AVL e-Fusion · 2016. 2. 4. · ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr....

1 23rd International AVL "Engine & Environment" Conference, September 8th - 9th, 2011, Graz, Austria| Dr. Helfried Sorger

Modern Electrification of Power Train needs Integration of Functions

AVL e-Fusion

Dr. Helfried Sorger AVL List GmbH 15.11.2011

2 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger

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

AVL e-Fusion Motivation

-10g CO2

+40% Cost

-60g CO2

+230% Cost

Key is a significant cost reduction of the power train

especially in the high volume compact class

Add-on cost / g CO2 reduction

ca. 90 €

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

AVL e-Fusion Vehicle targets

Hybrid

Parallel Plug-In

Hybrid

Pure Range

Extender

Electrical

ITW – Class [kg] 1130 1250 1250 1370

Maximum Velocity [km/h] > 180 > 180 > 140 > 140

Acceleration 0-100km/h [s] < 10 < 10 < 10 < 10

CO2-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

AVL e-Fusion System design of the drive train elements

Electrical performance as much as necessary – as little as possible

Hybrid

Parallel Plug-

In Hybrid

Pure Range

Extender

Electrical

Combustion Engine Maximum Power [kW] 65 42 28 -

Maximum Torque [Nm] 160 71 68 -

Transmission Number of gears [-] 7 2 2 2

Electric Motor Maximum Power [kW] 10 55 80 80

Maximum Torque [Nm] 120 225 250 250

Generator Nominal Power [kW] - - 25 -

Nominal Torque [Nm] - - 50 -

Battery Overall Energy [kWh] 1,2 11 11 26

AVL e-Fusion Modularity of the power train family

Combustion housing TCI

Combustion housing NA

Base Power Train Module

7 speed hybrid

DCT transmission

power electronics

2 speed hybrid

powershift transmission

power electronics

generator

range extender

intake module TCI

end cover electric drive

power electronics

parallel plug-in

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

Generator Nominal Power [kW] -

Nominal Torque [Nm] -

Battery Overall Energy [kWh] 11

AVL e-Fusion PARALLEL PLUG-IN HYBRID Torsion bar Connecting the single mass flywheel with secondary masses

torsion shaft

final drive

differential

e-motor

separation

clutch

sun gear

planet carrier planet

gear 1

planet

gear 2

inner ring gear

wet brake

wet clutch

outer ring gear

AVL e-Fusion PARALLEL PLUG-IN HYBRID 2 speed hybrid powershift transmission - schematic

AVL e-Fusion PARALLEL PLUG-IN HYBRID 2 speed hybrid powershift transmission

AVL e-Fusion PARALLEL PLUG-IN HYBRID Joint rotor

AVL e-Fusion PARALLEL PLUG-IN HYBRID Activation for 1st gear by wet brake

AVL e-Fusion PARALLEL PLUG-IN HYBRID Activation for 2nd gear by wet clutch

AVL e-Fusion PARALLEL PLUG-IN HYBRID Electromechanical actuation

AVL e-Fusion PARALLEL PLUG-IN HYBRID Cable actuated mechanical park lock

AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated suction oil pump

AVL e-Fusion PARALLEL PLUG-IN HYBRID Multifunctional dry separation clutch

Belt driven

AC-compressor

Belt driven

electro-mechanical water pump

Separation clutch

AVL e-Fusion PARALLEL PLUG-IN HYBRID Transmission mounted power electronics Integrated high voltage connection

AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated e-cooling circuit

AVL e-Fusion PARALLEL PLUG-IN HYBRID Combustion housing

Integrated cylinderhead

Screwed liners

Integrated intake manifold

Integrated exhaust manifold

Integrated cooling passages

Integrated oil passages

Integrated blow-By passages

AVL e-Fusion PARALLEL PLUG-IN HYBRID Oil cooler

AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated oil filter housing

AVL e-Fusion PARALLEL PLUG-IN HYBRID Thermostat housing

AVL e-Fusion PARALLEL PLUG-IN HYBRID Belt driven water pump

AVL e-Fusion PARALLEL PLUG-IN HYBRID

2 valve single camshaft drive

Roller finger follower

Camphaser

Decompression device

AVL e-Fusion PARALLEL PLUG-IN HYBRID Single roller chain drive

AVL e-Fusion PARALLEL PLUG-IN HYBRID Simple belt driven waterpump No classical auxiliary drive

AVL e-Fusion PARALLEL PLUG-IN HYBRID

Single piece plastic front cover

AVL e-Fusion PARALLEL PLUG-IN HYBRID Crankshaft carrier-integrated transmission bearings

AVL e-Fusion PARALLEL PLUG-IN HYBRID Mass balancer shaft

AVL e-Fusion PARALLEL PLUG-IN HYBRID Axial driven oil pump

AVL e-Fusion PARALLEL PLUG-IN HYBRID Plastic oilpan with common engine and transmission oil sump

AVL e-Fusion PARALLEL PLUG-IN HYBRID One piece valve cover

AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated oil separator

AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated oil separator and intake runner

AVL e-Fusion PARALLEL PLUG-IN HYBRID Engine mounted airfilter with integrated resonator system

AVL e-Fusion Mild Hybrid

Battery Overall Energy [kWh] 1,2

AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission

AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Extremely Small Package

Very small package

No synchronizers, just dog clutches

AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Schematic

AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Basic Function of a Double Clutch Transmission (“DCT”)

torsion bar for vibration isolation

dry double clutch input shaft 2 input shaft 1

output shafts

differential

Omitting the DMF

output shafts

AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Electric Machine with Planetary Gear Set

electric machine

planetary gear

AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Synchronization by the Electric Machine

ne=n2 (i-1) + n1 • Driving in gear 1

• Gear 2 disengaged

• Electric machine

accelerates to ne

• Gear 2 engaged

Synchronization

AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Boost and Recuperation by the Electric Machine

ne=n2 (i-1) + n1 • Driving in gear 1

• Gear 2 engaged (clutch open)

idling

positive torque

negative torque

Recuperation &

Generation Boost

Recuperation & Generation

AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Electric Creep by the Electric Machine

ne=n2 (i-1) + n1 • Gear 1 engaged (clutch open)

• Gear 2 engaged (clutch open)

at standstill

positive torque

forward

negative torque

backward

Electric Creep

AVL e-Fusion Pure Range Extender

Generator Nominal Power [kW] 25

Nominal Torque [Nm] 50

AVL e-Fusion Electric Drive

Combustion Engine Maximum Power [kW] -

Maximum Torque [Nm] -

AVL e-Fusion Vehicle results

Hybrid

Parallel Plug-In

Hybrid

Pure Range

Extender

Electrical

Maximum Velocity [km/h] 180 182 145 145

Acceleration 0-100km/h [s] 9,3 9,4 9,3 10

CO2-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 -

AVL e-Fusion PARALLEL PLUG-IN HYBRID Package and Weight

165 kg incl. power electronics and airbox is benchmark

AVL e-Fusion PARALLEL PLUG-IN HYBRID Package compact car

Fulfillment of all package constraints

AVL e-Fusion Cost analysis complete power train without battery

AVL e-Fusion Cost analysis complete power train including battery

Cost analysis complete power train including battery

Add-on cost

per g CO2 reduction

ca. 50 -65 €

Add-on cost

per g CO2 reduction

ca. 90 €

AVL e-Fusion · 2016. 2. 4. · ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr....

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