Cost-Effective Hybrid-Electric Powertrains November 3, 2003 Dr. Alex Severinsky Ted Louckes Fred Frederiksen Troy, Michigan 1
Content � Sources of improvements in fuel economy � Basis for cost-effective design � HEV powertrain implementations � Cost-effective HEV powertrain � Applications in various vehicles � Next step: cost-effective development 2
Engine must be cycled ON and OFF at light torque for high efficiency Efficiency Map for 3 L Engine Min torque 250 for efficient engine 200 operation Average engine torque for 150 Torque (Nm) driving the car ON 100 OFF 50 ON/ OFF 0 Engine Operation 0 1,000 2,000 3,000 4,000 5,000 3
Hyperdrive Control Methods U.S. Patents: 5,343,970; 6,209,672; 6,338,391; 6,554,088 Conventional Control ON/OFF Control Efficiency Map for 3.0 L Engine Efficiency Map for 2.0 L TC Engine 250 200 150 Torque (Nm) 100 50 0 0 1,000 2,000 3,000 4,000 5,000 1,000 2,000 3,000 4,000 5,000 6,000 Max torque curve Output shaft Average operating point 4
Range of Fuel Economy Improvement with Hyperdrive Control Method for the Engine Improvement on U.S. Combined Cycle Due to Limiting Minimum Engine Torque* Range of improvement High performance cars 50-60% SUVs 40-50% Ordinary cars 30-40% * Improvement depends on average road load and is independent of driving patterns Ref: Adamson, Louckes, Polletta, Severinsky, Templin, Hyperdrive as Powertrain Successor, Future Car Congress, June 2002, Arlington, Virginia, SAE paper 2002- 01-1909. 5
Range of Fuel Economy Change Due to Effect of Regenerative Braking On U.S. Combined Cycle Midsize sedan Midsize SUV Total Brake Losses 37% at 50 hp peak 32% at 60 hp peak 26% at 10 hp peak 21% at 10 hp peak Total brake losses on driving axle brakes 17% at 10 hp peak 14% at 10 hp peak Recoverable energy with 42 V ISG 7% 6% Recoverable energy with 144 V ISG 10% 8% At steady speed Decreased fuel economy due to increased weight 6
Double Advantage of the High Voltage System 300 V System 600 V System Increase in customer Additional value for better fuel Value economy: 30-40% Base profit / loss Decrease in electrical system cost: 30-35% Ref: Frederiksen, Louckes, Polletta, Severinsky, Templin ., Effects of High Battery Voltage on Performance and Economics of the Hyperdrive Powertrain, Hybridfahrzeuge und Energiemanagement, Braunschweiger Symposium, February 21, 2002, Technische Universitat Braunschweig. 7
How to Use Lead-Acid Batteries SoC 70% 40% * Repeat 84 times, fully 50% of rated 30% of rated recharge discharge time discharge time Result: after 5,500 cycles, (165,000% of capacity), Cells are at 98% of original capacity (only 2% degradation) Ref: Frederiksen, Louckes, Severinsky, Templin, Electronics as the Cornerstone of Future Fuel-efficient and Clean Vehicles; SAE-IEEE Convergence Conference, Detroit, MI, October 2002, SAE paper 2002-21-0033. 8
Use Existing Automotive Materials and Low Cost Manufacturing Technologies Steel, Copper, Aluminum, Lead, Silicon � ICEs, gasoline or diesel, all turbocharged � Induction motors � Lead-acid batteries, long term � High voltage semiconductors 9
TRW – U.S. Patent 3,566,717 Filed March 17, 1969, Granted March 2, 1971 Planetary power split gear set Engine Traction motor Starter generator Inverters motor Battery 10
VW – German Patent 2943554 Battery Engine Transmission Clutch Motor 11
Toshiba - Utility Model 2-7702 January 1990 Traction Starter motor Clutch generator motor Engine 12
Paice – How New Controls Operate 13
Selecting a Cost-Effective Powertrain • Prius II with Reported Performance and Fuel Economy • Planetary or Clutch 2-Motor Hardware • Hyperdrive Method of Control 14
Two-Motor Hybrid Powertrains Planetary Coupling Clutch Coupling Optional planetary gear 500/200 V converter Batteries, transmission Computer Batteries, Controller Computer Inverters Controller 200 V 6 Inverters Ah 500 V 2.4 Ah NiMH NiMH Central 30 hp PM Central Controller Generator Controller (+) (+) (-) (-) Front Front wheels Planetary gear wheels 9.4 hp Ind power split Clutch starter/ generator 67 hp PM 46 hp Ind. 1.5 L Atkinson VVT traction traction Gasoline motor motor 650 cc Turbocharged DOHC Engine 15
Summary Comparison Planetary coupling Clutch coupling Clutch + planetary Transmission N/A N/A 3 speed AT Engine power 77 hp 70 hp in Turbo 65 hp in Turbo Engine 1.5 L DOHC VVT 650 cc DOHC 630 cc DOHC Motor 1 (gen) 30 hp PM 10 hp Ind 9 hp Ind Motor 2 (trac) 67 hp PM 46 hp Ind 43 hp Ind Battery 200 V, 6 Ah NiMH 500 V, 2.4 Ah NiMH 500 V, 2.4 Ah NiMH Test Weight, lbs. 3,125 2,875 2,875 FUDS, mpg 65.4 74.1 73.4 HWFET, mpg 66.1 72.7 71.4 Combined (sticker), mpg 55.3 61.8 61.0 Accel 0-60 mph, sec 10.4 10.4 10.5 Top Spd, mi/h 108 108 106 16
Pontiac Vibe Standard Powertrain 1.8 L SI engine, dual overhead cam 4-speed automatic transmission with overdrive Transfer case for AWD 17
Hyperdrive Powertrain for Pontiac Vibe Batteries, 12 modules, Battery 50V, 4 Ah Computer Controller Central Inverters Controller (+) Rear wheels (-) 20 hp peak traction motor 1.2 L engine + turbocharger 17 hp starter/ 20 hp peak Clutch generator Traction motor 18
Vibe Base vs. Vibe Hyperdrive Summary of Design and Modeling Data (representative implementation) Base Hyperdrive U/M % improvement Fuel Economy ETW lbs 2,980 3,104 FUDS mpg 28.5 52.1 83 % HWFET mpg 40.2 46.9 16 % Combined (CAFÉ) mpg 32.8 49.6 53 % MPG Performance PTW lbs 2,980 3,104 0-60 mi/h sec 11.5 8.8 23 % 40-60 mi/h sec 6.0 3.9 35 % 0-85 mi/h sec 25.6 15.7 39 % ¼ mile sec 18.4 16.7 9 % Top Speed Mi/h 106.5 106.5 Continuous Requirement Gradeability @ 55 mi/h 6% 11.4% more @ 75 mi/h 4% 9.2% more 19
Grand Cherokee Standard Powertrain 4.0 L I-6 4-speed automatic transmission 4WD System 20
Hyperdrive Powertrain for Grand Cherokee Batteries, 16 modules, Battery 50 V, 6 Ah, Computer Controller Central Inverters Controller Front (+) wheels (-) 27 hp traction motor 3.0 L engine + turbocharger Clutch 40 hp traction 27 hp starter/ 3 speed AT motor generator 21
Grand Cherokee Base vs. Hyperdrive Summary of Design and Modeling Data (representative implementation) Base Hyperdrive U/M 4 L 2.7 L TC % Fuel Economy ETW lbs 3,792 3,915 FUDS mpg 17.8 35.1 97 % HWFET mpg 26.9 35.5 32 % Combined mpg 21.0 35.3 68 % MPG Performance PTW lbs 3,792 3,915 0-60 mi/h sec 9.4 6.7 29 % 40-60 mi/h sec 4.6 2.5 46 % 0-85 mi/h sec 25 12.8 49 % 1/4 mile sec 17.5 15.4 12 % Top Speed Continuous Mi/h 117 125 Continuous Gradeability Gradeability @55 mi/h % more 23.8 25.2 Gradeability @ 75 mi/h % more 13.2 16.5 22
Cadillac Escalade Standard Powertrain 6.0 L V8 4-speed automatic transmission AWD 23
Hyperdrive Powertrain for Cadillac Escalade Batteries, 16 modules, Battery 50 V, 6 Ah Computer Controller Central Inverters Controller Front (+) wheels (-) 20 hp traction motor 3.0 L engine + turbocharger Clutch 80 hp traction 38 hp starter/ 3 speed AT motor generator 24
Cadillac Escalade: Base v. Hyperdrive Summary of Design and Modeling Data (representative implementation) Base Hyperdrive Percent improvement Fuel Economy ETW 5,750 5,750 lbs FUDS 13.7 25.3 mpg 85 % HWFET 21.8 27.3 mpg 25 % CAFÉ component 17.4 26.2 mpg 50 % Performance PTW 6,200 6,200 lbs 0-60 mi/h 9.6 7.7 sec 20 % 40-60 mi/h 5.4 3.6 sec 33 % Gradeability @55 mi/h 18.7 18.8 % Top Speed Continuous 110 110 Mi/h Continuous Gradeability GCW (with trailer) 13,500 13,500 lbs Gradeability @ 80 mi/h 3.5 3.2 % Gradealility @ 65 mi/h 7.0 8.2 % Gradeability @ 55 mi/h 7.7 8.6 % 25
DaimlerChrysler Sprinter 1.9 L TDI 5-speed manual transmission RWD 26
Hyperdrive Powertrain for Diesel Sprinter Batteries, Battery 16 modules, Computer 50 V, 8 Ah Controller Drive Inverters Controller Front (+) wheels (-) 27 hp traction motor 1.9 L TDI Clutch 40 hp traction 20 hp starter/ 3 speed AT motor generator 27
DIESEL SPRINTER: HYPERDRIVE vs. BASE Base % improvement Hyperdrive Fuel Economy ETW 4,874 5,126 lbs ECE 10.6 5.6 L/100 km 47% ECE 22.2 42.0 Mi/g ECE 8.0 6.2 L/100 km 23% EUDC 29.4 37.9 Mi/g Combined (EPA) 25.4 40.2 Mi/g 37% Performance 0-60 mi/h 14 9 sec 36 % 40-60 mi/h 7 4 sec 43 % Gradeability Continuous Same as base Passing on grade Improved 28
Basis for Cost-Effective Development � Select several vehicle platforms and applications for hybridization � Design one battery module to fit all in different quantity � Design one or two motor-transmissions � Design power electronics with high flexibility to power rating � Develop controls as an operating system 29
Thank You 30
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