AVL e-Fusion · 2016. 2. 4. · ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger 6 AVL e-Fusion Vehicle targets Mild Hybrid Parallel Plug-In Hybrid

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

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

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

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 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

1 2 3

output shafts

4

5 6 7

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

1 2

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)

1 2


idling


positive torque

BOOST


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)

1 2


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

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

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

- 40%

- 14%


AVL e-Fusion Cost analysis complete power train including battery

- 10%

- 28%


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 €

Documents

AVL e-Fusion · 2016. 2. 4. · ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger 6 AVL e-Fusion Vehicle targets Mild Hybrid Parallel Plug-In Hybrid