48V: How much hybridization is possible with the new vehicle power? 14th International VDI Congress, Friedrichshafen Uli Christian Blessing Chief Engineer Hybrid
Agenda 1. Motivation 2. 7DCT300 Base Transmission 3. 7HDT300 Hybrid Transmission 4. 48 V Comparison 5. Plug-In Hybrid Solutions 6. Conclusion and Summary 2 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Motivation CO 2 IMPROVEMENTS FUN 2 DRIVE COSTS CUSTOMER/OEM NEEDS FUNCTIONALITY 3 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Motivation CO 2 IMPROVEMENTS high efficient powertrain power on demand actuation extended sailing functionality pure electric driving downsized engines CUSTOMER/OEM NEEDS high efficient hybridization hybrid as must-have option new driving functionalities easy scalability easy adaptation no serviceability real fuel efficiency improvement FUN 2 DRIVE increased launch performance boosting immediate reaction COSTS transmission kit volume of scale reduce rare earth materials FUNCTIONALITY shift-by-wire park-by-wire in-a-box solution integrated hybridization 4 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Motivation CO 2 IMPROVEMENTS high efficient powertrain power on demand actuation extended sailing functionality pure electric driving downsized engines FUN 2 DRIVE increased launch performance boosting and immediate reaction COSTS transmission kit reduce rare earth materials CUSTOMER/OEM NEEDS high efficient hybridization hybrid as must-have option new driving functionalities easy scalability easy adaptation no serviceability real fuel efficiency improvement FUNCTIONALITY shift-by-wire park-by-wire in-a-box solution integrated hybridization 5 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Looking for the Swabian CO 2 -Champion Situation Today - Near Future: Various concepts (minor to medium volumes) Various hybrid power levels: Mild Hybrid (48V with 15 kw) with significant volume demand Full Hybrid (~220V with 50 kw) Plug-In Hybrid (>360V more than 110 kw) Very high diversity on OEM requirements High costs (for piece price and ED+T) due to low overall volumes Rare earth materials should be avoided if possible Increasing CO 2 targets with benefits for pure electric driving (e.g. EU / China / US / ) Goal: One Hybrid Transmission kit, that can cover most of the needs 6 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Base Transmission 7DCT300
7DCT300 Base Transmission Key Facts: Input torque up to 300 Nm 7-speed + R with a gear ratio span of >8.5 Wet nested dual clutch with electrical on-demand cooling Electro mechanical gear and electro hydraulic clutch actuation Start/stop and extended sailing functionality Mechanical park lock Options: Park-by-Wire AWD Hybrid 8 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
7DCT300 Transmission Kit for various solutions Carry over of key components TCU with electric actuation for clutch and shift Wet clutch with electrical on-demand cooling Modular Software Architecture 6DCT150 6-Speed PowerShift 7HDT300 7-Speed Hybrid 7DCT300 7-Speed PowerShift 9 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Hybrid Transmission 7HDT300
7HDT300 Hybrid Transmission Key Facts: 7HDT300 based on 7DCT300 GETRAG torque split concept Carry-over of key components from DCT transmission kit High-speed e-machine One common oil circuit for cooling and lubrication Electrical park lock system (w/o add. actuator) Integrated e-machine with different power levels mild hybrid (48 V, 21 kw) plug-in hybrid (up to > 360 V; >110 kw) 11 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
7HDT300 Hybrid Transmission Additional Components for Hybrid E-machine (as tested-unit) Intermediate gear set Connectors for EM Bidirectional cooling flow pump (using same electric cooling pump as clutch cooling) Assembly of e-machine and inverter at GETRAG 12 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
7HDT300 Hybrid Transmission Hybrid Modes: Pure electric driving Extended sailing Recuperation Boosting Generator-mode / load-shift Charge@standstill Restart of internal combustion engine with Torquesplit effect Remark: Hybrid modes identical for 48V and Plug-In version 13 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
7HDT300 Consequent Evolution Overall Optimization: More compact package Less material and amount of parts Higher overall efficiency Same power and torque levels 2013 2014 14 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
7HDT300 Latest Design for 48V (Integrated Solution) Inverter 48V Bat. Connection Inverter cooling water Transmission mount Inverter CAN & 12V TCU c/o DCT differential c/o DCT 15 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
48V Comparison
48V Comparison: Belt vs. Flanged vs. Integrated Solution Belt Solution Flanged Solution Integrated Solution Key Facts: Air-cooled claw pole EM Belt-connection to ICE Integrated inverter Key Facts: Water-cooled EM Flanged to transmission Stand-alone inverter Key Facts: Oil-cooled EM Integrated in gearbox Stand-alone inverter Remark: For simplicity reasons, only these three main-stream examples have been chosen 17 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
48V Comparison: Belt vs. Flanged vs. Integrated Solution Belt Solution Flanged Solution Integrated Solution EM-Performance Max. torque Max. power Cont. power Efficiency up to 50 Nm 12 14 kw 2,5 3,5 kw up to 85 % up to 50 Nm up to 18 kw up to 8 kw * up to 94 % up to 50 Nm up to 21 kw up to 13 kw * up to 95 % Fuel Efficiency NEDC WLTP 10 12 % 7 9 % 17 20 % 12 14 % 19 22 % 14 16 % * depending on battery performance 18 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
48V Comparison: Belt vs. Flanged vs. Integrated Solution Belt Solution Flanged Solution Integrated Solution Hybrid Modes El. creep/drive Boosting Generator Driveabiltiy not possible limited possible medium possible * possible diff. gears) high possible * possible diff. gears high Others Package Efficiency easy belt-drive challenging Efficiency * depending on battery performance possible very high 19 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Integrated Solution offers much better el. driving performance Continuous Power of Belt vs. Integrated Solution 100 T in Nm Belt Solution 100 T in Nm Integrated Solution 50 Drag torque range of typical combustion engines 50 0 0 2.000 4000 6000 n in rpm 0 0 2.000 4000 6000 n in rpm Remark: The Flanged Solution is close to the Integrated Solution 20 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Easy Scalability: From 48V Mild Hybrid to 360V Plug-In Hybrid
Hybrid Transmission Kit: From 48V up to 360V Plug-In Hybrid 48V System 360V Plug-In System EM-Performance Max. torque Max. power Cont. power Efficiency Max. speed Max. phase current - up to 50 Nm - up to 21 kw - up to 13 kw * - up to 95 % - 18.000 rpm - 350 A - up to 150 Nm - more than 110 kw - up to 35 kw * - up to 96 % - 18.000 rpm - 450 A Changed stator windings and power connectors ensure easy scalability 22 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Hybrid Transmission Kit: From 48V up to 360V Plug-In Hybrid 48V System 360V Plug-In System Hybrid Modes El. creeping/driving Boosting/Generator Costs Fuel Efficiency NEDC WLTP limited (~20-30 km/h) possible (diff. gears) medium 19 22 % 14 16 % possible (>130 km/h) possible diff. gears high 26 80 % 19 68 % Changed stator windings and power connectors ensure easy scalability 23 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
Conclusion & Summary
48V: How much hybridization is possible, with this new vehicle power? Conclusion: Belt Solution: Offers a higher efficiency than a 12V system Requests a standard 48V system The overall driveabiliy is only little improved Flanged and Integrated Solution: Only in combination with a high-energy 48V system Pure el. driving is possible with real value-add for end-customers Summary: Integrated 48V system offers best ratio cost vs. CO 2 improvements Hybrid transmission kit can easily be scaled from 48V mass market up to Plug-In Hybrid needs 25 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
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