Electrification in Motion

Step 1 : September 2018

Groupe PSA will offer an electric or hybrid version on its entire new line-up by 2019

« GROUPE PSA IS COMMITTED TO A CLEAN AND SUSTAINABLE MOBILITY »

Reducing our vehicles’ environmental impact has been one of the major challenges guiding our technological choices for more than 20 years. To develop clean and sustainable mobility solutions, Groupe PSA has made judicious and publicly recognised technological choices regarding its internal combustion engines. Today, we are expanding our line-up with new electrified powertrains. We are technologically ready to play our part in the energy transition thanks to a multi-energy offering. Whatever the model they want, our customers will be able to buy it in an internal combustion, electric or hybrid version.

“EACH MODEL DEVELOPED BY PEUGEOT, CITROËN, DS, OPEL AND VAUXHALL WILL HAVE AN ELECTRIC OR HYBRID VERSION”

The five brands will offer clean mobility solutions in the form of all-electric zero-emissions vehicles or plug-in hybrid emitting less than 49g CO2/km.

Starting in 2019, every new model will also systematically come in a hybrid or all-electric version. Fifteen new electrified vehicles will be launched in just two years. Eight new plug-in hybrid models including DS 7 CROSSBACK E-TENSE 4×4, PEUGEOT 3008, PEUGEOT 508 and 508 SW, CITROËN C5 Aircross and OPEL and VAUXHALL Grandland X; and seven new electric models including DS 3 CROSSBACK E-TENSE, the 1st vehicle of the new electric generation which has just been revealed.

 

“100% OF THE PSA RANGE WILL BE ELECTRIFIED BY 2025”

Our product offensive is well launched today and 100% of PEUGEOT, CITROËN, DS, OPEL and VAUXHALL line-up will be electrified by 2025. Committed to societal responsibility, Groupe PSA aims to be a major European player in electrified mobility.

 

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THE PLUG-IN HYBRID MARKET

The number of plug-in hybrid and all-electric cars in the world crossed the 3 million mark at the end of 2017.

Projections put their number at:

5 million by the end of 2018 and 13 million[1] by 2020.

280 million electrified vehicles by 2040 (all-electric or plug-in hybrid), representing 14% of the 2 billion vehicles expected to be on the road.

[1] Source: French National Association for the Development of Electric Mobility (Association nationale pour le développement de la mobilité électrique).

Electrified market outlook

According to current forecasts for 2017-2025 worldwide, the market of electrified vehicles – 100% electric or plug-in hybrid – would be multiplied by 10 in less than 10 years.

In North America

  • 200,000 electrified vehicles in 2017; more than 1.7 million in 2025
  • A market multiplied by 9 by 2025
  • Plug-in hybrid vehicles would represent two thirds of the market with 1.2 million in 2025.

In Europe

  • 280,000 electrified vehicles in 2017; 3.5 million in 2025
  • A market multiplied by 13 by 2025
  • Plug-in hybrid vehicles may account for more than half of the market with 1.9 million vehicles in 2025

In China

  • 590,000 electrified vehicles in 2017; more than 4.7 million in 2025
  • A market multiplied by 8 by 2025
  • 100% electric vehicles would represent more than two thirds of the market (nearly 3.7 million vehicles in 2025)

The worldwide market undergoes substantial transformation

 Groupe PSA is ready to meet its worldwide customer’s expectations

 

EMP2 platform is suitable for internal combustion and hybrid versions

To ensure technological flexibility, both CMP and EMP2 platforms can produce internal combustion, electric and hybrid versions on the same production line.

The “Efficient Modular Platform” EMP2 is dedicated to compact and premium models (sedans, coupes, LAVs, SUVs and light commercial vehicles).

Launched in 2013 in Europe and in 2014 in China for internal combustion powertrains, EMP2 replaces the former BVH2 platform.

Its clever design now makes it possible to roll out new plug-in hybrid versions equipped with the best of hybrid technology.

 

Flexible production plants 

Ahead of the rollout at other facilities, the plants at Sochaux, Mulhouse, Rennes and Eisenach are equipped to produce a variety of models fitted with petrol or diesel powertrains, 4WD and 2WD hybrids for four- and five-door sedans, estates, MPVs, saloons and SUVs.

  • Sochaux: PEUGEOT 3008, OPEL Grandland X
  • Mulhouse: DS 7 CROSSBACK E-TENSE 4×4, PEUGEOT 508 and 508 SW
  • Rennes: CITROËN C5 Aircross
  • Eisenach: OPEL Grandland X
  • And more to come

 

 

Optimised investments

€630 million were invested in the development of the EMP2 platform.

Around €100 million were invested in plants for PHEV[1] industrialisation.

9% of the automotive annual turnover of Groupe PSA is dedicated to R&D activities.

 

 [1] PHEV: Plug-in Hybrid Electric Vehicles

 

PLUG-IN HYBRID: A CLEVER DESIGN

Olivier Salvat, Head of the PHEV Programme, Groupe PSA

“50% of journeys in Europe cover less than 15 km. Plug-in hybrid is an optimal solution for everyday electric driving for short journeys, with the internal combustion engine providing power for longer drives.”

 

What is a plug-in hybrid vehicle?

  • Hybrid vehicle is powered by at least two different energy sources. They use fossil fuel and electricity through both an internal combustion engine and an electric motor.
  • These vehicles have an electric battery that can be recharged while traveling via the deceleration energy recovery, or in an ordinary mains outlet when powered off. Plug-in hybrid can run in all-electric mode independently of the internal combustion engine.
  • They combine the advantages of an electric vehicle for short, everyday drives with those of an internal combustion engine for longer journeys.

 

The benefits of an hybrid vehicle

  • Average autonomy: 50km in 100% electric mode (WLTP)[1]
  • Consumption: -40% compared to a thermal vehicle. Emissions < 49g CO2/km (WLTP)
  • Freedom: access to ZEV[2] areas
  • Habitability: similar to that of a thermal vehicle
  • Performance: up to 300hp

 

A POWERFUL TECHNOLOGY

  • Groupe PSA’s plug-in hybrid vehicles provide combined output of up to 300hp and a driving range of 50 km in all-electric mode (WLTP).
  • Hybrid vehicles are available in two versions:
    • 4-wheel drive:
      • One 200hp 1.6l PureTech petrol engine meeting the future Euro 6.3 (Euro6.d) standard[3]
      • Two 80kW/110hp electric motors coupled with a 90kW and 13kWh battery and an eight-speed electrified automatic transmission.
    • 2-wheel drive:
      • One 180hp 1.6l PureTech petrol engine meeting the future Euro 6.3 (Euro6.d) standard[4]
      • One 80kW/110hp electric motor coupled with an 80kW and 12kWh battery and an eight-speed electrified automatic transmission.

 

A LAID-BACK AND CLEAN DRIVING

  • At up to 135 km/h, the average autonomy is 50 km in all-electric mode (WLTP).

 

[1] WLTP : Worldwide harmonized Light vehicles Test Procedures // similar to 60km NEDC (New European Driving Cycle)

[2] ZEV: Zero Emission Vehicle

[3] Due to come into force in January 2020 for new vehicles and January 2021 for the entire line-up.

 

    • The energy recovery system activates when the vehicle brakes or decelerates (taking the foot off the accelerator or putting it on the brake) and can extend the driving range by up to 10% in average.
    • The battery can be fully charged in 1 hour and 45 minutes in fast-charge mode.
  • Fuel mixed consumption is 2.2 l/100 km. Mixed emissions are below 49g of CO2/km (WLTP).That represents a 40% reduction in fuel consumption compared to a pure internal combustion model.

 

  • Four driving modes are possible: all electric, hybrid, 4×4 and sport.
  • The interior space is preserved (interior and boot).
  • DS7 CROSSBACK e-TENSE 4×4 will be the first plug-in hybrid available in Europe by September 2019. Seven other vehicles will gradually be launched by 2021 including PEUGEOT 508 and 508 SW, PEUGEOT 3008, OPEL and VAUXHALL Grandland X and CITROËN C5 Aircross.

 

  • For a customer driving 20,000 km per year with a plug-in hybrid, fully electric driving can represent up to 10,000 km per year with just one charge a day.

 

BEHIND THE SCENES OF THE ASSEMBLY OF A PLUG-IN HYBRID

 

A CLEVER DESIGN COMBINING TWO DIFFERENT SYSTEMS

To run in hybrid mode, a vehicle has to undergo some adjustments compared with a traditional vehicle. The challenge is to integrate all electrical and mechanical systems without affecting the benefits of models equipped with hybrid technology.

STEP 1: FRONT END ASSEMBLY

  • A four-cylinder 1.6l PureTech 200hp/147kW petrol engine (Produced at La Française de Mécanique, Douvrin plant).
  • An 80kW/110hp electric motor coupled with the EAT8 eight-speed electrified automatic transmission.

 

  • Compact design thanks to modular architecture: only 3.5 cm more on the front axle compared to an internal combustion version.
  • Ease of assembly: same process used for hybrid or internal combustion versions.

 

STEP 2: ASSEMBLY OF THE MAIN MECHANICAL SUBASSEMBLIES

Some adjustments are needed to ensure internal combustion/hybrid compatibility due to the additional parts (battery, electric motor, dedicated cooling system, etc.) or modified parts (rear axle, fuel tank, exhaust system, back trim, etc.).

 

  • The front end (step 1).
  • Thermal comfort electrically assisted
    • Electrical air heater Power 5kw/300V
    • Electrical air conditioning compressor Power 5Kw/300V
  • High-voltage Lithium-Ion battery 300V positioned under the rear seats
    • For SUVs (4×4): Energy 13kWh/ Power 90kW. The battery powers the front and rear wheels
    • For sedans and estates (2WD): Energy 12kWh/ Power 80Kw. The battery powers the front wheels
  • A regenerative braking system electrically assisted (“i-booster”) to recover the energy produced during braking and deceleration phases. It extends the driving range by 10% on average, thanks to the conversion of mechanical energy into electrical energy stored in the battery.
  • A new multi-arm rear axle
    • For the 4×4 version, the additional electric motor is integrated into a new rear axle, known as an electrically powered rear axle, including a gearbox and an inverter in addition to the electric motor.
    • The 2WD version features also benefits from the new multi-arm axle
    • Industrial efficiency is optimal since all the plug-in hybrid models produced on the EMP2 platform have a common rear architecture (train, tank, battery).

 

  • An on-board charger connecting the plug and the battery converts the electricity supplied by the electrical grid (110-220V) into direct current to recharge the battery.
  • An electric charging hatch on the opposite side from the fuel hatch.

 

  • Production flexibility thanks to a platform suitable for both internal combustion (petrol and diesel) and hybrid (2WD and 4×4) versions.
  • Simplicity of assembly, just as easy as for an internal combustion vehicle.

 

STEP 3: ASSEMBLY OF THE BODY

The production process is automated and allows the internal combustion or hybrid platform to fit into the same production line flow at the same time as the body for final assembly. Some minor modifications are made to the hybrid version from the internal combustion version.

There is very little impact on the vehicle’s line:

  • The interior is preserved (interior and boot) by fitting the battery under the rear seats.
  • New components are fitted seamlessly for customers (battery, power electronics, fuel tank, multi‑arm train).
    • The floor is suitable for the battery integration.
    • The vehicle’s frame is reinforced with the structure fitted to existing components to protect the interior and the battery.
    • The body is modified to integrate the charging jack on the left side.

 

  • These developments are integrated into the manufacturing process in body assembly workshops.

 

DID YOU KNOW?

THE PROTOTYPE WORKSHOP AT SOCHAUX PLANT

The prototype workshop is a compact mini-assembly line with 12 assembly stations (bodies arrive after metalwork and painting)

About 30 operators manually assemble all the vehicle components to:

Validate the assembly lines and synoptic view

Detect any difficulties (conformity of parts and assembly ergonomics)

Optimise assembly operations

Four to nine month stage (depending on the model), with a gradual ramp-up from 1 to 3 vehicles per day.

Roughly 180 prototypes are assembled in the workshop before being switched to the serial production line in the final assembly plant 18 months ahead of the commercial launch.

PLUG-IN HYBRID DS7 CROSSBACK E-TENSE 4x4
PLUG-IN HYBRID DS 7 CROSSBACK E-TENSE 4x4