Controlled Power Technologies CPT SpeedStart Belt-Integrated Starter Generator
CPT SpeedStart Belt-Integrated Starter Generator CPT SpeedStart is a highly adaptable 48V motor-generator to support the next generation of Internal Combustion Engines. It is aimed at P0 belt-driven motor generator hybrid applications to substitute the standard alternator and (depending on application) starter motor. The key e-motor features are: Integrated control and power electronics Liquid cooling of motor and electronics for extended duration operation Advanced control to achieve: Mild-hybrid functionality Excellent change of mind behaviour for stop-start operation Advanced torque profiles for belt-pre-tensioning E-Auxiliary drive (with de-clutch) Belt-Driven by the crankshaft XX 2 2018 Federal-Mogul LLC
Specification & Performance Specific performance requirements can be achieved with electromagnetic or electronic configurations and different control strategies and/or calibrations. The following data is typical within a similar mechanical and electronics package. Benefits C102-22T C102-41T C1001-28T Nominal Voltage 12V 48V 48V Diameter 155 mm 155 mm 170 mm Length 167 mm 167 mm 185 mm Cranking Torque 60 Nm 60 Nm 50 Nm Continuous Generating 2.7 kw 5.5 kw 6.0 kw Peak Generation 3.0 kw 10 kw 12.5 kw Continuous Motoring 1.0 kw 4.0 kw 4.5 kw Peak Motoring 1.7 kw 6.0 kw 8.0 kw Rated Efficiency* 74% 81% 85% Speed Range 0-20,000 RPM Rotating Inertia 0.0027 kgm 2 *Includes integrated electronics Thermal Management Active stator effectively cooled by engine coolant Full functionality with engine coolant up to 105 C and progressively derated performance to 120 C Controllability Integrated microprocessor supports advanced functionality Good efficiency over wide speed range High capability generation over full engine operating speed Simple and durable mechanical design Validated to 1.2 million cranking events and arduous environmental test standard Low rotating inertia Low parasitic losses Good dynamic response Good functional safety Zero current machine avoids self-excitation Multi-phase fault tolerant 2018 Federal-Mogul LLC 3
Features & Modes Generation Efficient high power electrical generation of energy over a wide speed range including low engine speed. Recuperation Recuperation is the capture of kinetic energy lost during deceleration of the vehicle. This is particularly beneficial for higher power, higher mass vehicles. Switched Reluctance Machines (SRM) are especially suited to hybrid applications as they enable high efficiency harvesting of kinetic energy over a wide operating speed range. The advanced thermodynamic design and cooling strategy used in CPT s e-motor also enables high levels of recuperated energy to be harvested over extended durations, typically 20-30 seconds and on a more frequent basis compared to other e-motor technologies. Motoring The high levels of recuperated energy harvested by CPT s e-motor can be recycled to supplement the torque output of the conventional Internal Combustion Engine in the following ways: Transient torque assist: Reduces fuel consumption and emissions during acceleration events Enhances driveability for down-speeding / down-sizing Cruising / sailing (fuel shut off above 10 km/h) Limited electric drive through crankshaft and drivetrain Cranking High performance conventional start / stop through shortened engine cranking times, change-of-mind capability and belt pre-tensioning Advanced engine shut-down strategy such as sailing 4 2018 Federal-Mogul LLC
Software & Motor Control CPT develops the software embedded within CPT SpeedStart entirely in-house, utilising industry standard tools such as Matlab and Simulink to develop and test control software. The software determines which mode the machine is operating in (generating, motoring, cranking, stand-by etc.) and also controls torque, voltage / current and speed. The development process is compliant with A-SPICE requirements and, depending on customer requirements, with ISO 26262. In 2016 the software was ported to the Infineon Aurix family of processors to facilitate the implementation of AUTOSAR v4.0 (from VECTOR) enabling further functional safety and more advanced control strategies (eg: current waveform shaping to control the torque more precisely). 2018 Federal-Mogul LLC 5
Applications CPT SpeedStart has been integrated in both gasoline and diesel powertrains with manual and automatic transmission configurations and many different automotive and nonautomotive vehicle platforms. Fuel Economy and CO 2 Reduction CPT has also participated in collaborative research programmes with a number of partners. A 48V 1.4l turbo-charged (TC) gasoline manual VW Passat and a 1.5l TC diesel manual Ford Focus have been developed as research platforms to optimise the system for fuel economy / CO 2 and performance. The gasoline Passat achieved a 13% improvement in fuel consumption and the diesel Focus 12%, both on the NEDC. Further system level strategy developments are likely to result in additional improvements. 10 ADEPT ADEPT Car Car WLTC Battery Power 8 6 4 Battery BAttery Power (kw) 2 0 0 200 400 600 800 1000 1200 1400 1600 1800 2000-2 -4-6 -8-10 Time(s) 6 2018 Federal-Mogul LLC
Applications Advanced Emission Reduction A combination of emission dynamometer test rigs and the 48V research vehicles have been used to evaluate the NOx and particulate reduction potential of applying 48V CPT SpeedStart to conventional passenger cars and light commercial powertrains. On a test rig running the WLTC a NOx reduction of 9.1% and a fuel saving of 4.6% was achieved for a 3.0l diesel engine fitted to a D segment vehicle. Vehicle testing is focusing on RDE cycles and activation strategies fully utilising the thermal management and dynamic control of the CPT SpeedStart technology. 250-200 20000 - Baseline NOx ppm 220-190 NOx ppm on small transients 17500 200-180 Supported by boosting 180-170 15000 160-140- 160 12500 120-150 100-140 10000 80-130 7500 60-40- 120 5000 20-110 0-100 2500-20- 90-40- 0 80-60- 70-2500 -80- -100-60 -5000-120- 50-140- 40-7500 -160- -180-30 Boosting Events -10000-200- 20-220- -12500 10 - -250-0 -15000 4030 4031 4032 4033 4034 4035 4036 4037 4038 4039 4040 4041 4042 4043 4044 4045 4046 4047 4048 4049 4050 Dilute NOx (ppm) Vehicle Speed (kph) Time Power (W) 2018 Federal-Mogul LLC 7
Thermal Management Heat rejection from the motor windings and power electronics must be carefully managed to maximise machine availability during both recuperation and motoring. A Switched Reluctance Machine (SRM) is ideally suited to liquid cooling since the majority of the losses are concentrated in the stator: other motor technologies are often thermally limited by the challenge of cooling a partially active rotor. Good thermal performance can be the most significant factor in both on-cycle (certification) and off-cycle (real world) performance. NVH & Dynamic Control Each electric machine has a particular noise signature. After a number of years of sophisticated analysis and testing at a component and in-vehicle level the CPT SpeedStart product is one of the quietest electric machines available. It has been mechanically optimised for both radiated and structure-borne noise. 8 2018 Federal-Mogul LLC
Control & Power Electronics CPT develops all motor electronics in-house using state of the art componentry and signifi cant knowledge of handling the high currents associated with low voltage hybrid systems. Design tools include thermal optimisation and sophisticated PCB layouts utilising multi-layer substrates. Electronics may be customised to adapt standard mechanical topographies to meet multiple performance requirements whilst commonising componentry wherever economically attractive. The most recent processor technology and high performance FETS and capacitors have been fully integrated to the thermally and EMC optimised package. Electro- Magnetic Optimisation CPT uses JMAG software to determine winding topographies for specifi c application requirements. This allows CPT to optimise many features of the machine which may affect the effi ciency of the electric machine or be infl uenced by manufacturing processes. Contour Plot: T 2018 Federal-Mogul LLC 9
Product Evaluation and Validation CPT has a full prototype build and commissioning capability in-house. CPT SpeedStart has been in development since 2005 and has accumulated many thousands of hours of running time. The move to 48V has necessitated the development of unique test rigs to validate the performance and durability across a range of duty cycles. Each machine configuration undergoes lifetime durability testing for motoring and generating under environmentally controlled conditions. CPT SpeedStart is also validated for more than 1.2 million cranking events, enabling the most sophisticated mild hybrid to be deployed (eg: including sailing / coasting modes) and the most challenging drive cycle to be considered (eg: short stop delivery van). Full design verification testing is conducted to meet specific customer application requirements. 10 2018 Federal-Mogul LLC
Our Company Empowering the Engine of Progress Founded in 2007, UK-based clean-tech developer Controlled Power Technologies (CPT) was acquired by Federal-Mogul Powertrain in 2017. The CPT product range with innovative electrification and hybridization systems enables the development of reduced-emissions powertrains with: 12V, 24V and 48V electric motor-generators for stop-start and mild hybridization applications, exhaust-driven electrification technologies, combustion engine e-boosting and fuel cell e-compressors. As one of two independent divisions that constitute Federal-Mogul LLC, Federal-Mogul Powertrain designs, develops and manufactures original equipment engine components and sealing and systems protection products. Federal-Mogul Powertrain is committed to delivering superior quality through innovation and engineering excellence enabled by cutting-edge proprietary technologies. The division works in partnership with its customers to meet increasingly demanding targets for fuel economy and emissions performance without compromising affordability or reliability. As one of the leaders in the passenger car, light commercial, heavy-duty and off-highway markets, Federal-Mogul Powertrain also supplies related technologies to the power generation, aerospace, marine, rail and industrial sectors. 2018 Federal-Mogul LLC 11
www.federalmogul.com Federal-Mogul Controlled Power Ltd Unit 4, Westmayne Industrial Park, Bramston Way, Laindon, Essex, SS15 6TP Phone +44 (0)1268 564800 CPTinfo@federalmogul.com www.cpowert.com 2018 Federal-Mogul LLC. All rights reserved. All trademarks are owned by Federal-Mogul LLC or one of its subsidiaries, in one or more countries.