2018 Schaeffler Symposium 9/6/2018 Markus Steinberger Hybrid Modules Supporting Many Needs

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Heather Floyd
5 years ago
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2 Market U.S. light vehicle sales? FWD RWD 17.2 million Market U.S. light vehicle sales? RWD 6.5 million 2

6.5 million RWD vehicles Market RWD 6.5 million vehicles Electrification: series hybrids Fleet and niche solutions Small percentage of electrification?

3 6.5 million RWD vehicles Market RWD 6.5 million vehicles Electrification: series hybrids Fleet and niche solutions Small percentage of electrification? Using existing transmissions Gaining efficiency Increasing performance Hybrid Module Engine start P2 RWD Architecture 6.5 million RWD vehicles ICE drive ICE drive E drive / regen. Combustion engine driving RWD architecture space Electric driving Electric boost and recuperation Engine start 3

4 The Appeal of Hybrids What do drivers like about hybrids? 6.5 million RWD vehicles Features Electric drive High power High torque Instantaneous powertrain feedback Properties Improved fuel economy Smooth launch Adequate price Hybrid Module 4

5 Hybrid Module Combustion engine driving Torus Lockup clutch Engine torque Disconnect clutch Transmission shaft Torque Hybrid Module Combustion engine driving Electric driving E motor Lockup clutch Transmission shaft Torque 5

Hybrid Module Combustion engine driving Electric driving Electric boost E motor Lockup clutch Transmission shaft Engine torque Torque Disconnect clutch Hybrid Module

6 Hybrid Module Combustion engine driving Electric driving Electric boost E motor Lockup clutch Transmission shaft Engine torque Torque Disconnect clutch Hybrid Module Combustion engine driving Electric driving Electric boost Battery charge / recuperation E motor Lockup clutch Transmission shaft Engine torque Torque Disconnect clutch 6

motor Torus Lockup clutch Transmission shaft Engine torque

Hydrostatic Clutch Actuator Wet clutch with Electric Pump

7 Hybrid Module Combustion engine driving Electric driving Electric boost Battery charge / recuperation Engine start E motor Torus Lockup clutch Transmission shaft Engine torque Torque Disconnect clutch Hybrid Module Dry clutch with Hydrostatic Clutch Actuator Wet clutch with Electric Pump Actuator Wet clutch controlled by valve body Disconnect clutch alternatives 7

Hybrid Module Sub Assemblies P2 Hybrid launch element Double clutch Single face clutch Torque converter Front DCT Minimal towing Minimal towing Low weight Towing High torque Low weight Dynamic feel

8 Hybrid Module Sub Assemblies P2 Hybrid launch element Double clutch Single face clutch Torque converter Front DCT Minimal towing Minimal towing Low weight Towing High torque Low weight Dynamic feel Smooth launch Dynamic feel Hybrid Module Sub Assemblies Advantage of TC in P2 RWD High slip capacity High towing capacity Torque ratio No change over lifetime No sensors or actuators Smooth launch P2 Hybrid launch element Torque converter Towing High torque Smooth launch RWD application 8

Hybrid Module Sub Assembly HV connector Disconnect

flange Torque converter Transmission flange Voltage

drive Fuel efficiency Performance Electrical

9 Hybrid Module Sub Assembly HV connector Disconnect clutch Engine LV connector E motor Transmission Engine flange Torque converter Transmission flange Voltage 48V 300V 800V Recuperation Fuel efficiency Electric drive Fuel efficiency Performance Electrical alternatives Electric drive Fuel efficiency Performance Power density 9

10 Space saving Hybrid Module Integrated E Motor E motor is attached to torque converter shell Space saving Hybrid Module Integrated E Motor E motor is attached to torque converter shell 10

11 Space saving Hybrid Module Integrated E Motor Removed parts: Shaft Seals Bearings Flexplate Aluminum wall Bolts Flexplate bolting Space saving Hybrid Module Integrated E Motor Integrated E motor allows reduced number of components number of drag sources space by 50 mm inertia Removed parts: Shaft Seals Bearings Flexplate Aluminum wall Bolts Flexplate bolting 11

circuit Stator Space saving Durability P2 Module Better fuel

12 Space saving Durability Hybrid Module Cooling Primary cooling circuit Disconnect clutch Rotor Stator Secondary cooling circuit Stator Space saving Durability P2 Module Better fuel economy Instantaneous feedback Higher performance Smooth launch 12

13 Space saving Durability There is more Housing Space saving Durability There is more E motor TC K0 13

14 P2 Front Wheel Drive FWD design FWD design P2 Front Wheel Drive Engine space: Power Number of cylinders Space Transmission space: Frame Number of gears P1 design: space neutral P2 design: +20 mm 14

15 P2 Front Wheel Drive Electric motor FWD design Crankshaft Transmission shaft P2 Front Wheel Drive Seal wall Electric motor FWD design Disconnect clutch Lockup clutch Engine side damper Torus Crankshaft Transmission shaft 15

16 P2 Drives FWD design RWD and FWD P2 FWD P2 module 17.2 million vehicles RWD P2 module 16

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Region E-Mobility DCT systems. Electrification of the Drive Train

Region E-Mobility DCT systems. Electrification of the Drive Train Region E-Mobility DCT systems Electrification of the Drive Train Efficient Future Mobility EFFICIENT FUTURE MOBILITY CO 2 Regulations Make Electrification Necessary Electrification in the automobile industry