SHORT UPDATE

FEV Overview FEV

© by FEV – all rights reserved. Confidential – no passing on to third parties

Your engineering partner worldwide

 Independent engineering company

 Founded in 1978

 Supporting engineering
developments from innovations up
to SOP

 Optimizing customers products

and processes

 Close to our customers:

subsidiaries on
35+ four continents

test cells for engines,

180+ transmissions, drivelines,

e-machines, batteries

Subsidiary Headquarter 4200+ employees

globally

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A partner you can trust

PORTFOLIO OF SERVICES – ORGANIZATION BY BUSINESS UNITS

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Supporting your development process

COMPLETE DEVELOPMENT AND SERVICES

Research Advanced development Series development Validation/hot test

SOP

First powertrains First powertrains off Start mass

available manufacturing line production

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Turning innovative ideas into reality

SOLUTIONS POWERED BY FEV

2-stage ADAS/
3-Way-Cat Diesel particulate VCR system Autonomous
filter driving

2-stage
Diesel injection Spray Guided Valve train 7 Speed eBooster
system Turbo variabilities DCT

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FEV Worldwide
Development of Engineering Sites

FEV IS GROWING GLOBALLY IN FAST PACE ESPECIALLY THE LAST 20 YEARS

Neuenhofstraße, Auburn Hills, Dalian, China Pune, India Sao Paolo, Brasil
Aachen, USA
ENGINEERING CAPABILITIES

Germany

First development on test India, Vehicle

cells at LAT / RWTH Aachen, Shanghai, China Dev. Center
Germany New Beijing
EU Vehicle Dev.
Subsidiaries Center

1978 ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙‘90∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙‘00∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙‘10∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙‘15∙∙∙∙∙∙∙∙2017

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3 Cyl. SI Engines - Reference project “1.0 liter EcoBoost engine”
Courtesy of Ford Motor Company

From 2012 – 2016 Technical Highlights and Data

– In Line 3 Gasoline Engine with 92 kW
/ 170 Nm @ 1.300 – 4.500 rpm /
overboost 200 Nm
– DI-VCT / Integrated exhaust manifold /
Oily belt for timing drive and oil pump
drive / Split cooling / Variable flow oil
pump

FEV´s Project Involvement

– Design and CAE for Pre-XO
– Procurement and QS 1
– Engine built, comissioning, run-in and
sign-off for 36 engines
– Combustion development for Stage 1

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Reference project – Base engine development AJ20D4
Courtesy of Jaguar Land Rover Limited

Technical highlights
 All new inline 4 Diesel engine called
Ingenium: Configurable, Flexible, Modular
 Max. power: 132 kW @ 4000 rpm
 Max. torque: 430 Nm @ 1750 – 2500
rpm
 cooled low pressure EGR
 variable camshaft timing
FEV‘s project involvement
 Base engine CAD support
 Base engine CAE support
 Single cylinder engine testing for
combustion layout and optimization
 Friction analysis and optimization
 Base engine dyno calibration

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Reference project – Natural gas engine development
Courtesy of Daimler AG

Product
 Daimler M936NGT engine for onroad applications
 Emission legislation Euro VI
 Stoichiometric combustion concept with 3-Way-Catalyst
 Advanced combustion system with external EGR
 Knock control for highest efficiency with different gas qualities
 Engine concept suitable for worldwide use

FEV responsibility Characteristic data

 Receipt of goods and quality assurance Number of cylinder 6 inline
 Complete warehouse for M936 parts at FEV, engine
Displacement (cm³) 7.698
configuration and commissioning by use of own ERP-database
 Engine assembly and run-in at test bench including detailed Bore / stroke (mm) 110 / 130
documentation for each engine Performance (kW) 222
 Thermodynamic development & preparation of certification
 Functional and endurance testing until release of parts for series Rated speed (1/min) 2000
production
 Hot climate and high altitude testing, arctic testing Torque (Nm) 1200
Max. torque speed 1200 - 1600

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parties 10
FEV’s dual wet clutch transmission family as Unique-Selling-Proposition
For transversal transaxle Powertrains, 5 – 7 speeds, 130 to 350 Nm

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Reference project – Premium hybrid development partner for BMW i8
Courtesy of BMW AG

Technical highlights
 Plug-In Hybrid Electric Vehicle with
 35 km eDrive
 4.4 s (0-100 km/h)
 250 km/h
 2.1 l/100 km
 Combustion engine: 1.5-liter I3
gasoline engine 170 kW / 320 Nm
 E-Motor: 96 kW / 250 Nm
 Axlesplit powertrain for dynamic AWD
FEV‘s project involvement
 Hybrid function development
 Hybrid calibration and OBD
 Calibration & validation eDrive system
 Functional safety for powertrain
 SW development battery management
system
 Durability testing hybrid powertrain

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 # SELECTED EXAMPLES

Business Unit Electronics & Electrification

Smart Vehicle – Selected Reference Projects

FEV … TURNING INNOVATIVE IDEAS INTO REALITY

Predictive Energy Management
 Long Range: Electric drive
planning using eHorizon
 Mid Range: Exploit braking
zones for SoC levelling
 Short Range: Optimize gear
shift based on sensor and map
data
Smart Camera System
 Test of camera component for
Tier1
 Recording of large datasets
including storage organization
 Test planning and execution
 Analysis of object/event
detection and documentation
Automated Cyber Security Testing
 Complete design, development
and integration responsible
 Management of vendor
integration of custom security
testing tools.
 Test case development of
threat actors from remote
attack surface
 Execution, verification and
validation of manual test cases
for automated system.

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Business card: FEV India Pune Technical Center

INDIA FOOTPRINT
FEV India Technical Center
 FEV India (ISO 9001-2008, ISO 17025):
 2006: Foundation of FEV India
 2009: Technical center operation
Delhi  2016: state of art 7 engine test benches
 2017: Vehicle application canter
 03/17: 180 team members

 Technical Portfolio:
Pune
Technical Center
 Benchmarking: vehicle and engine level
Chennai Representative Office  Design and CAE
 Prototyping, assembly & rating
 Mechanical development & validation
 Base engine performance & emission dev.
 After treatment, vehicle and OBD calibration
 Transmission design & calibration
 Control strategy & software development
 Testing solutions
FEV India Board of Directors
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Hall 1: Powertrain development

Equipment and layout of test field

 State of art facilities to perform mechanical
development, thermodynamic development, after
treatment calibration and friction benchmarking
(strip-down method).

 Total: 7 test benches ( FEV global standard):

 1 dedicated friction test bench (132 kW)
 2 mechanical development, durability &
localization validation test benches
 4 thermodynamic test benches for engine &
after treatment system development
 Engine proto assembly & measurement
 Multiple dyno systems from 30 kW to 500 kW
to set up the test bench as per test
requirements.

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FEV India Engine Test Field: Pictures

Layout Hall 1 Proto assembly

Friction Test Bench

Test Bench view

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|
Hall 3: Vehicle application and testing

IN BO ( VEHICLE APPLICATION BLOCK, HALL 3):

Equipment and layout of test field
 Vehicle emission chassis dyno facility:
− 220 kW, 4X2 roller bench, protected for 4X4
− Supplier: roller bench (Schenk), emissions (Horiba),
data acquisition system (D2T).
− Test cell ventilation: 25°C.
− Facility capable to operate homologation cycles i.e.
MIDC, NEDC, WLTC ,FTP-75 and equivalent.

 Building:
− Office area (1310 m2): ground (350 m2) + level 1 (480
m2) + level 2 (480 m2).
− Shop floor (2060 m2): ground (1380 m2) + technical
floor (680 m2).
− Protected for 2/3 W chassis dyno & NVH lab.

 Time Plan:
− Building in 6 months (i.e. Dec 2016).
Front view Rear view − Set up & comm. in one month (i.e. Jan 2017).
− Start of first project: Feb 2017

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 FEV India Vehicle Test Field: Pictures

Dilution Tunnel Analyser Room

Vehicle Test Cell - 01 Soak Room

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Further growth topics in the year 2017

POWERTRAIN NVH TEST BENCH

NVH Lab specification

 Specification
 Hemi-anechoic chamber - Quality class 1
 Cut off frequency of 50 Hz
 Acoustic wedge Tip to Tip clear dimensions –
7 m x 6 m x 4 m (L x W x H)
 Engine dyno: 1225 Nm @2500 rpm & 325kW
 Wheel dyno: 2000 Nm @ 800 rpm
 NVH measurement instruments
 Applications
 Engine NVH
 Powertrain NVH
 Transmission NVH
 Drive line NVH

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 Further growth topics in the year 2017

GLOBAL SOFTWARE DEVELOPMENT CENTER IN INDIA

 Electronics focus: Large interest in smart vehicles – especially
connectivity, infotainment via integration with smartphones etc. Several
Indian companies working on these areas and could help boost FEV
Smart vehicles program

 Electrification focus: Indian government’s push towards electrified

powertrains – incentives to the industry, Bharat Stage VI.

 Software Background on above topics

 Electronics and Electrification topics and others run with a Software
background
 Huge work estimated in software development but also in integration of
the various platforms, validation support
 Cost control while retaining FEV know how and quality
 Able to make use of local knowledge pool

 Targets 2017 – ramp up the team size to 100

FEV Software competence suited to local/global customer needs

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Message

 FEV is

 Core Research & development organization in the field of Automotive engineering

 Conventional powertrain development

 Future powertrain including e mobility & smart vehicles

 We want to develop specialist in Mechanical, electrical, electronics and embedded controls in

automotive domain

 If you have dream, we can partner with you to realize them

 If don’t , we give the eco system to develop your dreams

 Today we look for, strong technical fundamentals, passion towards automotive technology,

dedication, hard working and team player ………..

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FEV India Technical Centre

Thank you very much

for your attention!

© by FEV – all rights reserved. Confidential – no passing on to third parties