Planetary Module for Hybrid and Plug-In Hybrid vehicles

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1 Planetary Module for Hybrid and Plug-In Hybrid vehicles FEV e-pgs, the one fits all solution? Shanghai, September 17 th 2015 P. Janssen MSc, FEV GmbH 1

2 Introduction 1487 Leonardo da Vinci Helicopter 1900 Ferdinand Porsche 4WD E-Vehicle 2004 Aachen Colloquium e-pgs Diesel full Hybrid Some good ideas are just too far ahead of their time.. 2

3 Introduction: Fuel economy legislation will become more stringently Historical performance and targets of CO2 emission limits in different regions Legislation worldwide requires ambitious targets of fuel economy improvement From 2015 to 2020 a reduction of CO2 emissions by 26% is necessary in Europe So far most of the OEMs has fulfilled targets and with a small amount of electrified powertrains Without a massive electrification in all markets the 2025 targets cannot be achieved Now the time is right for highly integrated and/or dedicated hybrid solutions! Source: Improving the conversions between the various passenger vehicle fuel economy The ICCT By Zifei Yang 3

4 FEV s e-pgs family: High integrated or stand alone as PREX1/2 e-pgs PGS + EM replace converter Mild/Full Hybrid Carry over AT transmission PGS+EM for launch ( CVT mode ) PREX1 1 PGS, 3 Shift elements Range Extender/Hybrid 2 E-drive modes / 1 CVT mode / 1 Parallel Mode PREX2 2 PGS, 3 Shift elements Range Extender/Hybrid 2 E-drive modes / 2 CVT-modes / 2 Parallel modes Low complexity Single e-motor, no additional launch device Carry-over of base AT for e-pgs (hybrid module) Excellent launch feel and performance ICE and EM torque added for combined launch EM torque amplified by PGS for pure e-launch Full performance even with empty battery Creep behavior like conventional AT Robust Launch by control of ICE and E-Motor No slipping clutch involved no thermal issues Full hybrid functionality with excellent fuel economy No launch device losses PGS is locked after takeoff efficient parallel mode 4

5 Different integrated solutions for different base transmissions FEV e-pgs/prex concept useable thru complete range Conventional Vehicles Gear Box Fuel Tank Micro Hybrid Hybrid Electric Vehicles Mild Hybrid Full Hybrid Plug-In Hybrid 2 PGS, 3 Shift elements CVT & direct gears EM+ICE PGS & EM for launch Battery Electric Vehicles P-Rex Battery 2011: Planetary Plug-In 2010: X-Structure DCT Layshaft 4 Shift Elements, 18 helical gears Full power-shift 8+2R (+4EM) Dry clutch for launch 4 Shift Elements, 17 helical gears Full power-shift 10 speed Wet clutch for launch 2008: X-Structure Layshaft 2003: P2 Planetary Solution E-PGS PGS +EM replace converter Carry over AT/CVT transmission PGS + EM for launch PGS: Planetary Gear Set 5

6 Worlds 1 st Diesel Electric Full Hybrid Powertrain with e-pgs (ACK 2004) FEV Responsibility Concept (Planetary Gear Concept) T/M Integration & TCU Interface Launch device control Complete Hybrid Software Safety system and diagnostics PT Dynamometer Testing Vehicle Calibration and Testing Achievements 24 % Fuel consumption (Mileage Gain 32 %) 25 % Decrease in 0 to 100 km/h Acceleration Time Excellent Launch Quality, Robustness, Performance Significant Reduction of Exhaust Emission DMF Main View Oil cooled, outer rotor EM with PGS inside rotor 6AT base transmission 6

7 FEV s e-pgs family: PREX Gen 1 transmission with single mode PGS Technical highlights Application for small vehicle 2-speed pure electric driving 1-speed combustion engine for efficient highway driving Highly flexible CVT mode ( power combine ) Launch and creep without slipping clutch E- boost during launch even with empty battery Only one electric motor Successfully demonstrated in vehicle 7

8 Concept of the PREX Hybrid-Transmission Basic Idea of CVT-mode or e-pgs Mode Explanation Lever Diagram rpm Lever diagram visualizes the speeds at the planetary gearset members 0 Output PGS Ring PGS-Carrier PGS-Sun Combustion Engine Output E Motor Idle ( Geared neutral ) 0 Engine Output E Motor E-Motor Combustion Engine Launch, Lockup & Parallel Drive Clutch 0 Engine Output E Motor Positive torque, positive speed boost mode Positive torque, negative speed charge mode 8

9 e-pgs Concept Hybrid Module Planetary Gearset E-Motor CVT Input EM Engine AT/CVT Brake and One-Way Clutch EM POD Oilpump AT or CVT best suited as base gearbox E-Motor Wet clutch C1 9

10 e-pgs Selected Applications e-pgs Module for RWD AT Transmission e-pgs Module for FWD AT Transmission 10

11 e-pgs Selected Applications: Gasoline Plug-In Hybrid (SOP 2016) FEV Responsibility Main View Complete concept responsibility and layout for hybridization of conventional powertrain Design and simulation of e-pgs transmission Development of HV Battery incl. BMS Complete software development for HCU Technical safety concept (functional and electrical) Specification of all new/modified E/E components Achievements Fuel reduction by hybridization of 25% in charge sustaining Pure electric range of 50km with FEV HV battery Autosar structured HCU/BMS Software 11

12 e-pgs Lever Diagram: Functionality (1) Trans Input Explanation Lever Diagram rpm Lever diagram visualizes the speeds at the planetary gearset members 0 E-Motor PGS Carrie r PGS-Ring PGS-Sun Engine Transmission E Motor Engine Trans Input E-Motor Idle & Start Lock Engine Trans E Motor Engine Clutch C1 Takeoff, Lockup & Parallel Drive Engine Trans E Motor 12

13 e-pgs Lever Diagram: Functionality (1) Vehicle launch in PGS mode 1s/div Clutch capacity request C1 Generator mode Motoring mode Parallel Engine speed AT input speed E-Motor speed Hybrid vehicle launch with e-pgs mode until clutch C1 closed. Excellent, free programmable launch feeling with engine speed increasing 13

14 e-pgs Lever Diagram: Functionality (1) Vehicle launch in PGS mode 1s/div Clutch capacity request C1 Generator mode Motoring mode Parallel Engine speed AT input speed Boost Charge E-Motor speed Hybrid vehicle launch with e-pgs mode until clutch C1 closed. Excellent, free programmable launch feeling with engine speed increasing 14

15 FEV e-pgs Hybrid Concept PGS Lever Diagram: Functionality (2) Regenerative braking (Sailing) Engine Trans E Motor Electric drive (with one-way-clutch, OWC 1) ) OWC Engine Trans E Motor ICE restart from E-drive OWC Clutch C1 Engine Trans E Motor Balanced inertia so no reserve torque for ICE start needed 1) OWC and/or brake for full E-Drive 15

16 FEV e-pgs Hybrid Concept PGS Lever Diagram: Functionality (2) Engine restart from E-Drive ICE restart from E-drive Transmission Input E-Motor rpm Engine Clutch C1 OWC Engine 1) Trans E Motor 0 FEV_ePGS_CTI_Shanghai_2015_pj3_EN.pptx, 17. September ) OWC or brake for full E-Drive With the help of clutch C1, additional torque and inertia of E-Motor engine is restarted from E-Drive. Due to e-pgs system less E-Motor restart torque reserve is required

17 e-pgs Lever Diagram: Functionality (2) Engine restart from E-Drive Clutch capacity request C1 100ms/div E-Motor speed AT input speed Engine speed Engine Start during E-Drive using E-Motor inertia with low vibrations on T/M input (Principle of balanced inertias) 17

18 FEV e-pgs Hybrid Concept Comparison P2 Hybrid vs. e-pgs Item P2 Hybrid e-pgs Remark Integration level 0 + No new launch clutch, integrated cooling Cost 0 + Add PGS, No launch device, 12V starter or DMF Launch Performance 0 ++ No Launch clutch, Full performance also with empty battery Package 0 (+) + Nearly package neutral for TC-AT StartStop 0 + e-pgs fastest response (only drop 1 clutch). Support by E-Motor inertia during E-Drive start Re-start 0 + Inertia balanced, no need for torque reserve Launch quality & Comfort Thermal Launch Robustness Charge sustaining capability FEV excellent controllability by EM control robust high comfort FEV no slipping element, better than TC Launches energy neutral, charging whilst creeping Similar cost & package, but better comfort & launch performance under extreme conditions 18

19 Summary e-pgs System was developed and demonstrated in hardware in many different vehicle configurations such as FWD, RWD, AWD, Diesel, Gasoline, Plug-In, AT and CVT Launch by planetary gear has been recognized by automotive industry lately, since then many ongoing development programs, not only at FEV e-pgs Concept has advantages in several operating areas compared to conventional P2 Systems No need for torque reserve for ICE Start during E-Drive Launch quality and robustness, no Launch device needed e-pgs is the only one E-Motor hybrid system with unrestricted operation: Charge in standstill and slow speed driving always possible Full launch torque even with empty battery due to generator mode Launch and creep quality very robust (no friction clutch launch device) No or minimal additional length needed (when using TC based base transmission) e-pgs is the one fits all solution for TC based transmissions! 24

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