Modern Electrification of Power Train needs Integration of Functions

Transcription

1 AVL e-fusion Modern Electrification of Power Train needs Integration of Functions Dr. Helfried Sorger AVL List GmbH rd International AVL "Engine & Environment" Conference, September 8th - 9th, 2011, Graz, Austria Dr. Helfried Sorger 1

2 AVL e-fusion Motivation Electrification is the enabler for future fleet average fuel consumption targets The variety of future power trains will increase due to enhanced degree of electrification The progressive electrification of the power train results in a massive cost increase of the overall system 2

3 AVL e-fusion Motivation -60g CO2 +230% Cost -10g CO2 +40% Cost 3

4 AVL e-fusion Motivation Add-on cost / g CO 2 reduction ca. 90 Key is a significant cost reduction of the power train especially in the high volume compact class 4

5 TARGETS OF AVL e-fusion Modular power train family covering all applications: Conventional power train Mild hybrid Parallel plug-in hybrid Range extender Electric vehicle Same performance and fun to drive for all applications Significant reduction in fuel consumption for all applications Applicable for vehicle categories A, B and C (entry-level model) Unit cost reductions between 10 and 20% depending on the application Maximum weight reduction Minimum package space 5

6 AVL e-fusion Vehicle targets Mild Hybrid Parallel Plug-In Hybrid Pure Range Extender Electrical Drive ITW Class [kg] Maximum Velocity [km/h] > 180 > 180 > 140 > 140 Acceleration 0-100km/h [s] < 10 < 10 < 10 < 10 CO 2 -Emissions in NEDC-cycle [g/km] < 90 < 50 < 50 - Fuel consumption in NEDC-cycle [l/100km] < 3.7 < 2.1 < Electrical range [km] > 5 > 50 > 50 > 150 6

7 AVL e-fusion System design of the drive train elements Electrical performance as much as necessary as little as possible Mild Hybrid Parallel Plug- In Hybrid Pure Range Extender Electrical Drive Combustion Engine Maximum Power [kw] Maximum Torque [Nm] Transmission Number of gears [-] Electric Motor Generator Maximum Power [kw] Maximum Torque [Nm] Nominal Power [kw] Nominal Torque [Nm] Battery Overall Energy [kwh] 1,

8 AVL e-fusion Modularity of the power train family Combustion housing TCI Base Power Train Module intake module TCI Combustion housing NA end cover electric drive 7 speed hybrid DCT transmission power electronics 2 speed hybrid powershift transmission power electronics generator range extender power electronics parallel plug-in 8

9 AVL e-fusion Parallel Plug-In Hybrid Combustion Engine Maximum Power [kw] 42 Maximum Torque [Nm] 71 Transmission Number of gears [-] 2 Electric Motor Maximum Power [kw] 55 Maximum Torque [Nm] 225 Generator Nominal Power [kw] - Nominal Torque [Nm] - Battery Overall Energy [kwh] 11 9

10 Torsion bar Connecting the single mass flywheel with secondary masses 10

11 2 speed hybrid powershift transmission - schematic inner ring gear wet brake sun gear differential final drive torsion shaft separation clutch planet carrier wet clutch outer ring gear e-motor planet gear 2 planet gear 1 11

12 2 speed hybrid powershift transmission 12

13 Joint rotor 13

14 Activation for 1st gear by wet brake 14

15 Activation for 2nd gear by wet clutch 15

16 Electromechanical actuation 16

17 Cable actuated mechanical park lock 17

18 Integrated suction oil pump 18

19 Multifunctional dry separation clutch Belt driven AC-compressor Belt driven electro-mechanical water pump Separation clutch 19

20 Transmission mounted power electronics Integrated high voltage connection 20

21 Integrated e-cooling circuit 21

22 Combustion housing Integrated cylinderhead Screwed liners 22

23 Combustion housing Integrated exhaust manifold Integrated intake manifold 23

24 Combustion housing Integrated cooling passages 24

25 Combustion housing Integrated oil passages 25

26 Combustion housing Integrated blow-by passages 26

27 Oil cooler 27

28 Integrated oil filter housing 28

29 Thermostat housing 29

30 Belt driven water pump 30

31 2 valve single camshaft drive Decompression device Roller finger follower Camphaser 31

32 Single roller chain drive 32

33 Simple belt driven waterpump No classical auxiliary drive 33

34 Single piece plastic front cover 34

35 Crankshaft carrier-integrated transmission bearings 35

36 Mass balancer shaft 36

37 Axial driven oil pump 37

38 Plastic oilpan with common engine and transmission oil sump 38

39 One piece valve cover 39

40 Integrated oil separator 40

41 Integrated oil separator and intake runner 41

42 Engine mounted airfilter with integrated resonator system 42

43 AVL e-fusion Mild Hybrid Combustion Engine Maximum Power [kw] 65 Maximum Torque [Nm] 160 Transmission Number of gears [-] 7 Electric Motor Maximum Power [kw] 10 Maximum Torque [Nm] 120 Generator Nominal Power [kw] - Nominal Torque [Nm] - Battery Overall Energy [kwh] 1,2 43

44 AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission 44

45 AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Extremely Small Package No synchronizers, just dog clutches Very small package 45

46 AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Schematic 46

47 AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Basic Function of a Double Clutch Transmission ( DCT ) differential torsion bar for vibration isolation Omitting the DMF output shafts input shaft 2 input shaft 1 dry double clutch 47

48 AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Electric Machine with Planetary Gear Set electric machine planetary gear 48

49 AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Synchronization by the Electric Machine Driving in gear 1 n e =n 2 (i-1) + n 1 Gear 2 disengaged Electric machine accelerates to n e Gear 2 engaged 1 2 Synchronization 49

50 AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Boost and Recuperation by the Electric Machine Driving in gear 1 n e =n 2 (i-1) + n 1 Gear 2 engaged (clutch open) Electric machine idling Electric machine positive torque BOOST Electric machine negative torque 1 2 Recuperation & Generation Boost Recuperation & Generation 50

51 AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Electric Creep by the Electric Machine Gear 1 engaged (clutch open) n e =n 2 (i-1) + n 1 Gear 2 engaged (clutch open) Electric machine at standstill Electric machine positive torque forward Electric machine negative torque 1 2 backward Electric Creep 51

52 AVL e-fusion Pure Range Extender Combustion Engine Maximum Power [kw] 28 Maximum Torque [Nm] 68 Transmission Number of gears [-] 2 Electric Motor Maximum Power [kw] 80 Maximum Torque [Nm] 250 Generator Nominal Power [kw] 25 Nominal Torque [Nm] 50 Battery Overall Energy [kwh] 11 52

53 AVL e-fusion Electric Drive Combustion Engine Maximum Power [kw] - Maximum Torque [Nm] - Transmission Number of gears [-] 2 Electric Motor Maximum Power [kw] 80 Maximum Torque [Nm] 250 Generator Nominal Power [kw] - Nominal Torque [Nm] - Battery Overall Energy [kwh] 26 53

54 AVL e-fusion Vehicle results Mild Hybrid Parallel Plug-In Hybrid Pure Range Extender Electrical Drive Maximum Velocity [km/h] Acceleration 0-100km/h [s] 9,3 9,4 9,3 10 CO 2 -Emissions in NEDC-cycle [g/km] 87,5 32,2 32,9 - Fuel consumption in NEDC-cycle [l/100km] 3,69 1,36 1,39 - Fuel consumption in WLTP-cycle [l/100km] 3,83 1,47 1,50-54

55 Package and Weight 165 kg incl. power electronics and airbox is benchmark 55

56 Package compact car Fulfillment of all package constraints 56

57 AVL e-fusion Cost analysis complete power train without battery - 40% - 14% 57

58 AVL e-fusion Cost analysis complete power train including battery - 28% - 10% 58

59 Cost analysis complete power train including battery Add-on cost per g CO 2 reduction ca. 90 Add-on cost per g CO 2 reduction ca