Mario Brunner
AVL List GmbH (Headquarters)
Public
Entwicklungstrends und –methoden
für Hybridgetriebe und E-AchsenAST User Conference 2018
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
AVL – Transmission Overview
Concept / StructureTransmission synthesis,
Specification, Dimensioning
CalibrationACT – test bed
calibrationIn-vehicle calibrationDRIVE™ evaluation
Software & ControlsSpecification & coding
Safety
Integration & TestingRig and vehicle testing
Detail Design & AnalysisCAD Design
Structural and dynamic analysis
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
AVL – Transmission Overview
CURRENT NUMBER OF EMPLOYEES: ~400
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Video 3 high power sport car
Source: www.topgear.com
3 super sport cars as hybrid!
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
BEV ICE
excellent poor
Pollutants
CO2 – Tank to wheel
CO2 – Lifetime – EU mix
CO2 – Lifetime – China mix
Refueling / Charging time
Weight / Range
Cost / Range
Low speed performance
High speed performance
Transients
NVH
Total cost of ownership (actual status)
Electrification and ICE offer quite complementary characteristics
qualitative
KEY FEATURES OF CONVENTIONAL (ICE) AND BATTERY ELECTRIC POWERTRAIN (BEV)
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Source: IHS 10/2017production based
Electrified (P1,P2,P3,P4) - start stop not considered
EVT
DCT
CVT
CVT
EVT
MTMT
MT MTAT
AT
AT AT
DCT
CVT
CVT
CVT
DCT
DHT
DHT
RED
RED
RED
Market trends - IHS
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Annual Pro
duction V
olu
me (
Glo
bal)
–M
io
0
20
40
60
80
100
120
2015 2020 2025 2030
Light Vehicle Production Volume
Internal Combustion Engine
Electric Motor / Hybrid
Battery Electric Vehicle
Hydrogen Fuel Cell
AVL Prediction 03/2018Scenario ”Medium”
City Access
City Access
City Access
Zero Impact Emission
50 % Efficiency
e-GasE-Fuel
Battery Technology
Infra-Structure
Fleet CO2
WTW
Infra-structure
Fleet CO2
WTW
Fleet CO2
WTW
FC Technology
City Access
Electric Range
AVL forecastImpacts on Global Technology Shares
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
AVL forecastImpacts on Global Technology Shares
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
48V – P0, P1 limited electric experience
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
48V rear axle – 48V PHEV
Plug-in charging 48V and 12V
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
48V rear axle – 48V PHEV
Charging Socket
Trunk unchanged
Batteries, inverter and HCU below trunk level
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
48V rear axle – 48V PHEV
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
48V rear axle – 48V PHEV
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
48V rear axle – 48V PHEV NEXT STEPS
Electric motor135 Nm / 31 kW
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Add-on Hybrid transmissions
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Dedicated Hybrid Transmission (DHT)already available or coming soon
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Dedicated Hybrid Transmission (DHT)AVL Future Hybrid 7 mode
Characteristics:3 clutches & 1 brake7 transmission operation modes: 3 speeds for ICE operation (all can be boosted)
2 speeds for electric driving 2 torque-split eCVT mode
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Dedicated Hybrid Transmission (DHT)AVL Future Hybrid 8 mode
Characteristics:2 clutches & 2 brakes8 transmission operation modes: 5 speeds for ICE operation (all can be boosted)
2 speeds for electric driving 1 torque-split eCVT mode
Very simple core transmission
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Dedicated Hybrid Transmission (DHT)VW Vario.Drive
Characteristics:
1 e-motor 4 speeds for ICE operation modes 5 speeds for electric driving 2 variable modes
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Virtual System OptimizationConventional and Hybrid
Vehicle
Modelling
AVL VSM
Simulation of specific
driving maneuvers
Objective vehicle
assessment
AVL DRIVESPA
Balancing of vehicle variants
Optimization Loop
Build up virtual prototypes Virtual vehicle testing
Select best vehicle & components
Efficiency & driving attribute
assessment
Energy consumption
Demand of system simulation is increasing significantly virtual release & during the development
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Virtual System OptimizationBEV
BEV - parameter variation for different applications
15,4
15,6
15,8
16
16,2
16,4
16,6
16,8
0 1 2 3 4 5 6 7
NED
C e
l. en
ergy
co
ns.
(kW
h/1
00
km)
0-100km/h performance time (s)
Tesla BEV - 1 Gear variants
EM 200kW
EM 225kW
EM 250kW
EM 275kW
EM 300kW
ratio: 7
ratio: 15
Original Tesla
9,5
10
10,5
11
11,5
12
12,5
13
0 2 4 6 8 10 12 14 16NED
C e
l. en
ergy
co
ns.
(kW
h/1
00
km)
0-100km/h performance time (s)
EUCAR 2020 BEV - 1 Gear variants
EM 130kW
EM 110kW
EM 90kW
EM 70kW
first design
Shift point variationHigh performance Mid. performance
High performance Mid. performance
Power and gear ratio variation
BEV also need system simulation to find the compromise between efficiency, performance and cost
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
E-AXLEBase requirement
Highly integrated
Highly efficient
Best NVH
Thermal
SW
Highly integrated
Highly efficient
Best NVH
Highly integrated
Highly efficient
Best NVH
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
SET-TOP INTEGRATION
+ moderate packaging+ easy merge of electronics and axle
Gear-Box
INVERTER
E-MOTOR
SEMI-INTEGRATION
Today
+ improved packaging+ one cooling interface
Gear-Box E-MOTOR
INVERTER
POWER INVERTEROverview degree of integration
Inte
gra
tion
Inte
gra
tion
+ minimum packaging & weight+ maximum robustness+ maximum cost efficiency
E-MOTOR
Gear-Box
INVERTER
FULL-INTEGRATION
Future
• Minimum weight and dimensions
• Fewer connectors and cables
• Fewer interfaces
• Fewer sources for EMC radiation
Highly integrated
Highly efficient
Best NVH
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
E-MOTORHigh speed - main advantages
Torque ~ Weight
Power ~ Torque x Speed
Weight ~ Cost
SPEED UP!
Highly integrated
Highly efficient
Best NVH
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
E-MOTORCooling as enabler for power density
WATER JACKET
FORCED AIR COOLED
DIRECT OILOIL SPRAY
Cooling im
pro
vem
ent
Cooling im
pro
vem
ent
Cooling im
pro
vem
ent
Transferred Heat
Why direct oil with sleeve pipe?
• Oil passes along heat source - stator
• No drag losses at rotor
• Oil flooded windings are cooled
Torque
Speed
Peak torque curve
Constant torque curve
E-Machine cooling topologies
e-motor thermal optimization is key to optimize weight to power ratio
Highly integrated
Highly efficient
Best NVH
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
TRANSMISSION Lubrication optimization
AVL CFD
optimization
High speed at input shaft as major challenge!
➢ 3D CFD simulation mandatory in early development phase
➢Design confirmation and validation over early plastic models
Target is to guarantee lubrication without additional pump:
Highly integrated
Highly efficient
Best NVH
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
TRANSMISSION Lubrication optimization
Target is to guarantee lubrication without additional pump:
Highly integrated
Highly efficient
Best NVH
Oil flow simulation as key to reduce splashing losses and development time
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
TRANSMISSIONMicro geometry optimization
Pro
file
Lead
Full factorial at least 500
DoE – Design of Experiment:
Variante
Breitenballigkeit
[mic]
Kopfrücknahme
[mic]
Radius
Kopfrücknahme
[mm]
Schrägungswinkelkorrektur
[mic]
Höhenballigkeit
[mic]
1 5.0 9.0 140.6 -2.5 5.0
2 0.0 15.0 137.6 -6.7 10.0
3 0.0 15.0 143.6 10.0 10.0
4 3.3 3.0 143.6 -6.7 6.7
5 0.0 3.0 137.6 1.7 10.0
6 0.0 15.0 141.6 -15.0 0.0
7 10.0 3.0 143.6 -6.7 10.0
8 0.0 15.0 139.6 10.0 0.0
9 10.0 15.0 139.6 -15.0 10.0
10 0.0 11.0 139.6 10.0 10.0
11 6.7 7.0 137.6 -15.0 10.0
12 10.0 7.0 137.6 -6.7 10.0
13 10.0 15.0 143.6 -15.0 6.7
14 10.0 3.0 137.6 -15.0 0.0
15 10.0 11.0 139.6 -15.0 3.3
16 3.3 3.0 141.6 10.0 10.0
17 3.3 15.0 137.6 10.0 10.0
18 3.3 15.0 143.6 10.0 0.0
19 6.7 15.0 137.6 -6.7 0.0
20 0.0 3.0 141.6 -15.0 10.0
21 0.0 3.0 141.6 1.7 3.3
22 10.0 3.0 141.6 1.7 0.0
23 6.7 3.0 139.6 1.7 6.7
24 3.3 11.0 143.6 -15.0 10.0
25 0.0 15.0 137.6 10.0 6.7
26 10.0 15.0 143.6 1.7 10.0
27 6.7 3.0 141.6 -15.0 3.3
28 6.7 3.0 137.6 10.0 0.0
29 10.0 15.0 139.6 10.0 3.3
30 10.0 11.0 143.6 10.0 0.0
31 6.7 11.0 139.6 10.0 0.0
32 10.0 7.0 139.6 10.0 10.0
33 3.3 15.0 143.6 -15.0 3.3
34 6.7 3.0 143.6 10.0 10.0
35 3.3 3.0 139.6 -15.0 0.0
36 6.7 7.0 143.6 -6.7 0.0
37 0.0 11.0 137.6 -15.0 0.0
38 10.0 7.0 143.6 10.0 6.7
39 3.3 15.0 141.6 -6.7 10.0
40 0.0 11.0 143.6 1.7 0.0
41 0.0 3.0 137.6 -6.7 0.0
42 10.0 15.0 137.6 -15.0 3.3
43 3.3 7.0 137.6 1.7 0.0
44 0.0 7.0 137.6 10.0 3.3
45 0.0 7.0 139.6 -15.0 3.3
46 0.0 3.0 143.6 -15.0 0.0
47 10.0 3.0 137.6 10.0 6.7
Highly integrated
Highly efficient
Best NVH
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
TRANSMISSIONMicro geometry optimization
Intersection plot shows individual influence of micro geometry parameters on surface vibratoins.
benchmark
Lead Profile
Surf
ace v
elo
city level [d
B]
Helix Angle Correction [mic] Crowning [mic] Barreling [mic] Root Relief [mic] Tip Relief [mic] Torque [Nm]
Gear contact optimization needed for electr. powertrains efficiency and NVH optimization
Highly integrated
Highly efficient
Best NVH
Mario Brunner | AST User Conference Germany | 17 Oktober 2018 |Public
Summary
Technology variety is increasing significantly
Increasing demand for system simulation
More than 50% of the powertrainswill have an e-motor in 2030
Simulation based optimization required
Electrified powertrain confrontthe “transmission” with new challenges
Lubrication and NVH simulation optimization needed
www.avl.com
Thank You