AVL e-fusion Modern Electrification of Power Train needs Integration of Functions Dr. Helfried Sorger AVL List GmbH 15.11.2011 23rd International AVL "Engine & Environment" Conference, September 8th - 9th, 2011, Graz, Austria Dr. Helfried Sorger 1
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
AVL e-fusion Motivation -60g CO2 +230% Cost -10g CO2 +40% Cost 3
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
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
AVL e-fusion Vehicle targets Mild Hybrid Parallel Plug-In Hybrid Pure Range Extender Electrical Drive ITW Class [kg] 1130 1250 1250 1370 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 < 2.1 - Electrical range [km] > 5 > 50 > 50 > 150 6
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] 65 42 28 - Maximum Torque [Nm] 160 71 68 - Transmission Number of gears [-] 7 2 2 2 Electric Motor Generator Maximum Power [kw] 10 55 80 80 Maximum Torque [Nm] 120 225 250 250 Nominal Power [kw] - - 25 - Nominal Torque [Nm] - - 50 - Battery Overall Energy [kwh] 1,2 11 11 26 7
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
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
Torsion bar Connecting the single mass flywheel with secondary masses 10
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
2 speed hybrid powershift transmission 12
Joint rotor 13
Activation for 1st gear by wet brake 14
Activation for 2nd gear by wet clutch 15
Electromechanical actuation 16
Cable actuated mechanical park lock 17
Integrated suction oil pump 18
Multifunctional dry separation clutch Belt driven AC-compressor Belt driven electro-mechanical water pump Separation clutch 19
Transmission mounted power electronics Integrated high voltage connection 20
Integrated e-cooling circuit 21
Combustion housing Integrated cylinderhead Screwed liners 22
Combustion housing Integrated exhaust manifold Integrated intake manifold 23
Combustion housing Integrated cooling passages 24
Combustion housing Integrated oil passages 25
Combustion housing Integrated blow-by passages 26
Oil cooler 27
Integrated oil filter housing 28
Thermostat housing 29
Belt driven water pump 30
2 valve single camshaft drive Decompression device Roller finger follower Camphaser 31
Single roller chain drive 32
Simple belt driven waterpump No classical auxiliary drive 33
Single piece plastic front cover 34
Crankshaft carrier-integrated transmission bearings 35
Mass balancer shaft 36
Axial driven oil pump 37
Plastic oilpan with common engine and transmission oil sump 38
One piece valve cover 39
Integrated oil separator 40
Integrated oil separator and intake runner 41
Engine mounted airfilter with integrated resonator system 42
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
AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission 44
AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Extremely Small Package No synchronizers, just dog clutches Very small package 45
AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Schematic 46
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 5 7 6 1 3 4 2 output shafts input shaft 2 input shaft 1 dry double clutch 47
AVL e-fusion 7-Speed-Hybrid-Dual-clutch Transmission Electric Machine with Planetary Gear Set electric machine planetary gear 48
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
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
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
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
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
AVL e-fusion Vehicle results Mild Hybrid Parallel Plug-In Hybrid Pure Range Extender Electrical Drive Maximum Velocity [km/h] 180 182 145 145 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
Package and Weight 165 kg incl. power electronics and airbox is benchmark 55
Package compact car Fulfillment of all package constraints 56
AVL e-fusion Cost analysis complete power train without battery - 40% - 14% 57
AVL e-fusion Cost analysis complete power train including battery - 28% - 10% 58
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. 50-65 59