Rapid Concept Design and Optimisation of Hybrid Electric Powertrains Over Multiple Drive Cycles

Transcription

1 Rapid Cncept Design and Optimisatin f Hybrid Electric Pwertrains Over Multiple Drive Cycles Dr. Kathryn Taylr Rmax Technlgy Webinar 10 th September 2015

2 Rmax Technlgy Rmax Technlgy is a leading glbal prvider f integrated sftware and services fr gearbx, bearings and driveline systems fr Autmtive, Aerspace, Off-Rad, Rail, Bearings, Marine and Wind Energy. Over 25 years f engineering expertise Drivetrain design and analysis sftware tls used by 14 f the tp 15 autmtive OEMs Glbal rganisatin with 240 emplyees wrldwide acrss 12 ffices in UK, USA, Eurpe, and Asia Slide 2

3 Rmax R&D Overview HDV Lwer drivetrain parasitic lss reductin Redesign f gears, bearings, lubricants, and lubricatin system ODIN: Optimised Electric Drivetrain by Integratin Highly integrated EV drivetrain design EMMAS: Electr-Mechanical-Magnetic Actuatr Systems Rbust and quiet actuatrs fr aerspace applicatins Slide 3

4 CO 2 emissins legislatin and fines Current legislatin: 130 g/km fleet average carbn emissins by 2015 (average UK new car CO 2 emissins g/km in 2013) 2020 legislatin: 95 g/km OEMs are fined 95 per car per gram f CO 2 ver the limit 1.5 millin passenger cars prduced in the UK in 2013 (16.2 millin in Eurpe) If n imprvements are made, the fines in 2020 will be: 4.7 billin in the UK 51.2 billin in Eurpe Surce: SMMT New Car CO 2 Reprt 2014 Slide 4

5 Lw carbn vehicles Cars are price-sensitive: pass the cst n t the custmer and sales will drp The alternative is t reduce carbn; hybrids and EVs are an increasingly imprtant way t achieve this aim Number f alternative fuel vehicles New car market split by Vehicle Excise Duty band (figures are CO 2 emissins in g / km) Slide 5 Surce: SMMT New Car CO 2 Reprt 2014

6 Share f pwer Rmax drivetrain simulatin EV range-extender series parallel pwer-split mild hybrid micr hybrid cnventinal 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 6

7 The imprtance f real-wrld driving cnditins 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 7

8 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 8

9 M/G 1 Case Study: 2004 Tyta Prius Planetary gearbx Mtr/ generatr 1 M/G 2 Mtr/ generatr 2 Engine Final drive Battery Engine drives wheels directly Engine drives wheels thrugh mtr/generatrs 1 and 2 Pure electric driving Slide 9

10 Case Study: 2004 Tyta Prius Rmax has spnsred a PhD prject at Lughbrugh University Tyta Prius II test vehicle instrumented with GPS data lgger High vltage battery current and vltage sensrs Fuel flw meters In use with university Security fr 9 mnths cllecting GPS driving data arund campus and lcal area f twn Slide 10

11 Fuel cnsumptin (l/km) Case Study: 2004 Tyta Prius Lughbrugh University Urban Driving Cycle LUUDC-15 Measured data frm driving acrss campus (rute repeated 10 times) After several cycles, the simulated and measured fuel cnsumptin results agree t within 5% Measured Simulated Driving cycles Slide 11

12 Speed Speed Speed Imprvement in fuel cnsumptin Case Study: 2004 Tyta Prius New Eurpean Drive Cycle (NEDC) Time Highway Fuel Ecnmy Test (HWFET) 10% 9% 8% 7% 6% 5% 4% NEDC Artemis urban HWFET 8 cycles LUUDC_15 3% 2% Time Artemis Urban 1% 0% -1% -2% Time -3% vehicle mass air resistance final drive rati engine pwer battery pwer mtr pwer planetary rati generatr pwer Slide 12

13 Case Study: 2005 Hnda Accrd Mild parallel hybrid Simulated ver US legislative drive cycles city and highway Results within 2% f manufacturer certificatin tests Drive cycle Fuel cnsumptin l/100km / US mpg Difference Measured Simulated HWFET 6.36 / / % FTP / / % Slide 13

14 Summary Rmax has develped a vehicle simulatin tl fr rapid analysis and evaluatin f cncept driveline layuts Integrated drivetrain, engine, transmissin, and electrical cmpnent efficiency mdels Fast simulatin ver multiple drive cycles with sufficient mdel fidelity t enable engineering judgements Validated against vehicle test data Slide 14

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