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Cost-Effective

Hybrid-Electric Powertrains

November 3, 2003

Troy, Michigan

Dr. Alex Severinsky

Ted Louckes

Fred Frederiksen

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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

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Efficiency Map for 3 L Engine

250

200

150

100

50

0

0 1,000 2,000 3,000 4,000 5,000

To

rqu

e (

Nm

)

Engine must be cycled ON and OFF at light torque for high efficiency

ON/ OFF

Engine

Operation

Min torque

for efficient

engine

operation Average engine

torque for

driving the car

OFF

ON

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Hyperdrive Control MethodsU.S. Patents: 5,343,970; 6,209,672; 6,338,391; 6,554,088

ON/OFF ControlEfficiency Map for 2.0 L TC Engine

Conventional ControlEfficiency Map for 3.0 L Engine

250

200

150

100

50

0

0 1,000 2,000 3,000 4,000 5,000

To

rqu

e (

Nm

)

Max torque curve

Output shaft

1,000 2,000 3,000 4,000 5,000 6,000

Average operating point

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Range of Fuel Economy Improvement

with Hyperdrive Control Method for the Engine

Range ofimprovement

High performance cars 50-60%SUVs 40-50%Ordinary cars 30-40%

Improvement on U.S. Combined CycleDue to Limiting Minimum Engine Torque*

* 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.

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Range of Fuel Economy ChangeDue to Effect of Regenerative Braking

On U.S. Combined Cycle Midsize sedan Midsize SUV

Total Brake Losses 37% at 50 hp peak

26% at 10 hp peak

32% at 60 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

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Double Advantage of the High Voltage System

Base profit / loss

300 V System 600 V System

Increase in customer

value for better fuel

economy: 30-40%

Decrease in electrical

system cost: 30-35%

Additional

Value

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.

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70%

40%

SoC

50% of rated discharge time

30% of rated discharge time

* Repeat 84times, fully recharge

Result: after 5,500 cycles, (165,000% of capacity),Cells are at 98% of original capacity (only 2% degradation)

How to Use Lead-Acid Batteries

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.

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Use Existing Automotive Materials and Low Cost Manufacturing Technologies

8 ICEs, gasoline or diesel, all turbocharged

8 Induction motors

8 Lead-acid batteries, long term

8 High voltage semiconductors

Steel, Copper, Aluminum, Lead, Silicon

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TRW – U.S. Patent 3,566,717

Planetary powersplit gear set

Engine

Traction

motor

Inverters

Starter

generator

motor

Battery

Filed March 17, 1969, Granted March 2, 1971

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VW – German Patent 2943554

Battery

Transmission

Motor

Clutch

Engine

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Toshiba - Utility Model 2-7702

Engine

Starter generator

motor

Tractionmotor Clutch

January 1990

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Paice – How New Controls Operate

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Selecting a Cost-Effective Powertrain

• Prius II with Reported Performance and Fuel Economy• Planetary or Clutch 2-Motor Hardware• Hyperdrive Method of Control

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Planetary gear power split

Inverters

CentralController

Two-Motor Hybrid Powertrains

Front wheels

Batteries,ComputerController

67 hp PMtractionmotor

30 hp PMGenerator

1.5 L Atkinson VVTGasoline

500/200 V converter

650 cc Turbocharged DOHC Engine

46 hp Ind.tractionmotor

Clutch9.4 hp Indstarter/ generator

Optional planetary gear transmission

(+)

(-)

200 V 6 Ah NiMH

Inverters

CentralController

Front wheels

Batteries,ComputerController

(+)

(-)

500 V 2.4 Ah NiMH

Planetary Coupling Clutch Coupling

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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

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Pontiac Vibe Standard Powertrain

1.8 L SI engine, dual overhead cam

4-speed automatic transmission with overdrive

Transfer case for AWD

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1.2 L engine+ turbocharger

20 hp peakTraction motor

Clutch17 hp starter/ generator

12 modules,50V, 4 Ah

20 hp peaktractionmotor

Hyperdrive Powertrain for Pontiac Vibe

Rear wheels(+)

(-)

InvertersCentral

Controller

Batteries,BatteryComputerController

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Summary of Design and Modeling Data (representative implementation)

MPG

Vibe Base vs. Vibe Hyperdrive

Base Hyperdrive U/M % improvement

Fuel Economy

ETW 2,980 3,104 lbs FUDS 28.5 52.1 mpg 83 %

HWFET 40.2 46.9 mpg 16 %

Combined (CAFÉ) 32.8 49.6 mpg 53 %

Performance

PTW 2,980 3,104 lbs 0-60 mi/h 11.5 8.8 sec 23 %

40-60 mi/h 6.0 3.9 sec 35 %

0-85 mi/h 25.6 15.7 sec 39 %

¼ mile 18.4 16.7 sec 9 %

Top Speed Continuous

106.5 106.5 Mi/h

Gradeability Requirement @ 55 mi/h 6% 11.4% more

@ 75 mi/h 4% 9.2% more

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Grand Cherokee Standard Powertrain

4.0 L I-6

4-speed automatic transmission

4WD System

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3.0 L engine+ turbocharger

Hyperdrive Powertrain for Grand Cherokee

40 hptractionmotor

Clutch

27 hp starter/ generator

16 modules,50 V, 6 Ah,

(+)

(-)

3 speed AT

InvertersCentral

Controller

27 hp tractionmotor

Front wheels

Batteries,BatteryComputerController

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MPG

Grand Cherokee Base vs. Hyperdrive

Base 4 L

Hyperdrive 2.7 L TC

U/M %

Fuel Economy

ETW 3,792 3,915 lbs FUDS 17.8 35.1 mpg 97 %

HWFET 26.9 35.5 mpg 32 %

Combined 21.0 35.3 mpg 68 %

Performance

PTW 3,792 3,915 lbs 0-60 mi/h 9.4 6.7 sec 29 %

40-60 mi/h 4.6 2.5 sec 46 %

0-85 mi/h 25 12.8 sec 49 %

1/4 mile 17.5 15.4 sec 12 %

Top Speed Continuous 117 125 Mi/h

Continuous Gradeability

Gradeability @55 mi/h 23.8 25.2 % more Gradeability @ 75 mi/h 13.2 16.5 % more

Summary of Design and Modeling Data (representative implementation)

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Cadillac Escalade Standard Powertrain

6.0 L V8

4-speed automatic transmission

AWD

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Hyperdrive Powertrain for Cadillac Escalade

3.0 L engine+ turbocharger 80 hp

tractionmotor

Clutch

38 hp starter/ generator

16 modules,50 V, 6 Ah

(+)

(-)

3 speed AT

InvertersCentral

Controller

20 hp tractionmotor

Front wheels

Batteries,BatteryComputerController

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Cadillac Escalade: Base v. Hyperdrive

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 %

Summary of Design and Modeling Data (representative implementation)

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1.9 L TDI

5-speed manual transmission

RWD

DaimlerChrysler Sprinter

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1.9 L TDI40 hptractionmotor

Clutch

20 hp starter/ generator

16 modules,50 V, 8 Ah

(+)

(-)

3 speed AT

InvertersDrive

Controller

27 hp tractionmotor

Hyperdrive Powertrain for Diesel Sprinter

Front wheels

Batteries,BatteryComputerController

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DIESEL SPRINTER: HYPERDRIVE vs. BASE

Base Hyperdrive % improvement 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

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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

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Thank You