AVL—Int Autom Hybr PWT summit - Optimum PWT for China_Beste_handout.pdf

| International Automotive Hybrid Powertrain Summit| 31.03. – 01.04. 2021 |
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Hybrid Powertrain System
混合动力系统
The optimum Powertrain for
future requirements in China
中国未来需求的最佳动力总成
Beste, Frank
General Manager
AVL Shanghai Technical Center (STC)

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Source: AVL Energy Consulting Services
With direct use of electricity, BEV has by far the
highest efficiency
在直接使用电能的情况下，纯电动车的效率最高
Efficiency Chain of Different Energy Carriers
不同能源载体的效率链
Direct Use of Electricity Chemical Storage of Electricity
FCEV
BEV electricity
from H2
Electricity to H2
BEV
FCEV
BEV: direct use of green electricity
FCEV: green electricity to produce H2 , use in FC Vehicle
PtX: green electricity to produce eFuel, use in ICE Vehicle
BEV from H2: electricity to produce H2, reconversion to electr.
FCEV: green electricity to produce H2, use in FC Vehicle
PtX: green electricity to produce eFuel, use in ICE Vehicle
PtX/ICE
H2 to Electricity
PtX/ICE
Potential
PtX/ICE
New process
Based on chemical energy storage, FCEV and
PtX/ICE become highly competitive
通过化学能存储时，燃料电池汽车和气体燃料/内燃机较有竞争力

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ICE Technology
发动机技术
On the way towards
> 50 % Max. Efficiency
通过电气化的协同作用朝最大效率>50%
and 和
“Zero Impact Emission”
“零影响排放”
utilizing synergies
with electrification
发展

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 Environment & Future Energy
Scenarios
环境和未来能源应用场景
 Hybrid System Optimization
混动系统优化
 DHT architecture analysis
专用混合动力变速器的架构分析
 DHE - high specific power and
efficiency
专用混合动力发动机-高比功率和高效率
AGENDA
AGENDA

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Operation Strategy Calibration
• Gear Shift Program
• Engine Start/Stops
• Engine Load Shifting
• Torque Distribution
System Hardware Definition
• Topology
• Component Characteristics
• Trade-Offs (efficiency, perform., ￥, …)
• Cost Optimum
Customer Boundaries
(Pre)-Feasibility & Concept Evaluation Studies - Why?
(预) 可行性和概念评估研究 - 原因?
As cost efficient as possible without a reduction in quality

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AVL methodology for hybrid powertrain definition
AVL的混合动力总成定义方法
Step 1: Backward Simulation
Step 2: Forward Simulation with Detailed Controller
Innovation / Feasibility Phase Product Development
Concept Phase
Step 3: Forward Simulation with Detailed
Component Models
AVL Hybrid
System Optimizer
Definition of PWT
configuration
Definition of PWT
components & controls
Optimization of PWT
components & controls
Number
of
Variants
>1000 Variants
Combinations of:
* PWT Topologies
* ICE Variants
* EM Power Levels
* Battery Capacities
* …
<10 Variants
<3 Variants
AVL CRUISE
AVL VSM
AVL DRIVE
AVL CRUISE
AVL VSM
AVL DRIVE
Thermal Models
AVL CRUISE
AVL VSM
AVL DRIVE
Thermal Models
AVL CRUISE M

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AVL Hybrid System Optimizer for early system development
AVL混合动力系统优化方法在早期系统开发过程中的的应用
INPUTS
SIMULATION
OUTPUTS
Vehicle(s)
Performance
targets
Transmission(s) Cycle(s)
E-machine(s)
Engine(s) Battery
Fuel cons. optimization via
• Backward simulation
• ECMS1
• Hamiltonian-approach
Taking into account
• Component limitations
• Performance requirements
• Basic dynamic behavior
• Cost, drivability, emissions
Optimization of powertrain
hardware through variation of
• Transmission ratios
• E-machine size(s)
• Battery size
Applications: Conventional, xEV, Fuel Cell
AVL Hybrid System Optimizer
Cost data
Add. requirements:
NVH, Drivability
(engine starts, mode
selection), Emissions
Post-Processing
Fuel cons Fuel cons Cost
Requirements
analysis
Powertrain
cost
evaluation
System level
optimization, allowing
agile potential
comparison of multiple
system configurations in
various scenarios
1 ECMS: Equivalent Consumption
Minimization Strategy

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Operation Strategy Development, Hybrid System Optim.
工作策略开发, AVL混动系统优化器
INPUTS
SIMULATION
OUTPUTS
Fuel Cons. Optimization via
• Backward simulation
• ECMS1
• CS, CD or Combined2
Taking into account
• Component limitations
• Performance requirements
• System inertias
Stationary Simulations to
• Determine optimal ICE Start
and Stop triggers …
• Determine optimal LPS …
… at different SOC levels
Applications: Conventional, xEV, Fuel Cell
AVL Hybrid System Optimizer
Additional
Requirements:
NVH, Driveability, …
Theoretical Optimal Hybrid Operation
Rapid generation of pre-
calibrated maps for ICE
Start/Stop Triggers and
Load Point Shifting, taking
driveability into account
Calibrated Hybrid Operation
AVL HSO Based
Pre-Calibration
1 ECMS: Equivalent Consumption Minimization Strategy
2 Charge Sustaining, Charge Depleting or Combined Emissions (e.g. PHEV in WLTC)
Vehicle(s)
Performance
Targets
Cycle(s)
E-Machine(s)
Engine(s) Battery
Transmission(s)

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Scenarios
混动系统优化
efficiency
AGENDA
AGENDA

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提供平行轴&行星排方案
Layshaft & Planetary solution
available
单电机
Use 1 e-motor DHT
AVL DHT development – Overview
AVL DHT 开发 – 概览

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available
双电机
Use 2 e-motor DHT
available
单电机
Use 1 e-motor DHT

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1
2
3
Comparison – trends
对比 – 趋势
双电机
Use 2 e-motor DHT

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EM1
EM2
主要缺点是，EM1需要比内燃机相当大才可确保扭矩填充
Main disadvantage, EM1 needs to be big enough
compared to ICE to ensure torque filling
对比 – 趋势
双电机
Use 2 e-motor DHT

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EM1
EM2
实车已证实此技术
Technology is proven in a vehicle
对比 – 趋势
双电机
Use 2 e-motor DHT

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对比 – 趋势
双电机
Use 2 e-motor DHT
EM1
EM2

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Electric Driveline Simulation – AVL Capabilities Overview
电动传动系统仿真 - AVL能力概述
JMAG
Python
AVL Cameo
Tosca
Motorcad
Kisssoft
AVL Fire
AVL Excite
PSIM
Nastran
Adams
PreonLab
Abaqus

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Lubrication Concept – Simulation
润滑概念——仿真
PreonLab™ is a disruptive simulation solution for free-
surface flows in highly dynamic environments. No meshing
is required even for complex objects and kinematics. The
software enables fast and accurate analysis of water or
oil flows, helping to improve component design and
integration.
Analysis tasks 分析任务:
• Splash lubrication or force lubrication
飞溅润滑 or 强制润滑
• The flow and distribution of lubricants are analyzed
对润滑油的流动和分布进行分析
• The lubrication of each component is evaluated
对各零部件的润滑情况进行评估
• The torque loss during oil mixing is evaluated
对搅油过程中的扭矩损失进行评价
Link:
https://www.avl.com/it/fifty2-preonlab
PreonLab – FIFTY2 Technology

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Oil distribution
机油分布
Oil slide to supply the
axial sun bearing with oil
Main bearing
Check oil supply of main bearing and axial bearing with
- visual examination
- FMwMD sensors (Flow Medium with Medium Detection)
FMwMD sensor
in oil slide

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Input housing and bearing
Oil distribution
机油分布
Sensor Input 1
Sensors
Flow Rate
[ml/min]
Baseline
Flow Rate
[ml/min]
V1
Flow Rate
[ml/min]
V2
Sensor Input
1
(radial entry)
12.9 21.5 101
Sensor
slide+radial
entry
/ / 645
(only Sensor
slide 568)
Sensor Input
2
(radial exit)
4.66 3.41 71.2
Sensor Ring 15.3 17.9 177
Besides oil flow through additional channel, the flow towards the input radial bearing is also increased significantly.
Input side casing at the V2 design
Sensor Slide
Sensor slide+radial entry
Sensor Ring
Sensor Input 2

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available
双电机
Use 2 e-motor DHT
available
单电机
Use 1 e-motor DHT
Single e-motor solution
recommend as modular solution
(conv., 48V, HV)
 low cost due to high volume
Dual e-motor solution requires low
cost transmission technology
 best fuel consumption potential

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Scenarios
混动系统优化
efficiency
AGENDA
AGENDA

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Comparison – trends (fuel safe potential)
对比 – 趋势
双电机
Use 2 e-motor DHT
Future ICE Technology
State of the art ICE Technology
P2 EM Power 100kw
PS GEN Power 50kw  MOT Power 100kw
AVL DHT EM1 100kw  EM2 Power 30kw
–9%

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Gasoline Engine Development Trends: EUROPE vs. ASIA
汽油机开发趋势: 欧洲对亚洲
40
50
60
70
80
90
100
110
120
130
35,0 36,0 37,0 38,0 39,0 40,0 41,0 42,0 43,0 44,0 45,0
Specific
Power
‐
kW/l
Maximum Efficiency (BTE) ‐ %
Spec. Power versus max. Efficiency
SOP,
SOP Dev.
Europe
Japan, China,
Korea
SOP,
SOP Dev.
Europe is applying same base ICE´s both for stand alone and with Hybrid, Asia is adding dedicated
Hybrid Engines with top efficiency and also addressing high performance engines
R&D
R&D

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Transformation of the ICE with Hybridization
内燃机混动化的转变
Dedicated hybrid ICE
„TEAM play*“
*of the whole system
powertrain, ICE and EAS
混动专用发动机“团队合作”
整个动力总成系统，包含内燃机
和后处理
„In between“ designs
depending on
hybridization level
取决于混动化级别的设计
Conventional ICE
„SOLOIST play“
纯传统内燃机“独角戏”
Turbine matching “small“, “low“ CR
“小”涡轮，“低”压缩比
S/S (no e-drive)
Although dowspeeding,
operation in full map
全map运行
Operation in the map sweetspot
在map里，最佳经济区运行
Turbine matching “large“, “high“ CR
“大”涡轮，“高”压缩比

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Technology Roadmap Gasoline Engine
汽油机技术路线图
长期 Long Term
当前 Current 中期 Mid Term
整车效率
Vehicle
Efficiency
环境影响
Environmental
Impact
稀释
Dilution
3WC
三效催化器 GPF
汽油颗粒捕集器
高级增压
Advanced
Boosting
48V E-Cat.
48V电子催化器
单一内燃机
ICE only
单一内燃机
ICE only
转换管理
Conversion Management
TGDI
绝热内燃机
Adiabatic
Engine
组合循环
Combined
Processes
混动
Hybridization
混动
Hybridization
零环境影响
Zero Impact
互联
Connectivity
互联
Connectivity
米勒/阿特金森
Miller/
Atkinson
0
1
2
3
4
5
6
7
8
9
10
120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580
Valve
Lift
(mm)
Crank Angle (degCA)
爆震抑制
Knock
Inhibition

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Dedicated Hybrid Engines – Efficiency Roadmap
专用混合动力发动机-效率图谱
in production full engine results simulation (idealized, assumed future
technologies)
41,0%
42,8%
43,6%
44,9% 44,8%
47,3%
49,9%
51,4%
38%
39%
40%
41%
42%
43%
44%
45%
46%
47%
48%
49%
50%
51%
52%
Baseline (DHE) DHE (high CR) low boost low boost, lean refinement 2020,
Lambda=1
ideal TC, lean 50% reduced heat
loss, lean
combined process,
lean
max.
brake
thermal
efficiency
[%]
Mitsubishi 2.5 l
N/A Hybrid Engine
under
development
Maximizing thermal eff. by utilizing synergies with electrification. Significant improvements are possible with stoichiometric combustion
利用电气化的协同效应最大限度地提高热效率. 化学计量燃烧过程仍有可能显著提高效率

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谢谢
Thank You

AVL—Int Autom Hybr PWT summit - Optimum PWT for China_Beste_handout.pdf

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