I
02:15What do Chinese and US Consumers Love and Hate About Their EV's?
- Key finding from new vehicle experience study of Chinese and American EV buyers
- What technology solutions are coming that will improve the adoption of EV’s
- Will the new technologies have a significant impact on improving consumer sentiment?
Paul Haelterman, Vice President, Strategic Vision, USA
02:45Presentation Title tbc
Dapo Adewusi, F150 Lightning Vehicle Engineering Manager, Ford Motor Company, USA
03:15Electric Driveline Technology for Mercedes-AMG GT 63 S E PERFORMANCE
- Newly developed P3 e-drive
- 2-speed gearbox and electronical limited slip differential
- Performance results in practice and in-vehicle testing
Joe Mueller, Executive Director, American Axle Manufacturing, USA
03:45Networking Time and Visit of the Exibition
04:30The EtelligentReach Project - A new Level for Range and Dynamics
- New benchmarks for range and dynamics
- Next generation e-drive systems
- Decoupling and functionality for more efficient electric vehicles
Dr Daniel Lindvai-Soos, Director, Product Management, Magna Powertrain, Austria
05:00Marelli’s E-Axle Family Strategy: Agile Answer to a Moving EV Market
- Extensive application analysis based on advanced market data processing
- Family strategy definition for both layshaft and planetary architectures
- More opportunities for planetary configurations?
- Add-on systems: forced lubrication and park lock
Rahul Plavullathil, Head of E-Axle Mechatronics Department, Marelli Europe S.p.A., Italy
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E-Motors
02:15The Future of Electric Motors
- Sustainability without compromise
- Reducing cost and improving efficiency
- Application-based motor optimization
- Advanced cooling concepts
Jonathan Getz, eMotor Customer Solutions, Schaeffler, USA
02:45Electric Motor Design and Optimization Principles for Passenger Cars and Light Commercial Vehicles
- BEV light commercial vehicle simulation and relevant cycles
- Motor simulation and tool-chain used in the electric machine design process
- Inverter selection
- Analysis of the different configuration vs efficiency, battery size and total vehicle weight
Daniele Zecchetti, Electric Motor Research and Development Director, Marelli Europe S.p.A., Italy
03:15Highly Efficient In-Wheel Motor With Low Manufacturing Costs
- System efficiency up to 97% and range increase up to 20% with the same battery capacity
- Low unsprung masses and no negative impact on driving comfort and safety
- High material utilization and very small magnet mass per torque
Dr Alexander Rosen, Co-Founder and System Engineer, DeepDrive GmbH, Germany
03:45Networking Time and Visit of the Exibition
04:30Stator and Rotor Winding Innovations for Automotive High-Voltage E-Traction Drives
- Improved production techs for e-traction solutions
- Distributed high density (DHD) stator winding: An update
- DHD stator winding for 800V e-machines
- New rotor winding techs for high-performance EESM
Kumar Rajasekhara, CEO and President, Marsilli North America, USA
05:00The Production Process of Hairpin Stators (… and What is Not on the Drawing)
- Scalable stator production solutions – how to gain productivity
- I-Pin production
- What is not on the drawing – the importance of i-pin wire specification
Matthias Weber, Technology Lead E-Mobility and Test Equipment, Felsomat GmbH Co. KG, Germany
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Batteries I
02:15Battery Strategies of Stellantis: The Pathway to the Carbon Net Zero Society
Byung-Ki Ahn, VP, Global Head of Battery Cells, Modules and Packs, Stellantis, USA
02:45All-Solid-State Battery with Lower Stack Pressure
- Increasing all-solid-state battery internal particle conductivities
- Lowering the required stack pressure in all-solid-state battery
- Reducing the required stack-pressure by increasing internal particle conductivities in all-solid-state battery
Dr Rashid Farahati, Director Corporate Competence Center Americas, Schaeffler Group, USA
03:15Battery Algorithm Development
- State of charge estimation
- Kalman filtering
- Battery model calibration
- Cell testing methodology
Matthew Wise, Design Engineer, Schaeffler Transmission Systems, LLC, USA
03:45Networking Time and Visit of the Exibition
04:30Megawatt Charging for E-Motorsport: From 5% to 85% (SOC) in Just Under 90 Seconds
- Pioneering technology with extremely safe high-power battery cells for up to 3.75 MW charging power
- FlashCharge battery for sprint and endurance e-motorsports
- Complex tests results
David Wollschlaeger, Engineer, hofer powertrain, Germany
05:00A New Patented Intrinsic Safety Battery - iBDU (intelligent Battery Disconnect Unit) with Centralization of Functions
- Patented new intelligent battery disconnect unit is an ultimately centralized solution
- New potentials in designing dynamic models considering performance releases, efficiency aspects, and driving behavior
- Scaling the savings potential through several battery packs in one system
David Wollschlaeger, Engineer, hofer powertrain, Germany
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Thermal Management & Lubrication
02:15Increasing Power Density by Advanced Cooling of Electric Traction Motors
- Combined lumped-parameter and CFD analysis methodology
- Performance assessment of oil cooled electric motors
- Design exploration of oil cooled electric motors.
Robert Smyczynski, Head of Light Vehicle Innovation and Advanced Engineering, Dana Incorporated, Belgium
02:45Modular Electric Pumps and Drives for Cooling, Lubrication and Actuation
- Application overview
- Customer requirements and challenges
- Platform development
Alexander Reul, Manager – Advanced R&D, Buehler Motor, Germany
03:15New Full-Scale Testing Capabilities and Increasing Hardware Performance through Dedicated E-Fluids
- Full-scale e-testing provides insight into lubricant impacts
- These capabilities allow development of meaningful e-tests
- New e-hardware test for system efficiency will be discussed
- New e-hardware test for thermal management will be reviewed
David Whitticar, Driveline Test Engineer – Electrification, The Lubrizol Corporation, USA
03:45Networking Time and Visit of the Exibition
04:30How New E-Fluid Formulation Enable Efficiency and Better Performance Under High-Speed Conditions
- Reflecting trends on adaption of ultra-low viscosity fluids for BEV
- Efficiency driveline testing with low and ultra-low viscosity fluids
- Formulating high performing fluids for electric racing
Torsten Murr, Global Technology Manager Transmission Fluids, Shell Global Solutions Deutschland GmbH, Germany
05:00Presentation Cancelled
Improve Performance of EV Driveline Fluids Using Synthetic Base Oils and Novel PAOs- Use of low-viscosity, low-volatility (LVLV) PAOs in next generation EV fluids
- Share insights on rapid development of BEVs, our view on future fluids requirements and demand
- Overview of new EDU designs and ways in which LVLVs meet EV fluid requirements
Dr Rohan Hule, Global Marketing Leader, ExxonMobil Product Solutions, USA
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E-Drive Components I
02:15Ultra Compact Differential, Bearing and Seal for High Power Density E-Axle
- Volume: Differential -60% vs. standard bevel gear type
- Width: Ball bearing -30%, oil seal -20% vs conventional
- Power density improvement especially for co-axial type e-axle
- Vehicle performance / efficiency improvement by LSD effect
Makoto Nishiji, Chief Engineer, Senior General Manager, Driveline Department, JTEKT Corporation, Japan
02:45Scalable Torque Management Systems or How to differentiate in Electrification
- Basic principle of eXD mechanics
- Control strategies to enhance EV driveline challenges
- Design challenges and opportunities due to packaging
Mattias Magnusson, Manager Vehicle Dynamic and Hannafia Spånberg, Director Engineering Europe, BorgWarner, Sweden
03:15Development of Advanced Torque Vectoring System for EV: TVTC (Torque Vectoring by Twin Clutch)
- TVTC design concept and specification
- TVTC torque characteristics: accuracy, spin loss and response speed
- Ride and handling characteristics on vehicle
Hosub Lee, Senior Research Engineer, Hyundai-Wia Company, Republic of Korea
03:45Networking Time and Visit of the Exibition
04:30Tailored Actuation System for Electrified Drivetrains
- Challenges for actuation systems in electrified drivetrains
- Functionality of the smart hydraulic actuator and the modular architecture
- Comparison of the smart hydraulic actuator with the other actuation concepts
Christian Steinwandel, Chief Engineer eMobility, Schaeffler Group, USA
05:00Join One of the other Sessions
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NVH & Development Optimization
02:15Optimization of NHV-Behaviour and Tooth Contact Analysis with Consideration of Production Variance
- Influence of machine gear topologies at NVH behavior
- Generating synthetic gear topologies with scripting
- Considering the production tolerances and machining
- Tooth contact analysis of machined and scripted topologies
Marcus Morgenstern, CAE Engineer, IAV GmbH, Germany
02:45Fault Detection and Isolation in Electric Drive Systems
- Fault detection and isolation (FDI)
- Fault detection and isolation and reconfiguration (FDIR)
- Electric drive systems
Ahmad Ghaderi, Systems Chief Engineer, Dana Incorporated, USA
03:15E-Mobility and the New Challenges of NVH-Testing
- Performance and new requirements on NVH test benches
- NVH testing of EDUs and their components
- New special measurement systems and high frequency analyses
- Future trends of NVH – and EMC testing
Dr Joschi Sucker, Head of NVH Testing and Technology, ATESTEO GmbH & Co. KG, Germany
03:45Networking Time and Visit of the Exibition
04:30EDU Radiated Noise Simulation Using a Hybrid FEA and MBS Approach
- MBS model with flexible bodies, driven by electromagnetic forces
- Gear micro and macro geometry and detailed roller bearing representation
- MBS results and acoustic FEA used to generate radiated noise levels
- Comparison of noise levels to FEV’s test based scatterbands for EDUs
Joern Baumann, Senior Engineer, FEV North America, Inc., USA
05:00Twin E-Axle System Performance Optimization Through Load Split Tuning
- Achieving enhancements by optimization of the control strategy
- Application of system characteristic maps to determine the best load split
- Maximization of system reliability
Dr Michael Leighton, Technical Expert, AVL List GmbH, Austria
CTI Networking Night
CTI NETWORKING NIGHT @MEADOW BROOK HALL
OUTSTANDING OPPORTUNITY TO MINGLE WITH ALL PARTICIPANTS, SPEAKERS, EXHIBITORS AND SPONSORS
Make new business contacts in a relaxed atmosphere, discuss the topics of the day with your colleagues and peers while enjoying delicious food and drinks at the CTI NETWORKING NIGHT.
Meadow Brook Hall
350 Estate Drive
Rochester, Michigan 48309-4481
25 MAY 2023
Check-in & Welcome Coffee in the CTI SYMPOSIUM EXPO
Opening of Day 2 by the Chairman and CTI
Plenary Speeches
Hydrogen is the Future
Scalable Fuel Cell System Solutions for Mobility Industries with Emphasis on Heavy Duty Applications
Joint Discussion with the Plenary Speakers
Truck Electrification
BEV and FCEV trucks will both play a role for decarbonized transportation. Their success will significantly depend on the availability of green electricity and H2.
Networking Coffee in the Exhibition
Plenary Speeches
Semiconductor is a Key for the Future Smart and Green Mobility
New Developments in Electric Beam Axle Technology
Joint Discussion with the Plenary Speakers
Range Anxiety vs. Charging Infrastructure
The further adoption of BEVs will depend on the an adequate charging infrastructure. Concerted efforts of the industry and society are needed to meet our electrification goals.
Lunch Break in the Exhibition
Presentations during Lunch Break
Session G
How to Profitably Enter the Market and Scale in the Dynamic Electrification Space
- Effective capital deployment and risk mitigation
- Capital light assembly of electrification systems
- Entering strategic markets while maintaining optionality
- Cost-effective life cycle management of legacy products
Frank Webb, Director of Engineering, Edison Manufacturing & Engineering, USA
Session I
Grid to EV Battery: Challenges and System Approaches
- Integrated power electronics
- Efficient power conversion
- Architectural future
Dr Lewei Qian, Global Director of Power Electronics, APTIV, USA
Session K
Electromagnetic Clutch Technology
- Disconnect Application
- Differential Locker and Axial Locker Application
- Gear Shifting Application
Dr Yang Cao, Senior Supervisor, Jing-Jin Electric, China
DEEP DIVE SESSIONS
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Electric Drive Units II
02:00eS4500i: Highly Integrated Electric Drive Unit for Multiple Applications
- Introduction: first highly integrated Dana off-the-shelf eDrive
- eS4500i platform: multiple options for multiple customers
- Highly integrated layout: a closer look at motor-gearbox integration
Marco Silvestri, Project Engineer, Dana, Italy
02:30Development of Highly Scalable Compact Integrated Drive Module (iDM)
- iDM System target setting – Cost and Efficiency analysis of various system architectures
- Challenges and impact of high-speed electric motor to iDM system – Development analysis on innovative cooling system
- Compact iDM Design – Development of high-speed gearbox and highly integrated inverter
Andreas Mayer, Senior Lead Engineer – Advanced E-Motor and E-Drive Engineering, BorgWarner, USA
03:00Networking Time and Visit of the Exibition
03:40New Tech in EDUs for more Cont. Power and Overall Efficiency
- HV e-motors with innovative form litz winding technology
- 3-level inverter for highest power density in PE
- HV booster – charging 800V systems at 400V stations
Thomas Hackl, COO, hofer powertrain, Germany
04:10Sustainable High-Speed EDU Gen-2
- Additive manufacturing to increase peak power & efficiency
- How to evaluate the CO2-equivalent on an EDU
- Design-to-CO2-eq & calculation of CO2-eq over life cycle
Wilhelm Vallant, Product Manager, AVL List GmbH, Austria
04:40Gen-1 EDU: Double the Power
- 500+ kW rear EDU with torque vectoring
- Packaging two motors in the space of one
- Latest inverter and motor technology developed for series production
- Real-time integrated development environment accelerated the development
Matthew Memmer, Director of Engineering, TREMEC, USA
Change to Plenary Hall
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Batteries II
02:00Functional Safety for Electric Vehicle Switching and Protection Technology
- Growing market, growing voltages, growing current levels
- What could go wrong: EV system potential failure modes
- Safety solutions: advanced EV system protection and switching
Werner Happenhofer, VP Engineering, Eaton, USA
02:30Efficient Battery Repair and Diagnosis of xEV and SOH Assessment of Battery Models
- Is an OBD diagnosis always correct? Causes of faults in the course of a battery repair
- Efficient repair of a traction battery
- SOH evaluation of battery modules for further use
David Pflanzl, Product Manager E-Mobility, AVL DITest, Austria
03:00Networking Time and Visit of the Exibition
03:40Transform EV and Battery Labs into High-Performance Test Factories
- What are the key performance indicators for running a lob on highest efficiency?
- How to process the generated data automatically without human interaction?
- How to manage energy consumption in realtime with prediction into the future?
Gerald Sammer, Principal Business Development Manager, AVL List GmbH, Austria
04:10Understanding and Analyzing Battery Pack Energy Density
- Transfer functions reducing cell-level energy density
- Integration into modules and packs
- Energy density benchmarking across disparate battery designs
Andy Oury, Engineering Technical Leader – HV Battery Packs, General Motors, USA
Join One of the other Sessions
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Inverters & DC DC Converter
02:00New Concept of Switching Cell for 800V SiC Inverter Application
- Rising demand for SiC in high voltage power electronics for EVs
- New concept of switching cell for the next generation of 800V SiC inverter
Sanjaka Wirasingha, R&D Director – Americas, Valeo, USA
02:30EV Drivetrain Optimized Silicon Carbide Power Devices - Supply, Reliability and Longevity into Automotive Electrification Applications
- Manufacturing challenges of SiC from sand & coal to finished product optimized for EV powertrain
- SiC vertically integrated supply chain and scalability against market demand
- Reliability of SiC EV powertrain devices in high volume – intrinsic and extrinsic considerations
Dr Jeff Casady, Product Director, Wolfspeed, USA
03:00Networking Time and Visit of the Exibition
03:40Technology Roadmap of Si IGBT and SiC MOSFET Modules for Main Inverter Applications
- The functions and requirements of power modules in xEV applications
- Technical status of power modules, and key trends in substrates, interconnection, cooling, encapsulation materials, and electric designs
- Comparison between Si IGBT and SiC MOSFET modules based on in-house teardown studies on the latest modules on market (Denso, STMicroelectronics, Wolfspeed, etc.)
Dr Yu Yang, Senior Technology and Market Analyst, Yole Intelligence, France
04:10Highly Integrated On-Board-Charger and DC/DC Converter
- On-board charger integration with DC/DC converter
- Common transformer core for OBC and DCDC functions
- High power density OBC/DCDC
Bob Li, Chief System Architect, Ricardo Plc, USA
Join One of the other Sessions
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Truck Electrification
02:00Electrification of the HD Commercial Vehicle Market - Market and Technology Evaluation for Battery Electric Powertrains and Charging Solutions
- Emission regulations and the inflation reduction act – Pushing e-mobility in the CV business
- Ambitious zero emission targets of major OEM and how they want to tackle the targets set
- Electrification penetration rate for HD CV
- Charging hardware echnologies pushing the electrification penetration rate
Simon Buderath, Principal Strategy and Technology, P3 USA Inc, USA
02:30Heavy Truck Hybridization
- Drive cycle comparison for heavy truck hybridization
- Heavy truck hybridization options
- Reduction of emissions through heavy truck hybridization
Gustavo Gomes, Program Manager, Schaeffler Group, USA
03:00Networking Time and Visit of the Exibition
03:40Modular Electric Driveline Platform for Commercial Vehicles
- Innovative central drive and e-axle systems for medium and heavy-duty vehicles
- Introduction of modular e-powertrain platform components
- Technology outlook on e-motor and power electronics
Robert Levy, Technical Specialist, ZF CV Systems North America LLC, USA
04:10Commercial Fleet Vehicle Electrification - EV Platforms
- Next generation EV platforms, ready to carry the future of E-mobility: flat, scalable and modular providing maximum efficiency and full design freedom
- REEcorner technology with drive-by-wire, steer-by-wire and brake-by-wire capability
- REEboard technology: a completely flat and modular electric platform
Dario Bignamini, Head of Project & Engineering Management, Chief Engineer, REE Automotive, UK
04:40Making the Grade – Electrification of Commercial Duty Vehicles
- Improving Efficiency, Performance, and Driving Experience with Sigma’s Electric Powertrains
- Sigma Powertrain Products & Technology
- PowerSplit Dual Mode (PSDM)
John Kimes, Founder & CEO, Sigma Powertrain, USA
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E-Drive Components II
02:00The Invasion of Consumer Electronics Players: New OEMs Strategies and the Impacts on the Powertrain Supply Chain
- Detailed examination of the strategies of OEMs from consumer electronics
- Impacts on the e-axle and potential integration of other systems/controllers
- Future mode in BEV: enclosed chassis and contract manufacturing
Dr Yu Yang, Senior Technology and Market Analyst, Yole Intelligence, France
02:30Hidden Power Electronics Cost Drivers in the Development of E-Drive Systems
- Cost focus transition from ICEs to electric drive systems
- Cost impacts of over-specified system functions
- Cost structure of the inverter and the main cost influences
Jeffrey Musson, Head of Systems Development, GKN Automotive, USA
03:00Networking Time and Visit of the Exibition
03:40Magnetic Speed Sensor Revolution by Introducing New Sensing Technology
- TMR – new sensing technology optimized for the use at speed sensor
- Higher accuracy and flexibility in magnetic circuits and module design
- Rotational speed sensor
- Functional safety
Yunfeng Li, Senior Application Engineer, Infineon Technologies Austria AG
04:10Novel Multi-Functional Shift System for EV Drivetrains
- Evolution of shift systems and the transition to EV drivetrains
- Challenges and needs for next generation EV drivetrain systems
- New powershift technology with integrated one-way-clutch functionality
- New multi-functional torque management systems for disconnect and multi-speed shifting
John Jennings, Director of eMobility and Innovation, Amsted Automotive, USA
04:40Superior Performance Friction Systems for Multiple e-Axle Architecture
- Clutch based torque distribution in the BEV powertrain
- Effect of efluids on tribology and material formulation
- Application specific material requirements
Christoph Hagauer, Engineering Manager ePowertrain, Miba Frictec GmbH, Austria
Change to Plenary Hall
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EDU Optimization and Digital Twins
02:00Efficiency and Range Determination Aspects for EDU and BEV
- Test methods for vehicle range determination
- Test methods and case studies for electric drivetrain efficiency evaluations
- Vehicle thermal management and influence to driving range
Tom D’Anna, Director, eMobility – Validation & Controls, FEV, USA
02:30Optimal Sizing of Electric Drives for BEV Through Vehicle-Level Simulation
- Dynamic vehicle simulation toolchain using MATLAB/Simulink
- Modeling of electric drives for light-duty vehicles
- Validation of vehicle models with real-world data
- Data-driven optimization for powertrain components
Sandeep Saini, Sr. Staff Systems Engineer, Technology & Innovation North America, Vitesco Technologies, USA
03:00Networking Time and Visit of the Exibition
03:40How to Improve Sustainability of an Electric Vehicle with Torque Vectoring
- High-speed electric motor technologies
- Reduction of critical materials and recycling of electric motors
- Torque vectoring control improves stability, safety and increases vehicle dynamics
- High-speed 500 kW electric drive unit with 4.3 kW/kg power sensity
Mathias Deiml, Center Leader, AVL Software and Functions GmbH, Germany
04:10Demonstrating a Cloud-Based Gearbox Digital Twin Using Telematics Data for Reliability Predictions
- Creating a digital twin that actually works
- Setting up the communication infrastructure
- Challenges, solutions, results and future prospects
Lou Long, Business Development Director, Hexagon, USA
04:40Accelerating Development of a High Performance E-Axle Leveraging Digital Twin
- System complexity drives need for digital twin approach
- System modeling performance and thermal behavior of integrated inverter, e-machines and axle
- Mission cycle sensitivity on thermal behavior and system performance
- Correlating digital twin models using design development tools and bench data
Dr Matti Vint, Director Vehicle Electrification, Marelli North America, USA
Change to Plenary Hall