Rapid Concept Design Process for EV And HEV, Including Fuel Economy Robustness. Barry James Chief Technical Officer September 2015

Transcription

1 Rapid Cncept Design Prcess fr EV And HEV, Including Fuel Ecnmy Rbustness Barry James Chief Technical Officer September 2015

2 Cntents Strategy fr Fuel Ecnmy Imprvements Case Studies Reductin in lsses thrugh gear redesign in an HEV Cncept Design tl fr EV and HEV, with fcus n rbust fuel ecnmy Summary Capabilities available tday Slide 2 Cpyright 2015

3 Strategy fr Fuel Ecnmy Imprvements Reducing lsses in the full driveline system Reducing frictinal lsses in mechanical pwer transmissin Reducing lsses in the pwer surces e.g. mtrs and ICE s Fuel ecnmy imprvements must be ROBUST Must cnsider.. Driving cnditins, Temperature, Tlerances etc. Speed f simulatin must permit this t take place Slide 3 Cpyright 2015

4 SYSTEM APPROACH TO CONSIDER EFFICIENCY, NVH AND DURABILITY IN THE OPTIMISATION OF AN ELECTRIC ALL WHEEL DRIVE GEARBOX Dr. Artur Grunwald Gear System Engineer GKN Driveline Internatinal GmbH Barry James Chief Engineer Transprtatin Rmax Technlgy Ltd. Rmax Eurpean Summit 2011, 4th and 5th Octber / Frankfurt, Germany 4

5 Hybrid cncept and applicatin data FWD applicatin equipped with an electric rear axle FWD mde (discnnected) Pure electric drive mde All-wheel-drive (AWD) mde Nminal pwer 20kW Input trque 200Nm Output trque 1500Nm Input speed 7500rpm Ttal rati 1 : 7.5 Optimized fr efficiency & NVH Rmax Eurpean Summit 2011, 4th and 5th Octber / Frankfurt, Germany 5

6 Strategy fr macr-gemetry ptimizatin fr efficiency, NVH and durability Pressure angle α Helix angle β Mdule Face width Bending Cntact NVH Efficiency Bearings = increase = imprvement = deteriratin Rmax Eurpean Summit 2011, 4th and 5th Octber / Frankfurt, Germany 6

7 E-Drive efficiency test results f gearbx with imprved gear sets Drive and cast (shwn belw) cnditins measurements Dynamic calibratin and cntrlled test temperature Cnfirmatin f expected efficiency imprvements Reference Imprved Example f efficiency imprvement fr recuperatin cnditin (cast) Rmax Eurpean Summit 2011, 4th and 5th Octber / Frankfurt, Germany 7

8 Cncept Design tl fr EV and HEV, with fcus n rbust fuel ecnmy

9 PrtDrive: Integrated Tl fr the Rapid Cncept Design f Hybrid Electric Vehicle Systems Aim: An integrated sftware tl fr the rapid cncept design f hybrid and electric vehicles. Cnsrtium: An interdisciplinary team with expertise in all aspects f drivetrain design Prject activity: Efficiency mdels fr the engine, transmissin, and electric subsystems Integratin f these subsystems int a drivetrain mdel Case studies based n end users requirements t demnstrate the value f the tl Slide 9 Cpyright 2015

10 Challenge 1: Studying all pssible design variants EV range-extender series parallel pwer-split mild hybrid micr hybrid cnventinal Share f pwer Rmax simulatin scans acrss the spectrum f drivetrain designs frm pure electric t pure cnventinal Speed is mre imprtant than mdelling detail s lng as accuracy is sufficient t determine trends Rapid whle-system simulatin is needed t address the multiplicity f ptins at cncept stage Slide 10 Cpyright 2015

11 Challenge 2: Designing fr rbust fuel ecnmy Real-wrld fuel cnsumptin can be 20-50% higher than manufacturer figures, and this discrepancy is increasing rapidly Legislative drive cycles are nt representative f hw peple actually drive It is vital t cnsider real-wrld driving cnditins early in the design prcess Frm labratry t rad: A 2014 update f fficial and real-wrld fuel cnsumptin and CO 2 emissins fr passenger cars in Eurpe Slide 11 Cpyright 2015

12 Requirements fr Simulatin Speed T lk at different structures T lk at different mtr/ice types T lk at different driving cnditins Apprpriate accuracy Trends/cmparisns in efficiency mre imprtant than abslute values in cncept design Slide 12 Cpyright 2015

13 Efficiency Map: Rmax Simulatin versus Test Measured result IPMSM and DC-AC inverter efficiency: The machine parameters are derived within secnds Cmputed result *Switching SEMIKRON SKM400GB12T4 device: IGBT Slide 13 Cpyright 2015

14 Efficiency Map: Rmax Simulatin versus 3D FE The machine parameters are derived within secnds The tractin machines (IPMSMs) are well-knwn fr parameter nnlinearities Slide 14 Cpyright 2015

15 Drive cycle simulatin in the time dmain WLTP Artemis urban US06 Speed Speed + + Speed Speed Time Time Time Time Slide 15 Cpyright 2015

16 Rmax apprach t drive cycle simulatin Acceleratin WLTP Artemis urban US06 Acceleratin + + Acceleratin Speed Speed Speed The drive cycle is represented as a distributin f perating pints. Acceleratin Adding further drive cycles des nt increase the simulatin time Speed Slide 16 Cpyright 2015

17 Verificatin f Simulatin Methd Simulatins were run fr a battery electric passenger car using the Autnmie time-dmain simulatin sftware and Rmax simulatin methds. The energy cnsumptin trends were the same fr individual drive cycles, and when varying parameters in the mdel such as mass and transmissin rati. Rmax simulatins ran at least 10 times faster than the time-dmain mdel. Rmax(FTP) Rmax(NEDC) Slide 17 Cpyright 2015

18 MAGSPLIT: Magnetic Pwer Split Technlgy fr Parallel Hybrid Electric Vehicles Prject: C-funded by the UK Technlgy Strategy Bard under their Lw Carbn Vehicles prgramme Prject partners: Magnmatics (lead), Frd Mtr Cmpany, Arnld Magnetic Technlgies, Rmax Technlgy Duratin: 2 years ( ) Aims: Optimise Magnmatics Magsplit transmissin fr use in the Frd C-Max Hybrid Design, manufacture and test a prttype Magsplit device Slide 18 Cpyright 2015

19 Cncept Evaluatin and Drive Cycle Sensitivity 2000 rati variants, each with their wn shift strategy, were created and analysed in 1 week Sensitivity t varius drive cycles was cmpleted fr all designs, allwing the best (least sensitive) design t be selected Slide 19 Cpyright 2015

20 Summary: Prven Capability ready NOW Reducing lsses in the full driveline system Reducing frictinal lsses in mechanical pwer transmissin Reducing lsses in the pwer surces e.g. mtrs and ICE s Fuel ecnmy imprvements that are ROBUST Must cnsider.. Driving cnditins, Temperature, Tlerances etc. Rapid simulatin, sufficiently accurate Slide 20 Cpyright 2015

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