7hdt300 - how much electrical power does the combustion engine need uli blessing

8/11/2019 7HDT300 - How Much Electrical Power Does the Combustion Engine Need Uli Blessing

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International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG GmbH & Cie KG

7HDT300 - How much electrical power does thecombustion engine need?International VDI-Congress 2013 - Friedrichshafen

Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG


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International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions , GETRAG Corporate Group 2

Agenda

Motivation

Base Transmission 7DCT300

- key facts

- improvements

Hybrid Transmission 7HDT300- key facts

- hybrid configuration

- e-machine cooling

- 48 V System

- 360 V Plug-In hybrid

Summary


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International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions , GETRAG Corporate Group

Motivation


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Market Requirements

CO2 IMPROVEMENTS

CUSTOMER/OEM NEEDS

FUNCTIONALITY

FUN 2 DRIVE

COSTS


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Market Requirements

CUSTOMER/OEM NEEDS

FUNCTIONALITY

FUN 2 DRIVE

COSTS

CO2 IMPROVEMENTS

high efficient transmission

high efficient e-machine

power on demand actuation

extended sailing functionality

pure electric driving

downsized engines


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Market Requirements

CUSTOMER/OEM NEEDS

FUNCTIONALITY

COSTS

CO2 IMPROVEMENTS






downsized engines

FUN 2 DRIVE

increased launch performance

increased input speed

boosting

immediate reaction


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Market Requirements

FUNCTIONALITY

COSTS

CO2 IMPROVEMENTS






downsized engines

FUN 2 DRIVE



boosting

immediate reaction

CUSTOMER/OEM NEEDS

high efficient hybridization

hybrid as must-have option

new driving functionalities easy scalability

easy adaptation

no serviceability

real fuel efficiency improvement


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Market Requirements

FUNCTIONALITY

CO2 IMPROVEMENTS






downsized engines

FUN 2 DRIVE



boosting

immediate reaction

CUSTOMER/OEM NEEDS



new driving functionalities easy scalability

easy adaptation

no serviceability


COSTS

transmission kit

volume of scale

reduce rare earth materials


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Market Requirements

CO2 IMPROVEMENTS






downsized engines

CUSTOMER/OEM NEEDS



new driving functionalities

easy scalability

easy adaptation

no serviceability


FUNCTIONALITY shift-by-Wire

park-by-Wire

in-a-box solution

integrated hybridization

FUN 2 DRIVE



boosting

immediate reaction

COSTS

transmission kit

volume of scale

reduce rare earth materials


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Key Features

input torque 300 Nm

dry weight 65 kg (w/o DMF)

7-speed + R with a gear ratio span of > 8.5 wet nested dual clutch with electrical on-demand cooling

electro mechanical gear actuation and electro hydraulic clutch actuation

start/stop functionality and extended sailing functionaltiy (no add. HW)

control unit (TCU) mounted to housing

mechanical park lock

Optional Features

HEV (Mild- to Plug-In)

AWD

integrated park-by-wire

integrated transmission cooling


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Key Improvements of 7DCT300 compared to 6DCT250

improved launch performance:- clutch primary inertia reduction of up to 70% dedicated for downsized

turbo charged engines

- thermal capacity increase by 300%

- higher input speed 7.000 rpm 7.500 rpm

higher fuel economy Overall improvement of up to 4% in NEDC- gear ratio span 7.2 > 8.5

- low viscosity oil

- power-on-demand actuation

weight improvement: 72 kg 65 kg

global footprint improved driveability:

- higher torque control accuracy of wet double clutch

NEXT Generation Benchmark Transmission


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Hybrid Transmission 7HDT300


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Hybrid Transmission 7HDT300

Key Features

gearset

- 7HDT300 based on 7DCT300

- torque range, up to 300 Nm

- adaptable EM-ratio (rotor shaft to crank shaft)

one oil circuit for cooling and lubrication, fill for life

GETRAG Torque-Splitconcept for hybridization

electrical park lock system (w/o add. actuator)

ready for Start/Stop & Hybrid (w/o add. hardware)

integrated e-machine with different

power levels (15 kW up to >110 kW)

- Mild Hybrid (48 V)

- Plug-In Hybrid (up to > 360 V)


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7HDT300 Schematic Overview of Torquesplit Hybrid

2,4,6,R

clutch 2

clutch 1

sub transmission 2

sub transmission 1

1,3,5,7

engine

PCUe-machine

scalable functionality by using different e-machine lengths

Key Modifications

e-machine integration of active parts in transmission housing

e-machine permanently connected to ST2

e-machine using resolver as speed sensor


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7HDT300 Hybrid Features & Modes

General Hybrid Features

enable easy scalability from Mild- to Plug-In Hybrid (from 48 V up to > 360 V)

ensure low additional costs for hybridization including economy of scale

ensure high modularity with base transmission

side-by-side configuration of e-machine enables better vehicle packaging

Hybrid Modes

electric driving

extended sailing

recuperation

boosting

generator-mode / load-Shift

charge@standstill

restart of internal combustion engine with Torque-Spliteffect


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7DCT300 Hydraulic Overview

internalcooler

Similar in GETRAG

Similar in Market

Pressure Sensor

Clutch Motor

Gerotor Pump

Wet Clutch

Stand-alone

TCU

Hydraulic Pistons

e-Pump


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7HDT300 Hydraulic Overview

internal plusoptionalexternal

Similar in GETRAG

Hybrid Extension

Similar in Market

Pressure Sensor

Clutch Motor

Gerotor Pump

Wet Clutch

Stand-alone

TCU

Hydraulic Pistons

Reversing e-Pump

oil cooledHybrid EM


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7HDT300 E-Machine Cooling Concept

Cooling Features

modular approach to enable different cooling levels up to 11 kW ofcooling power

optimized to achieve higher e-machine continuous power

Stator CoolingJacket

Stator WindingHead Cooling

Rotor Shaft /Inner Cooling

Rotor AxialSurface Cooling


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48 V Solution


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7HDT300 48 V Details

2,4,6,R

1,3,5,7e-machine

engine

48 V Belt Solution

air-cooled claw pole e-machine

connected via belt to crankshaft

integrated power electronics

48 V Integrated Solution

oil-cooled e-machine (ASM/PSM)

integrated in transmission housing

stand alone power electronics

What is the value added ??

2,4,6,R

1,3,5,7

engine e-machine


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7HDT300 48 V Comparison Belt vs. Integrated

Belt Solution Integrated Solution

el. creeping/driving

boosting

generator-mode

efficiency

extended sailing

driveability costs

serviceability

not possible

limited

possible

medium

no electric accel.

limited improvement

low

average

possible (


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7HDT300 48 V Comparison Belt vs. Integrated

Belt Solution Integrated Solution

EM-Performance

max. torque

max. power cont. power

efficiency

Fuel Efficiency NEDC

WLTP

50 Nm

12 14 kW2,5 3,5 kW

up to 85 %

10 12 %

7 9 %

up to 80 Nm

up to 16 kWup to 8 kW

up to 92 %

19 22 %

14 16 %


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360 V Plug-In Hybrid Solution


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7HDT300 Plug-In Hybrid

Key Features

pure el. driving up to more than 130 km/h

high-power density to enable vehicle package

high speed e-machine w/o rare earth eliminates risk of political dependancy

E-Machine Facts

phase current: 420 A 420 A

nominal voltage: 250 V 360 V

max. torque: 165 Nm 165 Nm

max. speed: 18.000 rpm 18.000 rpm

peak power: >80 kW >110 kW

continuous power: >30 kW > 35 kW


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7HDT300 Comparison 48 V vs. Plug-In Hybrid

48 V Hybrid 360 V - Plug-In Hybrid

el. creeping/driving

boosting

generator-mode

costs

Fuel Efficiency NEDC

WLTP

limited (130 km/h)

possible

possible (diff. gears)

high

26 80 %

19 68 %


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Summary


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Summary

Base Transmission and Hybridization Kit

base transmission is ready for hybrid w/o any additional actuation

scalable solution enables hybridization from 48 V to 360 V Plug-In hybrid

oil-cooling of e-machine improves continuous power

48 V Solution

integration of e-machine enables higher performance and better driveability

pure el. creeping/driving and extended sailing possible

integration delivers better fuel efficiency than belt version

360 V Plug-In Hybrid

high power e-machine with more than 110 kW guarantees superb el. driving

up to more than 130 km/h high speed e-machine w/o rare earth eliminates risk of political dependancy

side-by-side configuration enables better vehicle package


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Thank you for your attention!

7hdt300 - how much electrical power does the combustion engine need uli blessing

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