State of the Art Development Methodologies for Hybrids and e- Drives

Transcription

1 AVL List GmbH (Headquarters) State of the Art Development Methodologies for Hybrids and e- Drives PDiM 18, Chalmers Conference Centre Andreas Volk

2 Content Introduction Technology selection - Do the right thing Validation of new design concepts Do the things right Integrated design verification Summary and outlook Andreas Volk DTV 29 November

3 Content Introduction Technology selection - Do the right thing Validation of new design concepts Do the things right Integrated design verification Summary and outlook Andreas Volk DTV 29 November

4 AVL Transmission Overview Concept / Structure Transmission synthesis, Specification, Dimensioning Calibration ACT test bed calibration In-vehicle calibration DRIVE evaluation Detail Design & Analysis CAD Design Structural and dynamic analysis Integration & Testing Rig and vehicle testing Software & Controls Specification & coding Safety Andreas Volk DTV 29 November

5 AVL Transmission Overview CURRENT NUMBER OF EMPLOYEES: ~400 Andreas Volk DTV 29 November

6 KEY FEATURES OF CONVENTIONAL (ICE) AND BATTERY ELECTRIC POWERTRAIN (BEV) Pollutants CO 2 Tank to wheel CO 2 Lifetime EU mix CO 2 Lifetime China mix Refueling / Charging time Weight / Range Cost / Range Low speed performance High speed performance Transients NVH Total cost of ownership (actual status) excellent BEV ICE poor qualitative Electrification and ICE offer quite complementary characteristics Andreas Volk DTV 29 November

7 Content Introduction Technology selection - Do the right thing Validation of new design concepts Do the things right Integrated design verification Summary and outlook Andreas Volk DTV 29 November

8 Overview typical EV-Drive Architectures LAYSHAFT Co-Axial LAYSHAFT Offset PLANETARY GEAR Co-Axial PLANETARY GEAR Offset I M I M I M I M Packaging Complexity Efficiency NVH Cost + package + efficiency - bad good better best Andreas Volk DTV 29 November

9 Example Direct (0) 1-Speed 2-Speed or more EV-Drive Transmissions Influence of subsystem parameters + Low complexity M+ Good NVH - High weight - Big package - Low efficiency - Grade ability - High current (drive away) Number of gears LAYSHAFT Co-Axial LAYSHAFT Offset PLANETARY GEAR Co-Axial PLANETARY GEAR Offset I I M + Low cost + Low weight 0 Medium package 0 Medium efficiency I M I + Small M package + High efficiency + Good Performance + Low weight + Red. motor torque - Cost of transmission - Complexity E-motor for 1-Speed transmission: max. torque 313 Nm max. power 70 kw E-motor for 2-speed transmission: max. torque 170 Nm max. power 70 kw Andreas Volk DTV 29 November

10 Challenges Driveline & EV-Driveline Efficiently identify product design parameters, that perfectly meet technological and monetary customer requirements Minimize development time with maximum possible product maturity Andreas Volk DTV 29 November

11 Content Introduction Technology selection - Do the right thing Validation of new design concepts Do the things right Integrated design verification Summary and outlook Andreas Volk DTV 29 November

12 Failure mode analysis Damage Calculation Verification / Validation Requirements Engineering AVL Validation Methodology DVP&R Design Verification Plan & Report FMEA CAE Reports Testing Simulation System analysis on component level to determine failure modes and damaging operation Failure mode based test program Test specification Andreas Volk DTV 29 November

13 Design load spectra MET150 X%ile ME customer Duty value Milage target vehicle code : vehicle curb weight [kg] : Gross vehicle mass [kg] : Trailer weight [kg] : Dyn.rolling.radius [m]: Electric machine : i=9,93 Laststufenlauf VAG J1 Vehicle data Vehicle Component Data Information about Data Sources Full Load Performance Elasticity Start Velocity General Vehicle Data: 1 Required Input 2 Optional Input 3 4 Drivetrain Description End Velocity km/h km/h Vehicle Model Year Vehicle Class E-Drive Description Transmission Description Maximum velocity km/h Gross Weight Weight Distribution between Front Axle (FA) & Rear Axle (RA) xxx xxx xxx Frontal Area Drag coefficient Driving Resistance Coefficient A Driving Resistance Coefficient B Driving Resistance Coefficient C Base Data Sheet for Vehicle Simulation Simulation Model Input Data: Vehicle Specification Performance based on published value or measurement data: Gas Tank Volume Total Length Total With Total Height Distance from Hitch to front axle Wheelbase Curb Weight (=dry weight) Brake Distribution between Front & Rear Axle Inertia Test Weight (ITW): xxx xxx Reference Vehicle Mass Time sec Liter 4462 mm 1865 mm 1632 mm 3620 mm 2675 mm 2300 kg 3200 kg km/h 55 / 45 FA / RA 51 / 49 FA / RA FA / RA Which Cycle? Please replace xxx with the Name of the Cycle kg kg kg kg kg 2,52 m^2 0, N 2x 8 Zyklen 80 C Stufenlastlauf Teil 1 Mmax (25 Zyklen zu je 56 Laststufen) 2 Zyklen 100 C 1x 2 Zyklen 100 C 1 Zyklus 25 Zyklen 1 Zyklus 120 C 1 Zyklus 120 C Nr. LS PAG Antriebsmoment Antriebsdrehzahl Abtriebsmoment Abtriebsdrehzahl gemittelt Abtriebsdrehzahl links Abtriebsdrehzahl rechts Dauer delta t t M n_in n_links n_rechts [-] [-] [Nm] [U/min] [Nm] [U/min] [U/min] [U/min] [s] 0,00 0,00 0,00 0,00 0,00 1 3Z ,23 5,23 190, , , ,89 2 3S ,00 25,23 190, , , ,89 3 4Z Damage Value (comparison 542 with Ref-1) 158 3,92 29,15-210, ,21 248,14 244,64 4 4S ,00 204,15-210, ,73 261,14 231,64 5 5Z ,00 206,15 250, ,79 540,30 543, km Road Profile India Europe Korea Total number of revolutions 1,60E+09 Type Total distance [km] : 400Nm/155kW max. Rec. Torque (70% T_max) 280 Nm 9,93 (fwd) Gear ratio : Input Torque (Nm) Usage space % 6 % 3S % ,00 364,15 250, ,27 527,30 556,80 7 6Z ,00 366,15-280, ,21 309,73 306,23 8 4S ,00 406,15-280, ,73 322,73 293,23 - Urban 0,55 0,50 0, SubUrban 0,15 0,30 0, Highway 0,20 0,15 0,20 2,61E Z DV regen Torque ,00 408,15 300, ,79 540,30 543,80 - Off-Road 10 0,10 0,053S 0,10 DV drive Torque ,94E ,00 428,15 300, ,27 527,30 556,80 0,330 Sum Z 1 Duty value (We=6) 7,55E ,05E ,00 430,15-210, ,21 248,14 244, S ,00 605,15-210, ,73 261,14 231, Z ,00 607,15 350, ,79 540,30 543,80 Inputshaft Speed (rpm) 14 3S Design 493 load spectra MET150 i=9, Duty value 21,00 (We=6) 628,15 350, ,27 527,30 556, Z ,00 630,15-280, ,21 309,73 306, S ,00 670,15-280, ,73 322,73 293, Z ,00 672,15 400, ,79 392,47 395, DV (k=6) ,0E+00 3,04E+15 0,00E S ,0E ,55E+15 0,00E ,00 692,15 400, ,27 379,47 408, Z ,0E ,14E+15 0,00E ,00 694,15-210, ,21 494,52 491, ,0E+00 1,78E+15 0,00E S ,00 819,15-210, ,73 507,52 478, ,0E+00 1,47E+15 0,00E Z ,0E ,21E+15 0,00E ,38 821,53 190, ,79 983,79 987, S ,0E ,83E+14 0,00E ,00 927,53 190, ,27 970, , ,0E+00 7,97E+14 0,00E Z ,69 930,22-280, ,21 432,93 429, ,0E+00 6,40E+14 0,00E S ,4E ,11E+14 7,24E ,00 980,22-280, ,73 445,93 416, Z ,8E ,04E+14 1,54E ,00 982,22 250, ,79 491,02 494, S ,5E ,16E+14 1,73E , ,22 250, ,27 478,02 507, ,1E+05 2,45E+14 1,73E Z , ,22-210, ,21 494,52 491, ,5E+05 1,87E+14 1,78E S ,2E ,42E+14 1,70E , ,22-210, ,73 507,52 478, Z ,4E ,06E+14 1,50E , ,22 300, ,79 527,98 531, ,1E+06 7,78E+13 1,67E S , ,22 300, ,27 514,98 544, ,5E+06 5,62E+13 1,42E Z ,4E ,99E+13 1,34E , ,22-280, ,21 432,93 429, S , ,22-280, ,73 445,93 416, Z , ,22 350, ,79 466,38 469, ,6E+05 7,97E+14 2,05E ,0E+05 9,83E+14 1,96E+20 Abtriebsdrehzahdrehzahdrehzahl Dauer Abtriebs- Abtriebs Antriebs- 1,4E+05 drehzahl 1,47E+15 2,00E+20 moment 1,6E+05 Antriebs- 1,21E+15 1,97E+20 Abtriebs moment ,4E+05 1,78E+15 4,31E gemittelt links rechts , ,27 250, ,79 540,30 543, [-] 0 0 [-] 0 [Nm] 1,3E+05 [U/min] 2,14E+15 2,68E+20 [Nm] [U/min] [U/min] [U/min] [s] 158, ,27 250, ,27 527,30 556, ,8E+05 2,55E+15 4,71E Z , ,27-280, ,21 309,73 306, Zyklen ,3E+05 3,04E+15 1,32E S ,9E ,60E+15 6,98E , ,27-280, ,73 322,73 293,23 delta t t M n_in n_links n_rechts Z ,0E ,24E+15 0,00E , ,57 190, ,79 983,79 987,29 0,00 0,00 0,00 0,00 0, S ,0E ,98E+15 0,00E , ,57 190, ,27 970, ,29 9,66 9,66 80, , , ,0E+00 5,82E+15 0,00E Z , ,95-210, ,21 494,52 491,02 284,00 293,66 80, , , ,0E+00 6,77E+15 0,00E+00 Sum Cyc S ,6E ,6E , ,95-210, ,73 507,52 478,02 7,74 301,40-80, ,21 371, Sum Distance (km) Z km , ,95 250, ,79 491,02 494,52 200,00 501,40-80, ,73 384,3 355 av. Time (min) h 8 2S , ,95 250, ,27 478,02 507,52 2,00 503,40 130, ,79 737,4 741 driving Speed [km/h] Zav. Velocity 80 46,13 km/h , ,95-280, ,21 432,93 429,43 100,00 603,40 130, ,27 724, S , ,95-280, ,73 445,93 416,43 2,38 605,78-130, ,21 248, Z , ,95 190, ,79 799,00 802,50 200,00 805,78-130, ,73 261, S , ,95 190, ,27 786,00 815,50 3,92 809,70 80, , , Z , ,95-210, ,21 494,52 491,02 50,00 859,70 80, , , S , ,95-210, ,73 507,52 478,02 2,00 861,70-80, ,21 790, Z , ,95 250, ,79 306,23 309,73 150, ,70-80, ,73 803, S , ,95 250, ,27 293,23 322,73 2, ,70 130, ,79 614, , ,95-280, ,21 432,93 429,43 114, ,70 130, ,27 601,2 631 Drehzahl [rpm] Drehmoment [Nm] N/kmh N/(kmh2) kg Temperaturen Additional Comments Back to INDEX Vehicle & Base Data only required in case of vehicle model with trailer for curb weight condition for gross weight condition FA = Front Axle; RA = Rear Axle including fuel, oil, driver,... Including 100kg (NEDC), 136kg (ftp, JP1015) Driving resistance function Stufenlastlauf Teil 1 Mmax (25 Zyklen zu je 56 Laststufen) The velocities here are just examples. Please feel free to define other velocities-time to specify similar performance target If available, please attach a picture of the Vehicle (with Dimensions). In addition, please attach a schematic picture/drawing of the powertrain. For the Driving Resistance: Either a physical description of the Vehicle is necessary (with Frontal Area, Drag Coefficient and Rolling Resistance of the Tire) or n_in n_links n_rechts M ,0E+06 2,77E+13 1,11E ,6E+06 1,88E+13 8,58E ,4E+06 1,24E+13 7,94E Temperaturen ,6E+06 7,98E+12 6,04E S ,4E ,94E+12 4,16E , ,22 350, ,27 453,38 482,88 5x 85 Zyklen 80 C 1x 42 Zyklen 80 C Z ,0E ,93E+12 2,96E , ,22-210, ,21 740,91 737,41 14 Zyklen 100 C 7 Zyklen 100 C S ,1E ,65E+12 1,82E , ,22-210, ,73 753,91 724,41 1 Zyklus 120 C 1 Zyklus 120 C ,3E+07 8,79E+11 1,12E Z ,4E ,33E+11 6,23E , ,33 400, ,79 330,87 334, S ,4E ,95E+11 2,82E , ,33 400, ,27 317,87 347, Z ,6E ,71E+10 1,24E+18 Stufenlastlauf Teil 2 nmax (550 Zyklen zu je 16 Laststufen) , ,33-280, ,21 494,52 491, ,9E+07 2,58E+10 5,03E S , ,33-280, ,73 507,52 478, ,8E+07 6,77E+09 1,90E , Z ,6E ,21E+09 5,50E , ,41 190, ,79 922,20 925, S ,1E ,06E+08 8,55E , ,41 190, ,27 909,20 938, Z ,2E ,65E+06 1,92E , ,41-210, ,21 740,91 737, ,8E+08 0,00E+00 0,00E S ,0E ,0E+08 2,0E+08 3,0E ,00E+00 1,00E , ,41 2,00E , ,73 753,91 724,41 100, ,6E+08 1,65E+06 4,24E Z ,4E ,06E+08 2,49E , ,41 250, ,79 429,43 432, S ,5E ,21E+09 1,86E , ,41 250, ,27 416,43 445, ,1E+08 6,77E+09 7,37E Z , ,57-210, , , , ,7E+07 2,58E+10 1,21E+18 50, S ,5E ,71E+10 2,74E , ,57-210, , , , Z ,0E ,95E+11 5,85E , ,73 300, ,79 429,43 432, S ,6E ,33E+11 1,14E , ,73 300, ,27 416,43 445, ,3E+07 8,79E+11 2,02E Z ,0E ,65E+12 3,34E , ,73-280, ,21 543,80 540,30 0, S ,7E ,93E+12 5,01E , ,73-280, ,73 556,80 527, Z ,4E ,94E+12 7,10E , ,73 350, ,79 306,23 309, ,2E+07 7,98E+12 9,24E S , ,73 350, ,27 293,23 322, ,6E+06 1,24E+13 1,07E Z , ,73-210, ,21 248,14 244,64-50, ,5E+06 1,88E+13 1,04E S ,3E ,77E+13 1,20E , ,73-210, ,73 261,14 231, ,5E+06 3,99E+13 9,94E+19 2, ,73 400, ,79 183,04 186, ,6E+06 5,62E+13 9,02E ,8E+05 7,78E+13 7,61E+19 20, ,73 400, ,27 170,04 199,54-100, ,2E+05 1,06E+14 6,61E+19 2, ,73-280, ,21 309,73 306, ,12 Übersetzung 0 0 6,2E+05 1,42E+14 8,78E+19 40, ,73-280, ,73 322,73 293, ,0E+05 1,87E+14 7,55E Laststufenlauf 0 0 VAG 0 J1 4,0E+05 2,45E+14 9,90E , ,35 190, , , , ,8E+05 3,16E+14 8,88E , ,2E+05 4,04E+14 8,74E+19 20, ,35 190, , , , ,0E+05 5,11E+14 1,04E+20 n_in n_links n_rechts M Stufenlastlauf Teil 2 nmax (550 Zyklen zu je 16 Laststufen) 3, ,27-210, ,21 248,14 244, ,3E+05 6,40E+14 1,49E+20 1 Zyklus 175, ,27-210, ,73 261,14 231,64 Nr. LS PAG driving Speed [km/h] the Driving Resistance Function (A, B, C) or Coast Down Measurement Drehmoment [Nm] Drehzahl [rpm] Load spectra MET150 i=9,93 X%ile ME customer Usage space Damage Value 6 (comparison with Ref-1) Market India Road Milage target km India Europe Korea Total number of revolutions 1,38E+09 Profile Type % % % vehicle code : - Urban 0,55 0,50 0,55 Total distance [km] : vehicle curb weight [kg] : 2300 SubUrban 0,15 0,30 0,15 Gross vehicle mass [kg] : Trailer weight [kg] : Dyn.rolling.radius [m]: Electric machine : 3200 Highway 0,20 0,15 0,20 DV regen. Torque 5,35E+21 - Off-Road 0,10 0,05 0,10 DV drive Torque 1,43E+22 0,354 Sum ,96E Nm/155kW max. Rec. Torque (70% T_max) 280 Nm 9,93 (fwd) Gear ratio : Input Torque [Nm] Durability Test Gang 1 i=14,75 Moment n- INPUT n-output Dauer [Nm] [RPM] [min] max min delta n-out = 50/min/sec Umdrehungen Moment Drehzahl Dauer Laufzeit Leistung Umdrehungen kumuliert [Nm] [RPM] [min] [min] [kw] [rev] [rev] , , , , , , , , , , , , , , , , , , , , , , , , , , , Load spectra MET150 i=9,93 Duty value (We=6) , Input Speed [rpm] No. Cycles [-] No. Cycles [-] Cycles DV clas 0(k=6) DV (k=6) , ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,38E+16 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E ,0E+00 1,08E ,00E , ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 8,30E+15 0,00E , ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,32E+15 0,00E ,0E+00 0,0E+00 1,7E+03 4,7E+03 3,3E+03 1,6E-01 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E ,8E ,75E+15 4,63E , ,0E+00 0,0E+00 1,1E+02 8,4E+02 4,5E+03 1,3E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 5,5E+03 3,52E+15 1,93E ,0E+00 0,0E+00 1,1E+03 3,9E+03 1,3E+04 1,5E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E ,8E ,57E+15 4,66E , ,0E+00 0,0E+00 1,5E+03 1,3E+04 4,6E+04 1,5E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,0E+04 1,84E+15 1,11E , ,0E+00 0,0E+00 1,5E+03 1,2E+04 8,6E+04 1,2E+01 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,0E+05 1,29E+15 1,29E ,0E+00 0,0E+00 2,9E+03 1,1E+04 3,3E+04 3,2E+01 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E ,7E ,88E+14 4,17E , ,0E+00 0,0E+00 1,7E+03 5,3E+03 8,2E+03 5,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,5E+04 5,95E+14 9,10E , ,0E+00 0,0E+00 4,5E+02 1,1E+03 2,4E+03 5,2E+05 2,5E+06 1,6E+06 1,2E+06 7,5E+05 3,2E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,8E+06 3,87E+14 2,65E ,0E+00 0,0E+00 0,0E+00 3,8E+02 1,2E+03 1,5E+05 1,0E+06 6,8E+05 2,5E+05 3,3E+05 1,5E+05 9,8E+04 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E ,7E+06 2,44E ,52E , ,0E+00 0,0E+00 0,0E+00 5,8E+02 6,0E+02 1,8E+05 1,2E+06 1,2E+06 3,2E+05 2,4E+05 1,4E+05 2,7E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 3,6E+06 1,48E+14 5,28E ,0E+00 0,0E+00 0,0E+00 9,0E+01 4,3E+02 1,3E+05 1,1E+06 1,6E+06 8,0E+05 3,9E+05 2,5E+05 1,5E+05 2,0E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,6E+06 8,58E+13 3,97E ,0E+00 0,0E+00 0,0E+00 1,6E+02 3,0E+02 2,4E+05 1,5E+06 2,1E+06 1,2E+06 3,1E+05 2,3E+05 1,4E+05 2,3E+05 1,5E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,1E+06 4,70E+13 2,85E ,0E+00 0,0E+00 0,0E+00 3,2E+02 2,8E+02 4,0E+05 1,5E+06 2,8E+06 1,2E+06 6,8E+05 3,7E+05 2,2E+05 1,1E+05 3,3E+05 1,1E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 7,7E+06 2,41E+13 1,87E ,0E+00 0,0E+00 0,0E+00 1,2E+01 2,6E+02 3,6E+05 2,1E+06 3,4E+06 2,4E+06 1,2E+06 4,8E+05 3,2E+05 1,7E+05 7,8E+04 4,1E+05 1,6E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,1E+07 1,14E+13 1,27E ,0E+00 0,0E+00 0,0E+00 0,0E+00 1,8E+02 5,2E+05 2,7E+06 4,5E+06 2,6E+06 1,4E+06 5,4E+05 4,4E+05 2,3E+05 1,1E+05 8,3E+04 3,9E+05 1,5E+05 0,0E+00 0,0E+00 0,0E+00 1,4E+07 4,83E+12 6,65E ,0E+00 0,0E+00 0,0E+00 0,0E+00 4,8E-01 6,8E+05 3,2E+06 5,5E+06 4,6E+06 2,0E+06 8,9E+05 5,1E+05 3,7E+05 1,9E+05 1,2E+05 1,5E+05 1,8E+05 1,2E+04 0,0E+00 0,0E+00 1,8E+07 1,77E+12 3,26E ,0E+00 0,0E+00 0,0E+00 0,0E+00 7,5E-01 6,2E+05 3,2E+06 8,0E+06 5,8E+06 3,0E+06 1,1E+06 7,0E+05 5,9E+05 3,3E+05 2,7E+05 1,0E+05 2,1E+05 1,4E+04 0,0E+00 0,0E+00 2,4E+07 5,31E+11 1,27E ,0E+00 0,0E+00 0,0E+00 0,0E+00 1,0E+00 9,5E+05 4,3E+06 9,5E+06 1,1E+07 4,4E+06 2,2E+06 1,0E+06 8,8E+05 5,6E+05 4,2E+05 3,3E+05 2,7E+05 1,7E+04 0,0E+00 0,0E+00 3,5E+07 1,18E+11 4,17E ,0E+00 0,0E+00 0,0E+00 0,0E+00 1,8E+00 1,0E+06 5,9E+06 1,3E+07 1,9E+07 7,3E+06 3,6E+06 2,4E+06 2,6E+06 1,5E+06 1,0E+06 5,6E+05 5,3E+05 3,1E+03 0,0E+00 0,0E+00 5,8E+07 1,56E+10 9,09E ,0E+00 0,0E+00 0,0E+00 0,0E+00 1,5E+01 1,7E+06 8,2E+06 2,4E+07 4,1E+07 1,8E+07 1,3E+07 5,5E+06 4,0E+06 3,9E+06 3,8E+06 1,1E+06 8,4E+05 9,4E+04 0,0E+00 0,0E+00 1,2E+08 7,29E+08 9,09E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,7E-01 7,6E+05 1,0E+06 3,2E+06 3,7E+06 1,2E+06 8,2E+05 3,1E+05 2,3E+05 2,9E+05 3,3E+05 4,0E+04 3,1E+04 5,1E+03 0,0E+00 0,0E+00 1,2E+07 1,00E+06 1,20E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,4E+02 5,3E+06 1,2E+07 4,6E+07 6,8E+07 2,5E+07 2,0E+07 1,1E+07 7,9E+06 1,5E+07 1,1E+07 2,9E+06 2,9E+06 7,1E+05 0,0E+00 0,0E+00 2,3E+08 1,00E+06 2,28E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,0E+00 1,8E+06 8,6E+06 3,0E+07 4,5E+07 1,8E+07 1,4E+07 8,8E+06 6,2E+06 2,5E+07 2,8E+07 3,7E+06 1,4E+07 8,1E+06 0,0E+00 0,0E+00 2,1E+08 7,29E+08 1,54E ,0E+00 0,0E+00 0,0E+00 0,0E+00 5,7E+00 1,6E+06 7,5E+06 2,0E+07 3,4E+07 1,5E+07 9,5E+06 6,3E+06 4,7E+06 1,5E+07 1,9E+07 4,9E+06 2,8E+07 3,2E+07 0,0E+00 0,0E+00 2,0E+08 1,56E+10 3,10E ,0E+00 0,0E+00 0,0E+00 0,0E+00 6,9E+00 2,4E+06 7,8E+06 2,0E+07 3,0E+07 1,5E+07 7,8E+06 4,0E+06 3,7E+06 5,5E+06 7,4E+06 3,0E+06 3,7E+06 8,2E+06 0,0E+00 0,0E+00 1,2E+08 1,18E+11 1,39E ,0E+00 0,0E+00 0,0E+00 0,0E+00 8,0E+00 2,4E+06 7,4E+06 2,4E+07 3,3E+07 1,1E+07 4,4E+06 2,5E+06 1,9E+06 2,8E+06 2,2E+06 1,5E+06 2,0E+06 2,2E+06 0,0E+00 0,0E+00 9,7E+07 5,31E+11 5,16E ,0E+00 0,0E+00 0,0E+00 0,0E+00 8,0E+00 1,9E+06 6,4E+06 1,6E+07 2,4E+07 1,0E+07 3,0E+06 1,8E+06 1,1E+06 1,3E+06 9,5E+05 1,0E+06 1,1E+06 2,0E+05 0,0E+00 0,0E+00 7,0E+07 1,77E+12 1,23E ,0E+00 0,0E+00 0,0E+00 0,0E+00 6,8E+00 1,1E+06 4,3E+06 8,5E+06 1,4E+07 5,3E+06 1,5E+06 6,9E+05 6,4E+05 5,2E+05 7,2E+05 3,4E+06 2,9E+06 1,1E+05 0,0E+00 0,0E+00 4,4E+07 4,83E+12 2,10E ,0E+00 0,0E+00 0,0E+00 0,0E+00 9,7E+00 8,8E+05 3,6E+06 7,4E+06 7,4E+06 1,9E+06 9,9E+05 4,8E+05 3,1E+05 2,1E+05 2,5E+06 1,4E+06 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,7E+07 1,14E+13 3,09E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,7E+01 5,8E+05 3,0E+06 4,5E+06 3,8E+06 1,7E+06 5,9E+05 3,2E+05 1,6E+05 2,0E+06 6,2E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,7E+07 2,41E+13 4,18E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,5E+01 6,5E+05 2,4E+06 3,9E+06 2,5E+06 6,7E+05 4,4E+05 2,6E+05 1,1E+06 7,2E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,3E+07 4,70E+13 5,93E ,0E+00 0,0E+00 0,0E+00 0,0E+00 2,7E+01 4,7E+05 1,7E+06 2,1E+06 1,8E+06 2,5E+05 2,6E+05 4,6E+05 9,7E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 7,9E+06 8,58E+13 6,81E ,0E+00 0,0E+00 0,0E+00 0,0E+00 6,1E+00 4,3E+05 1,4E+06 1,7E+06 7,0E+05 2,1E+05 2,3E+05 8,2E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 5,5E+06 1,48E+14 8,09E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,0E+05 1,1E+06 1,0E+06 5,9E+05 2,1E+05 3,4E+05 2,9E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,0E+06 2,44E+14 9,66E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,1E+05 9,5E+05 8,0E+05 5,8E+05 9,2E+04 4,6E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 3,3E+06 3,87E+14 1,28E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 5,6E+05 5,2E+05 4,7E+05 4,5E+05 9,1E+04 3,3E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,4E+06 5,95E+14 1,44E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,4E+05 3,0E+05 4,9E+05 2,1E+05 2,9E+05 1,2E+04 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,4E+06 8,88E+14 1,28E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 8,6E+04 1,0E+05 1,4E+05 1,0E+05 1,9E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,2E+05 1,29E+15 8,03E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,9E+04 6,4E+04 2,7E+04 3,1E+04 1,4E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 3,1E+05 1,84E+15 5,69E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,2E+04 4,3E+04 4,5E+04 3,0E+04 8,8E+04 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,3E+05 2,57E+15 5,87E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,9E+04 6,9E+03 9,4E+04 1,5E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,7E+05 3,52E+15 9,63E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 8,9E+04 1,5E+05 2,4E+05 1,9E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,7E+05 4,75E+15 3,16E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,32E+15 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 8,30E+15 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,08E+16 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,38E+16 0,00E+00 1,4E+09 Sum Cyc 0,0E+00 0,0E+00 1,1E+04 5,3E+04 2,0E+05 2,9E+07 1,1E+08 2,7E+08 3,6E+08 1,5E+08 8,7E+07 4,9E+07 3,8E+07 7,6E+07 7,9E+07 2,5E+07 5,7E+07 5,2E+07 0,0E+00 0,0E+00 1,4E+09 Sum Distance (km) km av. Time (min) h driving Speed [km/h] av. Velocity 42,83 km/h driving Speed [km/h] Duty value (We=6) Torque Amplitude [Nm] ,0E+00 1,0E+08 2,0E+08 3,0E+08 Torque Amplitude [Nm] ,00E+00 2,00E+21 4,00E Torque, Nm Torque, Nm Durability Test G1 No. Cycles = Moment [Nm] Time, min R UN I N NO. CYCLES = 1 Drehzahl [RPM] Moment [Nm] Time, min Drehzahl [RPM] Input Speed, rpm Duty Cycle Generation Input definition Markets Lifetime targets km Road profile distribution Vehicle simulation input data definition Load data generation Track Profile selection AVL CRUISE simulation System analysis Damage calculation Duty cycle definition Evaluation & balancing of part specific damages Duty cycle definition Design duty cycle verification Test program generation Reference customer load duty cycle Andreas Volk DTV 29 November

14 Load spectra MET150 ሶ i=9,93 X%ile ME customer Usage space Damage Value 6 (comparison with Ref-1) Market India Road Milage target km India Europe Korea Total number of revolutions 1,38E+09 Profile Type % % % vehicle code : - Urban 0,55 0,50 0,55 Total distance [km] : vehicle curb weight [kg] : 2300 SubUrban 0,15 0,30 0,15 Gross vehicle mass [kg] : 3200 Highway 0,20 0,15 0,20 DV regen. Torque 5,35E+21 Trailer weight [kg] : - Off-Road 0,10 0,05 0,10 DV drive Torque 1,43E+22 Dyn.rolling.radius [m]: 0,354 Sum Duty value (We=6) 1,96E+22 Electric machine : 400Nm/155kW max. Rec. Torque (70% T_max) 280 Nm Gear ratio : 9,93 (fwd) Input Torque [Nm] Input Speed [rpm] Cycles DV clas (k=6) DV (k=6) ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,38E+16 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,08E+16 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 8,30E+15 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,32E+15 0,00E ,0E+00 0,0E+00 1,7E+03 4,7E+03 3,3E+03 1,6E-01 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 9,8E+03 4,75E+15 4,63E ,0E+00 0,0E+00 1,1E+02 8,4E+02 4,5E+03 1,3E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 5,5E+03 3,52E+15 1,93E ,0E+00 0,0E+00 1,1E+03 3,9E+03 1,3E+04 1,5E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,8E+04 2,57E+15 4,66E ,0E+00 0,0E+00 1,5E+03 1,3E+04 4,6E+04 1,5E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,0E+04 1,84E+15 1,11E ,0E+00 0,0E+00 1,5E+03 1,2E+04 8,6E+04 1,2E+01 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,0E+05 1,29E+15 1,29E ,0E+00 0,0E+00 2,9E+03 1,1E+04 3,3E+04 3,2E+01 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,7E+04 8,88E+14 4,17E ,0E+00 0,0E+00 1,7E+03 5,3E+03 8,2E+03 5,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,5E+04 5,95E+14 9,10E ,0E+00 0,0E+00 4,5E+02 1,1E+03 2,4E+03 5,2E+05 2,5E+06 1,6E+06 1,2E+06 7,5E+05 3,2E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,8E+06 3,87E+14 2,65E ,0E+00 0,0E+00 0,0E+00 3,8E+02 1,2E+03 1,5E+05 1,0E+06 6,8E+05 2,5E+05 3,3E+05 1,5E+05 9,8E+04 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,7E+06 2,44E+14 6,52E ,0E+00 0,0E+00 0,0E+00 5,8E+02 6,0E+02 1,8E+05 1,2E+06 1,2E+06 3,2E+05 2,4E+05 1,4E+05 2,7E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 3,6E+06 1,48E+14 5,28E ,0E+00 0,0E+00 0,0E+00 9,0E+01 4,3E+02 1,3E+05 1,1E+06 1,6E+06 8,0E+05 3,9E+05 2,5E+05 1,5E+05 2,0E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,6E+06 8,58E+13 3,97E ,0E+00 0,0E+00 0,0E+00 1,6E+02 3,0E+02 2,4E+05 1,5E+06 2,1E+06 1,2E+06 3,1E+05 2,3E+05 1,4E+05 2,3E+05 1,5E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,1E+06 4,70E+13 2,85E ,0E+00 0,0E+00 0,0E+00 3,2E+02 2,8E+02 4,0E+05 1,5E+06 2,8E+06 1,2E+06 6,8E+05 3,7E+05 2,2E+05 1,1E+05 3,3E+05 1,1E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 7,7E+06 2,41E+13 1,87E ,0E+00 0,0E+00 0,0E+00 1,2E+01 2,6E+02 3,6E+05 2,1E+06 3,4E+06 2,4E+06 1,2E+06 4,8E+05 3,2E+05 1,7E+05 7,8E+04 4,1E+05 1,6E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,1E+07 1,14E+13 1,27E ,0E+00 0,0E+00 0,0E+00 0,0E+00 1,8E+02 5,2E+05 2,7E+06 4,5E+06 2,6E+06 1,4E+06 5,4E+05 4,4E+05 2,3E+05 1,1E+05 8,3E+04 3,9E+05 1,5E+05 0,0E+00 0,0E+00 0,0E+00 1,4E+07 4,83E+12 6,65E ,0E+00 0,0E+00 0,0E+00 0,0E+00 4,8E-01 6,8E+05 3,2E+06 5,5E+06 4,6E+06 2,0E+06 8,9E+05 5,1E+05 3,7E+05 1,9E+05 1,2E+05 1,5E+05 1,8E+05 1,2E+04 0,0E+00 0,0E+00 1,8E+07 1,77E+12 3,26E ,0E+00 0,0E+00 0,0E+00 0,0E+00 7,5E-01 6,2E+05 3,2E+06 8,0E+06 5,8E+06 3,0E+06 1,1E+06 7,0E+05 5,9E+05 3,3E+05 2,7E+05 1,0E+05 2,1E+05 1,4E+04 0,0E+00 0,0E+00 2,4E+07 5,31E+11 1,27E ,0E+00 0,0E+00 0,0E+00 0,0E+00 1,0E+00 9,5E+05 4,3E+06 9,5E+06 1,1E+07 4,4E+06 2,2E+06 1,0E+06 8,8E+05 5,6E+05 4,2E+05 3,3E+05 2,7E+05 1,7E+04 0,0E+00 0,0E+00 3,5E+07 1,18E+11 4,17E ,0E+00 0,0E+00 0,0E+00 0,0E+00 1,8E+00 1,0E+06 5,9E+06 1,3E+07 1,9E+07 7,3E+06 3,6E+06 2,4E+06 2,6E+06 1,5E+06 1,0E+06 5,6E+05 5,3E+05 3,1E+03 0,0E+00 0,0E+00 5,8E+07 1,56E+10 9,09E ,0E+00 0,0E+00 0,0E+00 0,0E+00 1,5E+01 1,7E+06 8,2E+06 2,4E+07 4,1E+07 1,8E+07 1,3E+07 5,5E+06 4,0E+06 3,9E+06 3,8E+06 1,1E+06 8,4E+05 9,4E+04 0,0E+00 0,0E+00 1,2E+08 7,29E+08 9,09E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,7E-01 7,6E+05 1,0E+06 3,2E+06 3,7E+06 1,2E+06 8,2E+05 3,1E+05 2,3E+05 2,9E+05 3,3E+05 4,0E+04 3,1E+04 5,1E+03 0,0E+00 0,0E+00 1,2E+07 1,00E+06 1,20E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,4E+02 5,3E+06 1,2E+07 4,6E+07 6,8E+07 2,5E+07 2,0E+07 1,1E+07 7,9E+06 1,5E+07 1,1E+07 2,9E+06 2,9E+06 7,1E+05 0,0E+00 0,0E+00 2,3E+08 1,00E+06 2,28E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,0E+00 1,8E+06 8,6E+06 3,0E+07 4,5E+07 1,8E+07 1,4E+07 8,8E+06 6,2E+06 2,5E+07 2,8E+07 3,7E+06 1,4E+07 8,1E+06 0,0E+00 0,0E+00 2,1E+08 7,29E+08 1,54E ,0E+00 0,0E+00 0,0E+00 0,0E+00 5,7E+00 1,6E+06 7,5E+06 2,0E+07 3,4E+07 1,5E+07 9,5E+06 6,3E+06 4,7E+06 1,5E+07 1,9E+07 4,9E+06 2,8E+07 3,2E+07 0,0E+00 0,0E+00 2,0E+08 1,56E+10 3,10E ,0E+00 0,0E+00 0,0E+00 0,0E+00 6,9E+00 2,4E+06 7,8E+06 2,0E+07 3,0E+07 1,5E+07 7,8E+06 4,0E+06 3,7E+06 5,5E+06 7,4E+06 3,0E+06 3,7E+06 8,2E+06 0,0E+00 0,0E+00 1,2E+08 1,18E+11 1,39E ,0E+00 0,0E+00 0,0E+00 0,0E+00 8,0E+00 2,4E+06 7,4E+06 2,4E+07 3,3E+07 1,1E+07 4,4E+06 2,5E+06 1,9E+06 2,8E+06 2,2E+06 1,5E+06 2,0E+06 2,2E+06 0,0E+00 0,0E+00 9,7E+07 5,31E+11 5,16E ,0E+00 0,0E+00 0,0E+00 0,0E+00 8,0E+00 1,9E+06 6,4E+06 1,6E+07 2,4E+07 1,0E+07 3,0E+06 1,8E+06 1,1E+06 1,3E+06 9,5E+05 1,0E+06 1,1E+06 2,0E+05 0,0E+00 0,0E+00 7,0E+07 1,77E+12 1,23E ,0E+00 0,0E+00 0,0E+00 0,0E+00 6,8E+00 1,1E+06 4,3E+06 8,5E+06 1,4E+07 5,3E+06 1,5E+06 6,9E+05 6,4E+05 5,2E+05 7,2E+05 3,4E+06 2,9E+06 1,1E+05 0,0E+00 0,0E+00 4,4E+07 4,83E+12 2,10E ,0E+00 0,0E+00 0,0E+00 0,0E+00 9,7E+00 8,8E+05 3,6E+06 7,4E+06 7,4E+06 1,9E+06 9,9E+05 4,8E+05 3,1E+05 2,1E+05 2,5E+06 1,4E+06 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,7E+07 1,14E+13 3,09E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,7E+01 5,8E+05 3,0E+06 4,5E+06 3,8E+06 1,7E+06 5,9E+05 3,2E+05 1,6E+05 2,0E+06 6,2E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,7E+07 2,41E+13 4,18E ,0E+00 0,0E+00 0,0E+00 0,0E+00 3,5E+01 6,5E+05 2,4E+06 3,9E+06 2,5E+06 6,7E+05 4,4E+05 2,6E+05 1,1E+06 7,2E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,3E+07 4,70E+13 5,93E ,0E+00 0,0E+00 0,0E+00 0,0E+00 2,7E+01 4,7E+05 1,7E+06 2,1E+06 1,8E+06 2,5E+05 2,6E+05 4,6E+05 9,7E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 7,9E+06 8,58E+13 6,81E ,0E+00 0,0E+00 0,0E+00 0,0E+00 6,1E+00 4,3E+05 1,4E+06 1,7E+06 7,0E+05 2,1E+05 2,3E+05 8,2E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 5,5E+06 1,48E+14 8,09E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,0E+05 1,1E+06 1,0E+06 5,9E+05 2,1E+05 3,4E+05 2,9E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,0E+06 2,44E+14 9,66E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,1E+05 9,5E+05 8,0E+05 5,8E+05 9,2E+04 4,6E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 3,3E+06 3,87E+14 1,28E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 5,6E+05 5,2E+05 4,7E+05 4,5E+05 9,1E+04 3,3E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,4E+06 5,95E+14 1,44E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,4E+05 3,0E+05 4,9E+05 2,1E+05 2,9E+05 1,2E+04 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,4E+06 8,88E+14 1,28E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 8,6E+04 1,0E+05 1,4E+05 1,0E+05 1,9E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,2E+05 1,29E+15 8,03E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 4,9E+04 6,4E+04 2,7E+04 3,1E+04 1,4E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 3,1E+05 1,84E+15 5,69E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,2E+04 4,3E+04 4,5E+04 3,0E+04 8,8E+04 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,3E+05 2,57E+15 5,87E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,9E+04 6,9E+03 9,4E+04 1,5E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 2,7E+05 3,52E+15 9,63E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 8,9E+04 1,5E+05 2,4E+05 1,9E+05 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,7E+05 4,75E+15 3,16E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 6,32E+15 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 8,30E+15 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,08E+16 0,00E ,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 0,0E+00 1,38E+16 0,00E+00 Sum Cyc 0,0E+00 0,0E+00 1,1E+04 5,3E+04 2,0E+05 2,9E+07 1,1E+08 2,7E+08 3,6E+08 1,5E+08 8,7E+07 4,9E+07 3,8E+07 7,6E+07 7,9E+07 2,5E+07 5,7E+07 5,2E+07 0,0E+00 0,0E+00 1,4E+09 Sum Distance (km) km av. Time (min) h driving Speed [km/h] av. Velocity 42,83 km/h driving Speed [km/h] ,4E+09 Torque Amplitude [Nm] Load spectra MET150 i=9,93 No. Cycles [-] 0,0E+00 1,0E+08 2,0E+08 3,0E+08 Torque Amplitude [Nm] Duty value (We=6) No. Cycles [-] 0,00E+00 2,00E+21 4,00E+21 Laststufenlauf VAG J1 Temperaturen 2x 8 Zyklen 80 C Stufenlastlauf Teil 1 Mmax (25 Zyklen zu je 56 Laststufen) 2 Zyklen 100 C 1x 2 Zyklen 100 C 1 Zyklus 1 Zyklus 120 C 1 Zyklus 120 C Nr. LS PAG gemittelt links rechts Dauer delta t t M n_in n_links n_rechts [-] [-] [Nm] [U/min] [Nm] [U/min] [U/min] [U/min] [s] 0,00 0,00 0,00 0,00 0,00 1 3Z ,23 5,23 190, , , ,89 2 3S ,00 25,23 190, , , ,89 3 4Z ,92 29,15-210, ,21 248,14 244,64 4 4S ,00 204,15-210, ,73 261,14 231,64 5 5Z ,00 206,15 250, ,79 540,30 543,80 6 3S ,00 364,15 250, ,27 527,30 556,80 7 6Z ,00 366,15-280, ,21 309,73 306,23 8 4S ,00 406,15-280, ,73 322,73 293,23 9 7Z ,00 408,15 300, ,79 540,30 543, S ,00 428,15 300, ,27 527,30 556, Z ,00 430,15-210, ,21 248,14 244, S ,00 605,15-210, ,73 261,14 231, Z ,00 607,15 350, ,79 540,30 543, S ,00 628,15 350, ,27 527,30 556, Z ,00 630,15-280, ,21 309,73 306, S ,00 670,15-280, ,73 322,73 293, Z ,00 672,15 400, ,79 392,47 395, S ,00 692,15 400, ,27 379,47 408, Z ,00 694,15-210, ,21 494,52 491, S ,00 819,15-210, ,73 507,52 478, Z ,38 821,53 190, ,79 983,79 987, S ,00 927,53 190, ,27 970, , Z ,69 930,22-280, ,21 432,93 429, S ,00 980,22-280, ,73 445,93 416, Z ,00 982,22 250, ,79 491,02 494, S , ,22 250, ,27 478,02 507, Z , ,22-210, ,21 494,52 491, S , ,22-210, ,73 507,52 478, Z , ,22 300, ,79 527,98 531, S , ,22 300, ,27 514,98 544, Z , ,22-280, ,21 432,93 429, S , ,22-280, ,73 445,93 416, Z , ,22 350, ,79 466,38 469,88 Temperaturen 34 4S , ,22 350, ,27 453,38 482,88 5x 85 Zyklen 80 C 1x 42 Zyklen 80 C 35 3Z , ,22-210, ,21 740,91 737,41 14 Zyklen 100 C 7 Zyklen 100 C 36 3S , ,22-210, ,73 753,91 724,41 1 Zyklus 120 C 1 Zyklus 120 C 37 4Z , ,33 400, ,79 330,87 334, S , ,33 400, ,27 317,87 347, Z , ,33-280, ,21 494,52 491, S , ,33-280, ,73 507,52 478, Z , ,41 190, ,79 922,20 925, S , ,41 190, ,27 909,20 938, Z , ,41-210, ,21 740,91 737, S , ,41-210, ,73 753,91 724, Z , ,41 250, ,79 429,43 432, S , ,41 250, ,27 416,43 445, Z , ,57-210, , , , S , ,57-210, , , , Z , ,73 300, ,79 429,43 432, S , ,73 300, ,27 416,43 445, Z , ,73-280, ,21 543,80 540, S , ,73-280, ,73 556,80 527, Z , ,73 350, ,79 306,23 309, S , ,73 350, ,27 293,23 322, Z , ,73-210, ,21 248,14 244, S , ,73-210, ,73 261,14 231,64 2, ,73 400, ,79 183,04 186,54 20, ,73 400, ,27 170,04 199,54 2, ,73-280, ,21 309,73 306,23 8,12 Übersetzung 40, ,73-280, ,73 322,73 293,23 Laststufenlauf VAG J1 3, ,35 190, , , ,89 20, ,35 190, , , ,89 Stufenlastlauf Teil 2 nmax (550 Zyklen zu je 16 Laststufen) 3, ,27-210, ,21 248,14 244,64 1 Zyklus 175, ,27-210, ,73 261,14 231,64 Nr. LS PAG gemittelt links Antriebsmoment Antriebsdrehzahl Abtriebsmoment Abtriebsdrehzahl Abtriebsdrehzahl Abtriebsdrehzahl Antriebsmoment Antriebsdrehzahl Abtriebsmoment Abtriebsdrehzahl Abtriebsdrehzahl Abtriebsdrehzahl rechts Dauer 2, ,27 250, ,79 540,30 543,80 [-] [-] [Nm] [U/min] [Nm] [U/min] [U/min] [U/min] [s] 158, ,27 250, ,27 527,30 556,80 1 1Z , ,27-280, ,21 309,73 306,23 2 1S , ,27-280, ,73 322,73 293,23 delta t t M n_in n_links n_rechts 3 2Z , ,57 190, ,79 983,79 987,29 0,00 0,00 0,00 0,00 0,00 4 2S , ,57 190, ,27 970, ,29 9,66 9,66 80, , , Z , ,95-210, ,21 494,52 491,02 284,00 293,66 80, , , S , ,95-210, ,73 507,52 478,02 7,74 301,40-80, ,21 371, Z , ,95 250, ,79 491,02 494,52 200,00 501,40-80, ,73 384, S , ,95 250, ,27 478,02 507,52 2,00 503,40 130, ,79 737, Z , ,95-280, ,21 432,93 429,43 100,00 603,40 130, ,27 724, S , ,95-280, ,73 445,93 416,43 2,38 605,78-130, ,21 248, Z , ,95 190, ,79 799,00 802,50 200,00 805,78-130, ,73 261, S , ,95 190, ,27 786,00 815,50 3,92 809,70 80, , , Z , ,95-210, ,21 494,52 491,02 50,00 859,70 80, , , S , ,95-210, ,73 507,52 478,02 2,00 861,70-80, ,21 790, Z , ,95 250, ,79 306,23 309,73 150, ,70-80, ,73 803, S , ,95 250, ,27 293,23 322,73 2, ,70 130, ,79 614, , ,95-280, ,21 432,93 429,43 114, ,70 130, ,27 601,2 631 Drehzahl [rpm] Drehmoment [Nm] ,00 100,00 50,00 0,00-50,00-100,00-150,00 Stufenlastlauf Teil 1 Mmax (25 Zyklen zu je 56 Laststufen) n_in n_links n_rechts M Stufenlastlauf Teil 2 nmax (550 Zyklen zu je 16 Laststufen) n_in n_links n_rechts M Drehmoment [Nm] Drehzahl [rpm] Duty Cycle Generation - WORKFLOW REFERENCE CUSTOMER BEHAVIOR LIFETIME TARGET CONVENTIONAL DRIVING, WOT ACC., REVERSE DRIVING, DAMAGE CALCULATION TESTING BOUNDARIES for DC - SYNTHETIC LOAD DATA - SYSTEM and DYNO LIMITATIONS Reference customer behavior: Abbreviation: DC duty cycle D REF reference damage measured time resolved data or simulated D DC duty time cycle resolved damage data. D DC t DC duty cycle damage rate time to reach Customer usage contains different driving condition: normal driving, WOT acceleration, reverse driving, impulse starts, etc. D REF ሶ D DC BALANCING DETERMINATION OF TEST TIME FOR EACH DC LOAD POINT TO CAPTURE THE REFERENCE DAMAGE 25 Zyklen DUTY CYCLE D DC = ሶ D DC t DC - Design verification - Testing 550 Zyklen Andreas Volk DTV 29 November

15 Duty Cycle generation Detail Reference Customer Customer Input: Percentage split into Urban and Sub Urban AVL Usage Space Definition Additional Korea Market S.no Item Percentage distribution Percentage distribution 1 City 30% (Rough city) 20% (Rough city) General road (Included up 2 and down hill curve road) 40% (Smooth city) 50% (Smooth city) 3 High way 20% 20% 4 Off road 10% (Non paved) 10% (Non paved) Life time target: km Highway directly transferred Non Paved directly transferred in Off-Road percentage Altitude profiles are included in some of the used track profiles Day and night operation is not considered in simulation Road Profile Type India Europe Korea Distance Distance Distance % [km] % [km] % [km] Urban 55% % % Sub Urban 15% % % Highway 20% % % Off-Road 10% % % Sum 100,0% ,0% ,0% Special Maneuvers Total Number Distance [km] Total Number Distance [km] Total Number Distance [km] WOT_0-v_max kph Driving - R µ-transient Hill-Start Percentage split into Urban and Sub Urban Highway directly transferred Non Paved directly transferred in Off-Road percentage Andreas Volk DTV 29 November

16 Duty Cycle generation Detail Damage calculation models System analysis Failure mode definition Failure Modes [311-1] HCF - bending input shaft S1 [412-2] Wear coast - tooth flank gear G23 [312-1] HCF coast - toot root gear G11 [412-3] HCF drive - toot rooth gear G23 [312-2] Wear coast - tooth flank gear G11 [412-4] Wear drive - tooth flank gear G23 [312-3] HCF drive - toot root gear G11 [416-1] HCF - ball bearing B21 [312-4] Wear drive - tooth flank gear G11 [416-2] Wear - ball bearing B21 [312-1] HCF - ball bearing B11 [417-1] HCF - roller bearing B22 [312-2] Wear - ball bearing B11 [417-2] Wear - roller bearing B22 [313-1] HCF - roller bearing B12 [681-1] HCF coast - toot rooth gear G32 [313-2] Wear - roller bearing B12 [681-2] Wear coast - tooth flank gear G32 [411-0] HCF - bending intermed shaft S2 [681-3] HCF drive - toot rooth gear G32 [411-1] HCF coast - toot rooth gear G21 [681-4] Wear drive - tooth flank gear G32 [411-2] Wear coast - tooth flank gear G21 [682-1] HCF - roller bearing B31 [411-3] HCF drive - toot rooth gear G21 [682-2] Wear - roller bearing B31 [411-4] Wear drive - tooth flank gear G21 [683-1] HCF - roller bearing B32 [412-1] HCF coast - toot rooth gear G23 [683-2] Wear - roller bearing B32 Example: Failure mode activation methodology SUBSYSTEM FAILURE MODE FAILURE LOCATION CAUSE OF FAILURE EFFECT ON SYSTEM ACTIVATION Input Shaft / Gear in Wear (fracture fatigue) Tooth flank Mech. load (poor lubrication, pitting) NVH Damage of transmission High load operation Andreas Volk DTV 29 November

17 DVP Input - Damage Calculation Input Damage model Output Test cycles Reference cycles Model calibration Real world damage measurement Simulations LOAD TRANSFER FUNCTION: Contact Stress = f(torque EM ) DAMAGE CALCULATION D i = f Contact Stress ሶ D Damage rate (Damage per hour) Dሶ Test = 1 D t i Test AF = ሶ D Test ሶ D Ref Dሶ Ref = 1 D t i Ref ሶ AF... Acceleration factor D... Damage rate Andreas Volk DTV 29 November

18 Reference cycles Voltage, Temperature Test cycle on test bed Voltage, Temperature Test procedure Voltage, Temperature Online Target Monitoring Test procedure / measured test cycle vs. reference Input Damage model Output Model calibration Real world damage measurement Simulations Rel. accumulated Damage test cycle does not reach the validation target, test cycle has to be modified Temperature Voltage Temperature Voltage MATHEMATICAL EXPRESSION D i = f U i, M i, T ambi, test cycle modification test cycle reaches the validation target Temperature Voltage Online comparison of damage from reference (target damage) to test cycles target reached! Andreas Volk DTV 29 November

19 RAD (relative accumulated damage) Result Comparison Normalized damage Failure: HCF drive; tooth gear G11 The lowest ratio is most demanding for the design. Excepting damage modes are: Ratio 9,91 HCF tooth root G11 drive/coast Ratio 9,3 HCF coast tooth root G21 Ratio 8,27 HCF tooth root gear G21 drive/coast. Andreas Volk DTV 29 November

20 RAD (relative accumulated damage) Result Test Program Damage normalized on market The comparison is based on the calculated damage Test Program MET150 i=9,91 LP Time Input Speed Input Torque Power [h] [rpm] [Nm] [kw] LP LP LP ,6 LP ,5 LP ,4 LP ,2 LP ,2 LP ,4 Test Time: 714 h Synthetic balancing on failure mode based testing Test Program balancing was carried out respecting the following boundary conditions: Max. RAD < 1,85 Min. RAD < 0,85 Andreas Volk DTV 29 November

21 Correlation between RIG Testing, DVP&R and FMEA 1. Collection of simulation data 2. Definition of test cycle structure *) 3. Segmentation of simulation data Content of important LCT operating conditions Part/component damaging operation aggravating conditions conclusion (cycle needs to contain ) input shaft high ICE torque torque irregularities (low high ICE load at low speeds (LPM) eng. Speed) missalignment; inbalance needle bearings open C0 high speed difference input/output high amount of pure electric driving closed C0 (no relative speed) low lubeoil flow high oil temp missalignment; runout output shaft high torque ICE+EM missalignment; inbalance; runout boost operation hydr. seal rings high apply pressure high oil temp high amount of pure electric driving alternating pressure cycles high speed difference in/out high ICE revs (hydraulic) high ICE speed high relative speed at high pressure missalignment; runout housing high sum torque high bending torque eop & hydraulics high flow and pressure demand high oil temp contamination of oil varying eop speed demands e-drive high e-drive max. e-drive high e-drive (coil) temp torque high oil temp high recuperation torque high LT-circuit temp operation at bending resonance boosting from low ICE-revs / impulse starts long periods with full pressure demand (ICE-torque) high number of impulse starts as much as possible of e-drive operation high number of alternation drive/recuperation (pressfit) main bearing high ICE revs high oil temp and high lube oil flow high ICE revs; max. allowed inbalance of input shaft (check 5001) missalignment, unbalanced components clutch pack wear slipping operation impulse starts; poor lubrication/cooling high number of impulse starts contamination of oil clutch piston full piston travel and clutch torque high pressure gradients high number of impulse starts bending & wear high accumulated piston travel high number of C0 openings / pure electric driving contamination of oil 4. Load analysis Characterization of segments 6. Assembly of test cycle 5. Selection of relevant segments Andreas Volk DTV 29 November

22 Transmission - Variation of subsystem parameters (DoE) to be optimized Weight NVH Efficiency Transmission Error Efficiency Data Cloud CAMEO- Optimization: Optimization is done by an evolutionary algorithm -62% -28% -49% Single correlations between the parameters can be shown Optimized micro geometry parameters regarding Transmission Error can be estimated for specific operating points. +0.3% +0.5% +0.4% Andreas Volk DTV 29 November

23 Surface velocity level [db] Driveline NVH-Performance Variation of subsystem parameters (DoE) Influence of micro geometry parameters on surface vibrations MECHANICAL NOISE Lead Profile Helix Angle Correction [mic] Crowning [mic] Barreling [mic] Root Relief [mic] Tip Relief [mic] Torque [Nm] Andreas Volk DTV 29 November

24 Content Introduction Technology selection - Do the right thing Validation of new design concepts Do the things right Integrated design verification Summary and outlook Andreas Volk DTV 29 November

25 Tilt Test Bed - ONE dyno configuration Power Rotational Speed Torque Max. tilting speed 1 Dyno (Tilt rig) 41,5 kw rpm 100 Nm 30 /s Max. tilting position 60 Additional facts Climatic chamber with temperature range -72 to +180 C 8-Channel high resolution camera system Andreas Volk DTV 29 November

26 Tilt test bed - Test assembly Transmission Windowed or transparent housing assembled at Tilt test bed Driven reverse and forward up to top speed Tilted to simulate acceleration, deceleration, environmental conditions,.. Oil flow documented by footage and pictures Andreas Volk DTV 29 November

27 Tilt test bed - Action Andreas Volk DTV 29 November

28 Virtualization of Testing Andreas Volk DTV 29 November

29 Drive Testbeds Three dyno High Load configuration Power 3 Independent Dynos 13,2 kw Gear Ratio 1:320 Rotational Speed Torque 11 rpm Nm Additional facts Flexible installation of intermediate reduction transmissions Test of a differential gear / e-axle, transversal engine installation Test of a powertrain Rear drive, longitudinal engine installation Andreas Volk DTV 29 November

30 Specialized Rig Approach Single failure activation Fatigue (HCF) HCF - Simulation Damage - Calculation Node # torque cycles - Overrolling_driving E E E E Total sum Andreas Volk DTV 29 November

31 Specialized Rig Approach Single failure activation Fatigue (HCF) Andreas Volk DTV 29 November

32 Specialized Rig Approach Single failure activation Tooth contact 20Nm 200Nm 20Nm 200Nm Fdgadg <ssgg Similar contact pattern can be observed between simulation and testing Andreas Volk DTV 29 November

33 Specialized Rig Approach Single failure activation Lifetime hybrid P2 module Testing Target: Prove of C0 clutch component life time Execution: Run impulse starts on component rig Andreas Volk DTV 29 November

34 Specialized Rig Approach Single failure activation Lifetime hybrid P2 module Content of important operating conditions Part/component damaging operation aggravating conditions conclusion (cycle needs to contain ) dedicated test Gen2 durability JAC input shaft high ICE torque torque irregularities (low high ICE load at low speeds (LPM) eng. Speed) missalignment; inbalance HLCT high C0 apply pressure pressure oscillations in oil channels shift element durability high ICE speed missalignment; inbalance shift element durability welding torque irregularities (low eng. Speed) high ICE torque HLCT clutch hub, splines torque irregularities (low eng. Speed) high inbalance, misalignment, rotational speed high ICE torque, high number of C0 activations low lube flow HLCT, impulse start test vehicle driving at high speed high speed difference needle bearings open C0 input/output high amount of pure electric driving low lubeoil flow / high lube oil flow high oil temp missalignment; runout, contaminated lube oil impulse start test pilot bearing high travel of DMF oscillating / torque irregularities (low eng. Speed) HLCT output shaft high torque ICE+EM missalignment; inbalance; runout boost operation vehicle HLCT WOT acceleration high C0 apply pressure pressure oscillations in oil channels shift element durability vehicle WOT acceleration high EM/ICE speed missalignment; inbalance shift element durability weldings torque irregularities (low eng. Speed) vehicle high ICE&EM or EM torque HLCT WOT acceleration from standstill clutch basket, splines torque irregularities (low eng. Speed) high inbalance, misalignment, rotational speed high ICE torque, high number of C0 activations vehicle low lubrication flow HLCT WOT acceleration from standstill hydr. seal rings high apply pressure high oil temp, contaminated oil high amount of pure electric driving high speed difference input/output shaft high ICE revs high ICE speed missalignment; runout shift element durability housing high sum torque operation at bending resonance high bending torque boosting from low ICE-revs / impulse starts unbalanced thermal load vehicle driving, rough road eop & hydraulics high flow and pressure demand high oil temp, contamination of oil long periods with full pressure demand (ICE-torque) varying eop speed demands high number of impulse starts high oil pressure levels, varying pressure levels foaming of oil, contaminated suction filter (pressure drop) vehicle test e-drive high e-drive max. e-drive torque high EM speeds as much as possible of e-drive operation high recuperation torque high e-drive (coil) temp, high oil temp high number of alternation drive/recuperation (pressfit) high LT-circuit temp; frequent change of LT temp level vehicle test high recuperation power main bearing high ICE revs high oil temp and high lube oil flow high ICE revs; max. allowed inbalance of input shaft missalignment, unbalanced components shift element durability clutch pack wear slipping operation impulse starts; poor lubrication/cooling high number of impulse starts contamination of oil, frequently repeated starts impulse start test clutch piston full piston travel and clutch torque high pressure gradients, high revs, high oil temperature high number of impulse starts bending & wear high accumulated piston travel high number of C0 openings / pure electric driving contamination of oil shift element durability vehicle test only! Status: Online damage calculation from test bed data Andreas Volk DTV 29 November

35 Specialized Rig Approach Single failure activation Tooth contact, abuse According to load profiles multi configuration setup Andreas Volk DTV 29 November

36 Testing Simulation Validation & Verification Seamless integration Testing & Simulation Retching of park lock system of BEV in slope situation Short reaction time by combine of simulation and testing strength Simulation input for testbed setup and test strategy Test specification (speeds, loads) Frontloading approach Validation and tune of simulation by test results Information gained without real HW Fast results & variants conducted in virtual world Maturity level checked virtual before HW Andreas Volk DTV 29 November

37 VDA Overview Back to back testing Use of UuT s Customized gearboxes wheel side Inverter and cables from customer Condition monitoring system (additional from STD I, A, Ohm, mm/sec) Powerful coolant devices Air: -40 C 160 C Coolant: -35 C 120 C Small Footprint (1,8m x 1,5m x 1,5m) Scalable system, multi stage (room size 5m x 3m) Andreas Volk DTV 29 November

38 Back to back Customer Application Andreas Volk DTV 29 November

39 3M Test bench E-Motor use cases Transmission approach 1 x Dyno Prime 2 x Dyno Train Power 400 kw 220 kw Rotational Speed Torque Additional facts rpm rpm rpm* Nm HV-Emulator up to 500kW Test bed transmission speed up (ratio *2,1 and 3,6 available) Test transmission Dyno Train Test bed transmission HBM Support bearing Dyno Prime Dyno Train Mounting bracket Andreas Volk DTV 29 November

40 <65 mm <60mm >290mm Schematic Structure and Specification high speed transmission POS Specification Limits/Targets Additional information Design 2 stage gear box 6 5 Output UuT x x x x x x x x x x x x Input E-Machine Input speed Output speed 1 Center distance (input shaft - output shaft) 2 Width of gearbox housing 10000[rpm] & [rpm] >290[mm] <300mm As slim as possible 4 Output shaft Hollow shaft Coaxial and axially parallel operation possible 5 Inner diameter output shaft 40mm Width max.: 300mm 2 6 Outer diameter output shaft 3 Distance center output shaft gearbox housing <60mm <65[mm] Directly influences limits of possible speed Andreas Volk DTV 29 November

41 Overview high speed transmission Lubrication Gears Lubrication Bearing (support) Housing inspection Windows CFD correlation Lubrication Bearing (suction) Output shaft Support stands bushing mounted Prime Mover Andreas Volk DTV 29 November

42 Overview high speed transmission Different application Off axis Coaxial layshaft/coaxial Andreas Volk DTV 29 November

43 Cycle based validation approach - Mechanical Development needle bearings open C0 closed C0 (no relative speed) high speed difference input/output low lubeoil flow high oil temp missalignment; runout high amount of pure electric driving PT test output shaft high torque ICE+EM missalignment; inbalance; runout boost operation Component Test hydr. seal rings high apply pressure alternating pressure cycles (hydraulic) high oil temp high speed difference in/out high ICE speed high amount of pure electric driving high ICE revs high relative speed at high pressure missalignment; runout Component Test housing high sum torque operation at bending resonance high bending torque boosting from low ICE-revs / impulse starts Component Test eop & hydraulics high flow and pressure demand high oil temp contamination of oil long periods with full pressure demand (ICE-torque) high number of impulse starts varying eop speed demands Component Test e-drive high e-drive max. e-drive torque high recuperation torque high e-drive (coil) temp high oil temp high LT-circuit temp as much as possible of e-drive operation high number of alternation drive/recuperation (pressfit) LPC, Component Test main bearing high ICE revs high oil temp and high lube oil flow high ICE revs; max. allowed inbalance of input shaft (check 5001) missalignment, unbalanced components PT test clutch pack wear slipping operation impulse starts; poor lubrication/cooling high number of impulse starts contamination of oil PT test clutch piston bending & wear full piston travel and clutch torque high pressure gradients high accumulated piston travel high number of impulse starts high number of C0 openings / pure electric driving contamination of oil Component Test?????? Not all damage figures sufficient activated at validation phase only 20% sufficient! 16 CW of powertrain testing at full assembly Andreas Volk DTV 29 November

44 Failure mode based validation approach - mechanical development All damage figures sufficient activated at validation phase Big data analytics load profile corrections on damage figure calculations 100% controlled 14 CW of component #3 different rigs Andreas Volk DTV 29 November

45 Content Introduction Technology selection - Do the right thing Validation of new design concepts Do the things right Integrated design verification Summary and outlook Andreas Volk DTV 29 November

46 Integrated design verification - Transmission lubrication system Lubrication system check Proven benefits ROAD Tilt Rig Simulation. Reduction of development time $ Reduction of cost Concept layout validated before trying in vehicles. Overnight validation of new HW variants to prove simulation results. Multiple HW variants validated short period. Reduced time on costly test environments (Powertrain, climate, vehicle). Several variants of housing, e-motor designs, cooling layouts and baffle plates. Increased product quality. Regular reference cycles and measurement point checks to find design improvements and reduce errors. Andreas Volk DTV 29 November

47 Integrated design verification - Transmission gear train Gear optimization Proven benefits ROAD Specialized Gear Rig Simulation Line of Action Summarized Mesh Point. Reduction of development time $ Reduction of cost High model maturity in an early design phase reduces efforts in later development phases. Reduce validation time in case of design changes. Reduced cost risks in case of design changes over all development phases. Potential for reduced number of prototypes. Test beds dedicated ONLY for model validation by isolating gear pair failures Increased product quality. Knowledge of influence parameters on different attributes (NVH, strength, efficiency) gained with manageable efforts. Andreas Volk DTV 29 November

48 Integrated design verification - Transmission efficiency Sub-System Efficiency Proven benefits Powertrain Transmission test bed Simulation. Reduction of development time Reduced development risk by assessment of subsystem performance in an early stage of development. $ Reduction of cost Reduced testing costs by shifting test to on subsystem environment. Isolated assessment of EV-Drive reducer on high-speed transmission test bed. Increased product quality. Detailed knowledge of sub-system performance helps to set development targets. Andreas Volk DTV 29 November

49 Integrated design verification - Failure mode based durability testing System durability testing Proven benefits ROAD EV-Drive test bed Simulation. Reduction of development time $ Reduction of cost Potential reduction of duration and number of durability runs due to specific damage of components / failure modes. Reduced development time and number of test samples. Potential for decrease of design safety factors. Online damage monitoring during the complete durability run Increased product quality. Damage figures over the complete durability run helps to improve product robustness. Andreas Volk DTV 29 November

50 Testing attributes 0% 2 0% 1 0% 6 0% 1 0% 18% 1 0% 5% 4 0% 1% 2 0% 5 0% 2 6% 0% 2 0% 1 3% 1 5% 2 5% 1 5% 0% 5% 3 5% 2 5% 1 0% 1 5% 5% 5% 32% 25% 5% 1 0% 2% 2% 4 0% 4 8% 25% 5% 25% 3 0% 1% 4% 8% 84% 5% 8% 25% 15% 3 0% 0% 9 0% 0% 8% 2 0% 1 0% 4 0% 0% 5% 1 0% 7 5% 0% 2 0% 15% 2 0% 25% 5% 25% 15% 2 0% 3 0% 1 0% 28% 2 0% 1 0% 15% 3 0% 1 0% 1 0% 5% 4 0% 0% 45% 15% 15% 5% 1 0% 2 0% 2 0% 1 0% 1 0% 35% 0% 3 0% 28% 15% 5% 1 0% 0% 1 5% 7 5% 0% 2 5% 1 0% 4 5% State of the art test environments Test environment Simulation Simulation Virtual Test Bed Component Test Bed E-Motor Engine Test Bed Powertrain EV-Drive Test Bed Powertrain Chassis Test Dyno Bed Road Testing Performance Emissions EMC Fuel Electric consumption range OBD Drivability Handling ADAS Sound // NVH NVH Functional safety savety Durability Mechanical / Robustn. Durability Climate Thermal comfort durability 1 today 15% future 3% today 1 future 1 today 15% future 8% today 15% future 3% today 15% future 1 today 2 future 1 today 2 future 5% today 15% future 5% today 1 future 5% today 1 future 1 today 2 future Price indication for environments Andreas Volk DTV 29 November

51 Summary and Outlook The deep knowledge of sub-system influence parameters and respective cross influences are mandatory to meet the target requirements By increasing the productivity within existing testing environments (failure mode based testing) and shifting to other testing environments (integrated design verification) time to market requirements can be met. Andreas Volk DTV 29 November

52 Thank You