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1 23rd International AVL "Engine & Environment" Conference, September 8th - 9th, 2011, Graz, Austria| Dr. Helfried Sorger
Modern Electrification of Power Train needs Integration of Functions
AVL e-Fusion
Dr. Helfried Sorger AVL List GmbH 15.11.2011
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2 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
Electrification is the enabler for future
fleet average fuel consumption targets
The variety of future power trains will increase
due to enhanced degree of electrification
The progressive electrification of the power train results
in a massive cost increase of the overall system
AVL e-Fusion Motivation
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3 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Motivation
-10g CO2
+40% Cost
-60g CO2
+230% Cost
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4 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Motivation
Key is a significant cost reduction of the power train
especially in the high volume compact class
Add-on cost / g CO2 reduction
ca. 90 €
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5 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
TARGETS OF AVL e-Fusion
Modular power train family covering all applications:
Conventional power train
Mild hybrid
Parallel plug-in hybrid
Range extender
Electric vehicle
Same performance and fun to drive for all applications
Significant reduction in fuel consumption for all applications
Applicable for vehicle categories A, B and C (entry-level model)
Unit cost reductions between 10 and 20% depending on the application
Maximum weight reduction
Minimum package space
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6 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Vehicle targets
Mild
Hybrid
Parallel Plug-In
Hybrid
Pure Range
Extender
Electrical
Drive
ITW – Class [kg] 1130 1250 1250 1370
Maximum Velocity [km/h] > 180 > 180 > 140 > 140
Acceleration 0-100km/h [s] < 10 < 10 < 10 < 10
CO2-Emissions in NEDC-cycle [g/km] < 90 < 50 < 50 -
Fuel consumption in NEDC-cycle [l/100km] < 3.7 < 2.1 < 2.1 -
Electrical range [km] > 5 > 50 > 50 > 150
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7 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion System design of the drive train elements
Electrical performance as much as necessary – as little as possible
Mild
Hybrid
Parallel Plug-
In Hybrid
Pure Range
Extender
Electrical
Drive
Combustion Engine Maximum Power [kW] 65 42 28 -
Maximum Torque [Nm] 160 71 68 -
Transmission Number of gears [-] 7 2 2 2
Electric Motor Maximum Power [kW] 10 55 80 80
Maximum Torque [Nm] 120 225 250 250
Generator Nominal Power [kW] - - 25 -
Nominal Torque [Nm] - - 50 -
Battery Overall Energy [kWh] 1,2 11 11 26
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8 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Modularity of the power train family
Combustion housing TCI
Combustion housing NA
Base Power Train Module
7 speed hybrid
DCT transmission
power electronics
2 speed hybrid
powershift transmission
power electronics
generator
range extender
intake module TCI
end cover electric drive
power electronics
parallel plug-in
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9 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Parallel Plug-In Hybrid
Combustion Engine Maximum Power [kW] 42
Maximum Torque [Nm] 71
Transmission Number of gears [-] 2
Electric Motor Maximum Power [kW] 55
Maximum Torque [Nm] 225
Generator Nominal Power [kW] -
Nominal Torque [Nm] -
Battery Overall Energy [kWh] 11
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10 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Torsion bar Connecting the single mass flywheel with secondary masses
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11 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
torsion shaft
final drive
differential
e-motor
separation
clutch
sun gear
planet carrier planet
gear 1
planet
gear 2
inner ring gear
wet brake
wet clutch
outer ring gear
AVL e-Fusion PARALLEL PLUG-IN HYBRID 2 speed hybrid powershift transmission - schematic
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12 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID 2 speed hybrid powershift transmission
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13 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Joint rotor
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14 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Activation for 1st gear by wet brake
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15 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Activation for 2nd gear by wet clutch
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16 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Electromechanical actuation
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17 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Cable actuated mechanical park lock
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18 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated suction oil pump
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19 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Multifunctional dry separation clutch
Belt driven
AC-compressor
Belt driven
electro-mechanical water pump
Separation clutch
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20 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Transmission mounted power electronics Integrated high voltage connection
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21 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated e-cooling circuit
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22 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Combustion housing
Integrated cylinderhead
Screwed liners
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23 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Combustion housing
Integrated intake manifold
Integrated exhaust manifold
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24 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Combustion housing
Integrated cooling passages
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25 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Combustion housing
Integrated oil passages
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26 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Combustion housing
Integrated blow-By passages
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27 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Oil cooler
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28 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated oil filter housing
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29 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Thermostat housing
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30 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Belt driven water pump
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31 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID
2 valve single camshaft drive
Roller finger follower
Camphaser
Decompression device
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32 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Single roller chain drive
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33 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Simple belt driven waterpump No classical auxiliary drive
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34 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID
Single piece plastic front cover
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35 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Crankshaft carrier-integrated transmission bearings
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36 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Mass balancer shaft
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37 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Axial driven oil pump
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38 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Plastic oilpan with common engine and transmission oil sump
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39 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID One piece valve cover
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40 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated oil separator
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41 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Integrated oil separator and intake runner
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42 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Engine mounted airfilter with integrated resonator system
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43 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Mild Hybrid
Combustion Engine Maximum Power [kW] 65
Maximum Torque [Nm] 160
Transmission Number of gears [-] 7
Electric Motor Maximum Power [kW] 10
Maximum Torque [Nm] 120
Generator Nominal Power [kW] -
Nominal Torque [Nm] -
Battery Overall Energy [kWh] 1,2
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44 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission
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45 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Extremely Small Package
Very small package
No synchronizers, just dog clutches
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46 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Schematic
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47 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Basic Function of a Double Clutch Transmission (“DCT”)
torsion bar for vibration isolation
dry double clutch input shaft 2 input shaft 1
1 2 3
output shafts
4
5 6 7
differential
Omitting the DMF
output shafts
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48 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Electric Machine with Planetary Gear Set
electric machine
planetary gear
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49 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Synchronization by the Electric Machine
ne=n2 (i-1) + n1 • Driving in gear 1
• Gear 2 disengaged
• Electric machine
accelerates to ne
• Gear 2 engaged
1 2
Synchronization
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50 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Boost and Recuperation by the Electric Machine
ne=n2 (i-1) + n1 • Driving in gear 1
• Gear 2 engaged (clutch open)
1 2
• Electric machine
idling
• Electric machine
positive torque
BOOST
• Electric machine
negative torque
Recuperation &
Generation Boost
Recuperation & Generation
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51 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion 7-Speed-Hybrid-Dual-clutch Transmission Electric Creep by the Electric Machine
ne=n2 (i-1) + n1 • Gear 1 engaged (clutch open)
• Gear 2 engaged (clutch open)
1 2
• Electric machine
at standstill
• Electric machine
positive torque
forward
• Electric machine
negative torque
backward
Electric Creep
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52 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Pure Range Extender
Combustion Engine Maximum Power [kW] 28
Maximum Torque [Nm] 68
Transmission Number of gears [-] 2
Electric Motor Maximum Power [kW] 80
Maximum Torque [Nm] 250
Generator Nominal Power [kW] 25
Nominal Torque [Nm] 50
Battery Overall Energy [kWh] 11
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53 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Electric Drive
Combustion Engine Maximum Power [kW] -
Maximum Torque [Nm] -
Transmission Number of gears [-] 2
Electric Motor Maximum Power [kW] 80
Maximum Torque [Nm] 250
Generator Nominal Power [kW] -
Nominal Torque [Nm] -
Battery Overall Energy [kWh] 26
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54 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Vehicle results
Mild
Hybrid
Parallel Plug-In
Hybrid
Pure Range
Extender
Electrical
Drive
Maximum Velocity [km/h] 180 182 145 145
Acceleration 0-100km/h [s] 9,3 9,4 9,3 10
CO2-Emissions in NEDC-cycle [g/km] 87,5 32,2 32,9 -
Fuel consumption in NEDC-cycle [l/100km] 3,69 1,36 1,39 -
Fuel consumption in WLTP-cycle [l/100km] 3,83 1,47 1,50 -
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55 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Package and Weight
165 kg incl. power electronics and airbox is benchmark
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56 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion PARALLEL PLUG-IN HYBRID Package compact car
Fulfillment of all package constraints
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57 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Cost analysis complete power train without battery
- 40%
- 14%
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58 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
AVL e-Fusion Cost analysis complete power train including battery
- 10%
- 28%
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59 ECO-MOBILITY 2011 | November 15th - 16th 2011 | AVL List GmbH | Dr. Helfried Sorger
Cost analysis complete power train including battery
Add-on cost
per g CO2 reduction
ca. 50 -65 €
Add-on cost
per g CO2 reduction
ca. 90 €