Hybrid Powertrain Development for Straightforward Vehicle Integration

Transcription

1 Hybrid Powertrain Development for Straightforward Vehicle Integration Patrick Debal - Punch Powertrain Integrating Electrical & Electronic Vehicle Systems Hethel

2 Presentation Overview Punch Powertrain Introduction Hybrid powertrain development Vehicle integration without compromises Integrating the electric drive Powertrain control Integrating the hybrid controller Status the hybrid development Conclusions Hybrid Powertrain Development for Straightforward Vehicle Integration 2

3 Punch Powertrain Introduction Pioneer in CVT for passenger cars Volvo, Rover, Mini Single customer, single product 2006: Following take-over by Punch International New customers (10), mainly in South-East Asia Assembly plant in Nanjing (CN) 300k/year Become N 3 CVT producer globally New developments: Conventional CVT-based powertrains HEV and EV powertrains Acquired switched reluctance motor technology Multi-customer, multi-product 2010: New shareholders, stronger financial position Hybrid Powertrain Development for Straightforward Vehicle Integration 3

4 Hybrid Powertrain Development Perform Flexible Fuel Economy Cost Vehicle Integration Integrated Solution Hybrid Powertrain Development for Straightforward Vehicle Integration 4

5 Hybrid Powertrain Development CVT based full HEV powertrain Switched reluctance motor, state-of-the-art technology Motor connected after variator for best efficiency Punch to make transmission, motor, power electronics and controllers B-, C- and D-segments & small vans Hybrid Powertrain Development for Straightforward Vehicle Integration 5

6 Vehicle Integration w/o Compromises Target: minimal changes in the engine bay Powertrain length = identical to non-hybrid Powertrain height = identical to non-hybrid Why? Hybrid Powertrain Development for Straightforward Vehicle Integration 6

7 Vehicle Integration w/o Compromises How to assess? Smart ForFour = Punch Hybrid Demonstrator Hybrid Powertrain Development for Straightforward Vehicle Integration 7

8 Integrating the Electric Drive Enlarged housings Chain drive with 2 sprockets E-motor and transmission interface Accomodate 251 mm motor on top of 335 mm transmission Hybrid Powertrain Development for Straightforward Vehicle Integration 8

9 Integrating the Electric Drive Hybrid Powertrain Development for Straightforward Vehicle Integration 9

10 Integrating the Electric Drive Hybrid Powertrain Development for Straightforward Vehicle Integration 10

11 Integrating the Electric Drive Comparison standard VT2 and hybrid VT Hybrid Powertrain Development for Straightforward Vehicle Integration 11

12 Integrating the Electric Drive Hybrid Powertrain Development for Straightforward Vehicle Integration 12

13 Powertrain Control POWERTRAIN MANAGEMENT HCU BCU CAN ECU TCU MCU BMS ICE EMG CVT + PowEl Bat Hybrid Powertrain Development for Straightforward Vehicle Integration 13

14 Integrating the Hybrid Controller CAN Throttle is hard wired to ECU ICE ECU TCU In HEV the throtlle is input for HCU and the HCU commands the subsystems. + CVT Hybrid Powertrain Development for Straightforward Vehicle Integration 14

15 Integrating the Hybrid Controller Migrated ECU SW to prototype controller Mapped engine control on engine test bed (ECU I/O) Implemented maps on prototype controller Added functions: Put throttle position on CAN Replace throttle command by HCU torque request TAG-400 ECU Hybrid Powertrain Development for Straightforward Vehicle Integration 15

16 Integrating the Hybrid Controller Driver input (throttle pedal) ECU By autocoding Requested wheel torque (HCU) Efficient powertrain operation (HCU) Engine torque (ECU) Motor torque (MCU) CVT ratio (TCU) Hybrid Powertrain Development for Straightforward Vehicle Integration 16

17 Integrating the Hybrid Controller Engine Operation with Stepped Transmission NEDC Mol MaxTrq 100 But the engine needs recalibration for emissions EngineTorque [Nm] Engine Operating Points Hybrid Powertrain EngineSpeed [rpm] 60 Torque [Nm] 40 MOL NEDC MaxTorq Speed [rpm] Hybrid Powertrain Development for Straightforward Vehicle Integration 17

18 Integrating the Hybrid Controller Regenerative braking: Only on driven wheels HCU communicates available electric torque BCU sets electric brake torque 1 Low brake demand 2 High brake demand Required brake torque No conventional braking Actual conventional brake torque Max. regen brake torque Actual regen brake torque Actual regen brake torque Hybrid Powertrain Development for Straightforward Vehicle Integration 18

19 Status of the Hybrid Development Hybrid optimisation automated Matlab tool using component data Demonstrator with good driveability Powertrain is being calibrated for driveability E-motor issues cleared Powertrain will go on test bench for strategy validation Upgrade of powertrain being prepared Lessons learned from 1 st build Production intent design Hybrid Powertrain Development for Straightforward Vehicle Integration 19

20 Conclusions Punch s full hybrid powertrain offers: A compact package fitting most popular vehicle segments A powertrain control system requiring minimal changes to existing software Good driveability Ready for the market Hybrid Powertrain Development for Straightforward Vehicle Integration 20

21 Thank you for your attention Questions? Hybrid Powertrain Development for Straightforward Vehicle Integration 21