Controlled Power Technologies - federalmogul.com€¦ · validate the performance and durability across a range of duty cycles. Each machine configurationundergoes lifetime durability

Controlled Power Technologies CPT SpeedStart®

Belt-Integrated Starter Generator

2 ©2018 Federal-Mogul LLC

XXXX

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 •Advancedtorqueprofilesforbelt-pre-tensioning • E-Auxiliary drive (with de-clutch)• Belt-Driven by the crankshaft

CPT SpeedStart® Belt-Integrated Starter Generator

3©2018 Federal-Mogul LLC

Specification&Performance

Specific performance requirements can be achieved withelectromagnetic or electronic configurations and different controlstrategies and/or calibrations. The following data is typical within a similar mechanical and electronics package.

C102-22T C102-41T C1001-28TNominal Voltage 12V 48V 48VDiameter 155 mm 155 mm 170 mm

Length 167 mm 167 mm 185 mmCranking Torque 60 Nm 60 Nm 50 NmContinuous Generating 2.7 kW 5.5 kW 6.0 kWPeak Generation 3.0 kW 10 kW 12.5 kWContinuous Motoring 1.0 kW 4.0 kW 4.5 kWPeak Motoring 1.7 kW 6.0 kW 8.0 kWRated Efficiency* 74% 81% 85%Speed Range 0 - 20,000 RPMRotating Inertia 0.0027 kgm2

*Includes integrated electronics

Thermal Management• Active stator effectively cooled by engine coolant • Fullfunctionalitywithenginecoolantupto105˚Candprogressivelyderatedperformanceto120˚C

Controllability• Integrated microprocessor supports advanced functionality

Goodefficiencyoverwidespeedrange• 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

Benefits


Features&Modes

GenerationEfficienthighpowerelectricalgenerationofenergyoverawidespeed range including low engine speed.

RecuperationRecuperation is the capture of kinetic energy lost during deceleration of the vehicle. This is particularly beneficial forhigher power, higher mass vehicles.

Switched Reluctance Machines (SRM) are especially suited to hybridapplicationsastheyenablehighefficiencyharvestingofkinetic 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.

MotoringThe 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


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.

In2016 thesoftwarewasported to the InfineonAurix familyof 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).


-10

-8

-6

-4

-2

0

2

4

6

8

10

0 200 400 600 800 1000 1200 1400 1600 1800 2000

BAtt

ery

Pow

er (k

W)

Time (s)

ADEPT Car WLTC Battery Power

CPT SpeedStart® has been integrated in both gasoline and diesel powertrains with manual and automatic transmission configurations and many different automotive and non-automotive vehicle platforms.

Fuel Economy and CO2 ReductionCPT 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 / CO2 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.

Applications

10

8

6

4

2

0

-2

-4

-6

-8

-10

Bat

tery

Pow

er (k

W)

Time(s)

ADEPT Car WLTC Battery Power


Time

Dilu

te N

Ox (p

pm)

2001901801701601501401301201101009080706050403020100

20000

17500

15000

12500

10000

7500

5000

2500

0

-2500

-5000

-7500

-10000

-12500

-15000

Vehi

cle

Spee

d (k

ph) Pow

er (W)

250-

220-200-180-160-140-120-100-80-60-40-20-0-

-20--40--60--80-

-100--120--140--160--180--200--220-

-250-

-

-

4030 4031 4032 4033 4034 4035 4036 4037 4038 4039 4040 4041 4042 4043 4044 4045 4046 4047 4048 4049 4050

Baseline NOx ppmNOx ppm on small transientsSupported by boosting

Boosting Events

Advanced Emission ReductionA 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 fuelsavingof4.6%wasachievedfora3.0ldieselenginefittedto 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.

Applications


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 bethemostsignificantfactorinbothon-cycle(certification)andoff-cycle (real world) performance.

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.

ThermalManagement

NVH&Dynamic

Control


CPT develops all motor electronics in-house using state of the art componentry and significant knowledge of handlingthe 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.

CPT uses JMAG software to determine winding topographies for specificapplicationrequirements.ThisallowsCPTtooptimisemanyfeaturesofthemachinewhichmayaffecttheefficiencyof the electric machine or be influenced by manufacturingprocesses.

Control&Power

Electronics

Electro-Magnetic

OptimisationContour Plot: T


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.

Eachmachineconfigurationundergoeslifetimedurabilitytestingformotoringandgeneratingunderenvironmentally 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).

Fulldesignverificationtestingisconductedtomeetspecificcustomerapplicationrequirements.

Product Evaluation and Validation


Founded in 2007, UK-based clean-tech developer Controlled Power Technologies (CPT) was acquired byFederal-MogulPowertrainin2017.TheCPTproductrangewithinnovativeelectrificationandhybridization 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 electrificationtechnologies,combustionenginee-boostingandfuelcelle-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.

Our Company Empowering the Engine of Progress

www.federalmogul.com

Federal-Mogul Controlled Power LtdUnit 4, Westmayne Industrial Park,Bramston Way, Laindon, Essex, SS15 6TP

Phone +44 (0)1268 564800

[email protected]

©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.

Documents

Controlled Power Technologies - federalmogul.com€¦ · validate the performance and durability across a range of duty cycles. Each machine configurationundergoes lifetime durability