48V: How much hybridization is possible
with the new vehicle power?
14th International VDI Congress, Friedrichshafen
Uli Christian Blessing – Chief Engineer Hybrid
Ready for the CO2-Challenge
Agenda
2
1.
Motivation
2.
7DCT300 Base Transmission
3.
7HDT300 Hybrid Transmission
4.
48 V Comparison
5.
Plug-In Hybrid Solutions
6.
Conclusion and Summary
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
June 25, 2014
Ready for the CO2-Challenge
Motivation
CO2 IMPROVEMENTS
FUN 2 DRIVE
COSTS
CUSTOMER/OEM NEEDS
FUNCTIONALITY
3
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
June 25, 2014
Ready for the CO2-Challenge
Motivation












4
CO2 IMPROVEMENTS
high efficient powertrain
power on demand actuation
extended sailing functionality



FUN 2 DRIVE
increased launch performance
boosting
immediate reaction
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







COSTS
transmission kit
volume of scale
reduce rare earth materials
FUNCTIONALITY
shift-by-Wire
park-by-Wire
in-a-box solution
integrated hybridization
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
June 25, 2014
Ready for the CO2-Challenge
Motivation









5
CO2 IMPROVEMENTS
high efficient powertrain
power on demand actuation
extended sailing functionality
pure electric driving
downsized engines
FUN 2 DRIVE







CUSTOMER/OEM NEEDS
high efficient hybridization
hybrid as must-have option
new driving functionalities
easy scalability
easy adaptation
no serviceability
real fuel efficiency improvement
increased launch performance
boosting and immediate reaction
COSTS
transmission kit
reduce rare earth materials




FUNCTIONALITY
shift-by-Wire
park-by-Wire
in-a-box solution
integrated hybridization
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
June 25, 2014
Ready for the CO2-Challenge
Looking for the Swabian CO2-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 CO2 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
June 25, 2014
Base Transmission 7DCT300
Ready for the CO2-Challenge
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
June 25, 2014
Ready for the CO2-Challenge
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
9
6DCT150
7HDT300
7DCT300
6-Speed PowerShift
7-Speed Hybrid
7-Speed PowerShift
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
June 25, 2014
Hybrid Transmission 7HDT300
Ready for the CO2-Challenge
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
June 25, 2014
Ready for the CO2-Challenge
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
June 25, 2014
Ready for the CO2-Challenge
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
June 25, 2014
Ready for the CO2-Challenge
7HDT300 – Consequent Evolution
Overall Optimization:
 More compact package
 Higher overall efficiency
 Less material and amount of parts
 Same power and torque levels
2013
14
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
2014
June 25, 2014
Ready for the CO2-Challenge
7HDT300 – Latest Design for 48V (Integrated Solution)
Inverter
cooling water
Inverter
48V Bat. Connection
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
June 25, 2014
48V Comparison
Ready for the CO2-Challenge
48V Comparison: Belt vs. Flanged vs. Integrated Solution
Belt Solution
Key Facts:



Air-cooled claw pole EM
Belt-connection to ICE
Integrated inverter
Flanged Solution
Key Facts:



Water-cooled EM
Flanged to transmission
Stand-alone inverter
Integrated Solution
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
June 25, 2014
Ready for the CO2-Challenge
48V Comparison: Belt vs. Flanged vs. Integrated Solution
Belt Solution
18
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
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
June 25, 2014
Ready for the CO2-Challenge
48V Comparison: Belt vs. Flanged vs. Integrated Solution
Belt Solution
19
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
possible
very high
* depending on battery performance
© GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing
June 25, 2014
Ready for the CO2-Challenge
Integrated Solution offers much better el. driving performance
Continuous Power of Belt vs. Integrated Solution
T in Nm
Belt Solution
100
Integrated Solution
100
Drag torque range of
typical combustion
engines
50
0
T in Nm
0
2.000
4000
50
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
June 25, 2014
Easy Scalability:
From 48V Mild Hybrid to 360V Plug-In Hybrid
Ready for the CO2-Challenge
Hybrid Transmission Kit: From 48V up to 360V Plug-In Hybrid
360V Plug-In System
48V 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
June 25, 2014
Ready for the CO2-Challenge
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
limited (~20-30 km/h)
possible (diff. gears)
medium
possible (>130 km/h)
possible diff. gears
high
Fuel Efficiency
 NEDC
 WLTP
19 – 22 %
14 – 16 %
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
June 25, 2014
Conclusion & Summary
Ready for the CO2-Challenge
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. CO2 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
June 25, 2014
Thank you for your attention