hybrid & electric technology - transfluid · lipo/lifepo4 battery complete with battery...

Hybrid & ElectricTechnology

Founded in Milan Italy in 1957, Transfluid hasalways been a point of reference in the world ofindustrial transmission equipment and thestandard that its competitors measurethemselves.Fluid couplings, variable speed drives, brakes,clutches, couplings and hydraulictransmissions constitute the core of theproduct line, while ultra-modern technology,careful selection of materials and meticulousassembly are the key ingredients in the recipethat has placed those products at the forefrontof the market. Thousands of customerscontinue to choose Transfluid for the mostdiverse and demanding applications, knowingthey can rely on Transfluid’s technicaldepartment, where design, engineering andplanning experts are always on hand toquickly resolve client’s problems.Italian dynamic innovation, coupled withongoing staff development and more than fiftyyears of hard-earned expertise, are thefoundation of the company’s success.Transfluid’s unique approach has sparkedsmall but important revolutions in the fieldof heavy-duty transmissions, for whichrecognition has come in the form ofinternational awards.Transfluid’s catalogue boasts a wide range ofproducts, and each unit produced is tested forsafety, quality and durability. Being a worldleader in the design and manufacture of fluidcouplings, Transfluid has earned a reputationfor diligent service, which assures thecompetence of the applications through carefulquality control and on-site technical assistance.In addition to the Italian Headquarter.Transfluid’s broad sales network consists offive branches located in China,France, Germany, Russia and United States,one representative office in Brazil and 32distributors located throughout the world.

The industrial market has been focused ondeveloping new technologies to reduce theirecological impact on land and sea.Global awareness of air, noise and waterpollution attributed to internal combustionengines has caused vehicle manufacturers toinvest large amounts of money and resourcesinto developing hybrid systems used inautomobiles and small commercial vehicles.However, because of the wide variety of driveline designs used in industrial andmarine markets, a standardized, quality,heavy duty “hybrid product” has beenimpractical to develop.Accepting the challenge to provide a hybridproduct for this neglected market Transfluidis ready to introduce a solution for lowto medium power marine and industrialapplications.For decades Transfluid has beenmanufacturing a wide range of powertransmission equipments and electricmotors/generators.Profiting from their experience in thousandsof industrial and marine applications andusing their existing technology it resulted inthe development of the technology of thefuture.

Transfluid Transfluid’s Hybrid

The hybrid system works in three specificmodes:

- electric propulsion to drive or sail at ZERO emissions and in absolute silence

- engine propulsion that uses the electric machine as generator to recharge the batteries

- “booster” function that allows the electric motor, during acceleration, to assist the engine in providing extra torque to the driveline

The input side is a hydraulic or pneumaticcontrolled clutch.When disengaged, the engine is disconnectedfrom the rest of the driveline allowing thevehicle or vessel to be operated by the electricmotor instead of the engine.During engine operation, the clutch is engagedand the electric motor becomes a generator,recharging the batteries, if required.By operating the engine and electric motor atthe same time, the “booster” operation isengaged, increasing the total available powerto the driven machine.All operations are controlled via Transfluid’sproprietary electronic controller MPCB-R5,which communicates with all equipementsthrough CAN BUS protocol, making thesystem a simple “plug and play” solution.

The System How It Works

B D

E R

Industrial hybrid

HTV700

Workingscheme

BATTERYCHARGER

DIESEL ENGINE

SENSORS

Split power drivedrive with SAE B pto

Clutch actuationsolenoid valve

Three speed forward, onespeed reverse Powershift

Transmission

Drop box for 2 or 4 wheeldrive, available with wide

variety of reduction ratios

SAE standard dry clutch,operated by solenoid valve, to connect and disconnect internal combustion engine

B D

E R

LEGENDPOWER WIRE

CAN WIRE

DIGITAL WIRE

HM560with Hydrostatic Transmission

HYBRIDMODULE WITHINTEGRATEDMULTIDISC

DRY CLUTCH

LiPo/LiFePO4 BATTERY COMPLETE WITH

BATTERYMANAGEMENT SYSTEM

RANGERMATIC31 - 700

DISPLAY

MPCB-R5

ELECTRIC BOX

BATTERYCHARGER

AIR POWER PACK

DIESEL ENGINE

SENSORS

PEDAL CAN bus

CONTROL PANEL

GEAR SELECTOR

FREQUENCYDRIVE

DROPBOXDP280

ELECTRICMACHINE

PARKINGBRAKESL 750

Split power drivedrive with SAE B pto


SinglePump drive

HydraulicPumpSAE standard dry clutch,

operated by solenoid valve, to connect and

disconnect internal combustion engine

Electric machine that can operate as electric motor or electric generator

Electric machine that can operate as elec-tric motor or electric generator

Electric selector control unit withintegrated soft shift ability

Drop box installation with6 different inclination anglepositions

Spring loaded wet discs parkingbrake, operated by solenoid valve

Marine hybrid

HTM700

SAE standard dry Clutch,operated by solenoidvalve, to connect anddisconnect internalcombustion engine

Split power drivewith SAE B pto


Workingscheme

BATTERYCHARGER

SENSORS

DIESEL ENGINE

HM560with Cardan Shaft

SAE standard dry Clutch,operated by solenoidvalve, to connect and

disconnect internalcombustion engine

Split power drivewith SAE B pto


Forward-Reverse Powershiftmarine gear

Cardan shaft

Electric selectorwith integratedSoft-Shift ability



LiPo/LiFePO4 BATTERY COMPLETE WITH

BATTERYMANAGEMENT SYSTEM DISPLAY

ELECTRIC BOX

FREQUENCYDRIVE

ELECTRICMACHINE CONTROL LEVER:

- THROTTLE- F/N/R- ELECTRIC/DIESEL- BOOSTER- REGENERATION

HYBRID MODULE WITHINTEGRATED MULTIDISC

DRY CLUTCH

MPCB-R5

DIESEL ENGINE

AIR POWER PACK

LEGENDPOWER WIRE

CAN WIRE

In close cooperation with leading battery andmotorcontroller manufacturers the HM Moduleseries(560-2000-3350-6300) was developed toprovide a standard, simple, quality solution.Designed to “sandwich” between an engine witha SAE flywheel and housing and transmissionwith a SAE input, the HM module provides aseamless solution that is easier to apply andsimpler to operate than any application specificsolution. Additionally, the electric machine (themotor generator) can be mounted in multiplepositions in order to provide the best fit for theengine compartment. To install, all that isrequired is a short distance between the engineand transmission, this make it an ideal solutionfor retrofits and new designs.

Transfluid also provides two packages thatcouple the HM technology with their power shifttransmissions and marine products. TheHTV700 is a complete vehicle transmissionproduct utilizing a power shift transmission,4wddrop box and brake. Designed to beexceptionally compact it is ideal forgroundsupport equipment and small mining andconstruction machines. The HTM700 is a hybridmarine transmission. The electric function isbecoming mandatory in many ports where theyare trying to mitigate the air and water pollutioncaused by tendering and docking vessels. TheHTV700 is applicable for engines up to 95 kW(127 hp) while the HTM700 is capable of 140kW(187 hp). Both Packages are equipped with acome home feature.

The hybrid series

Technical specifications

288,1

667

702

305

821

458

1185,5

690

1284 (SAE1/0)1231 (SAE 0/0)

830 (SAE 1/0)777 (SAE 0/0)

476

718,5

398,5

284,5809,3

620

1006

686

343868

658

1098777

389

1008

772

HM560 Hybrid ModuleSAE 4 to SAE 4 distance = 305 mmMax N° of Electric Machine: 1Max Tot Elec. Input Power:20kW @ 3000rpm



HM6300 Hybrid ModuleSAE 1 to SAE 0 distance = 830 mmSAE 0 to SAE 0 distance = 777 mmMax N° of Electric Machine: 4Max Tot Elec. Input Power:150kW @ 3000rpm

By dedicating significant resources in theresearch and development of the HybridSystem range of products Transfluid is capableof providing complete hybrid solutions as wellas the technical support required bymanufacturers to implement these products.Transfluid’s Hybrid System easily integratesinto traditional propulsion systems assuringan efficient solution to green power and fueleconomy.All modules fit between the engine andtransmission, occupying limited space, asthough they are an integrated and independentcomponent in the propulsion driveline.

Not only the ecological sustainability is one ofthe advantages of Hybrid solutions but fuelsavings and energy management are of thesame importance. With the “booster” function,designers can consider a lower power engineyet still maintain the desired performances.Ship owners can retrofit their vessels therebyproviding lower costs and profiting fromimmediate benefits.

Transfluid is not just a supplier, but also apartner. By providing innovative technologycoupled with competitive pricing, even themost difficult hybrid problems can be quicklysolved.

E. M

ACH

INE

WEI

GHT

kg (l

b)

MAX

SPE

EDrp

m

E. M

ACH

INE

MO

TOR

MO

DEPo

wer

kW

(hp)

MO

TOR

MO

DEFr

om b

atte

ryA

max

GEN

ERAT

OR

MO

DEPo

wer

kW

(hp)

GEN

ERAT

OR

MO

DE

To b

atte

ry

A m

ax

BATT

ERY

Vdc

MO

TOR

CON

TRO

LLER

HYB

RID

TRAN

SMIS

SIO

N

100100100100300300300

SIZE 8SIZE 20SIZE 20SIZE 20SIZE 75SIZE 75SIZE 75L

3000300030003000300030003000

22 (48)25 (55)42 (92)46 (101)54 (119)70 (154)110 (242)

EM180-8EM180-12EM220-15EM220-20EM220-35EM290-50EM290-75

HM560-HT700HM560-HT700HM560-HT700HM560-HT700HM2000-HM3350-HM6300HM2000-HM3350-HM6300HM2000-HM3350-HM6300

639512016095130195

6 (8)9 (12)11 (15)15 (20)27 (36)38 (51)57 (76)

96140175235134190287

8 (11)12 (16)15 (20)20 (27)35 (47)50 (68)75 (102)

EM180-8EM180-12EM220-15EM220-20EM220-35EM290-50EM290-75

180 (240)-4000435 (580)-3000620 (830)-2200

140 (185)-3000

115 (155)-3000350 (470)-2600500 (670)-2200

95 (125)-3000

560 (414)2000 (1478)3350 (2476)

300 (222)560 (414)

SAE4-10” SAE3-11.5” SAE1-14”

SAE4-10” (4)

SAE4-10” (4)

HM560HM2000HM3350

HTV700HTM700

HYB

RID

TRAN

SMIS

SION

INPU

T &

OU

TPU

TSt

anda

rd (1

)SA

E J6

17 &

J62

0

MAX

INPU

T TO

RQU

E N

m (l

b-ft

)

INPU

T PO

WER

IN

DUST

RIAL

kW

(hp)

-rpm

INPU

T PO

WER

M

ARIN

E kW

(hp)

-rpm

WEI

GHT

kg (l

b)

120 (265)350 (772)560 (1236)

1100(1475)-2100920 (1230)-21006300(4647)SAE1/0-14”/18” HM6300 900 (1986)245(2) (540)221(3) (487)

(1) SAE J620: different Input or Output connections available upon request(2) Without drop box & brake(3) With cooler(4) DIN 120 available

Why Transfluid

BATTERY

ELECTRICMACHINE

SPLIT POWERDRIVE

CLUTCH

I.C.ENGINE

START

STOPEMERGEMERGSAFG

MPCB-R5 & Display Harness

PRESSURE TRANSDUCER

CABLING

MPCB - R5

CONNECTORS PROXIMITIES SWITCH

rpmINPUT

rpmOUTPUT

ON/OFFCUSTOMER

DIESELELECTRIC

BATTERY

SELECTOR BOOSTER RIGENERATION

fromDISPLAY

CAN BUS

or or

LiPo/LiFePO4 BATTERY

COMPLETE WITH BATTERY MANAGEMENT

SYSTEM

DISPLAY

SOLENOID VALVECONNECTORSSLIDING OPENING

THROTTLEPEDAL

GEAR SELECTOR

MOTOR CONTROLLER

CONTROLS:THROTTLEENGINEFWD/REV/N

+Vdc Key

-Vdc Batt.

+ vdc

SUPPLY PRIMARY

BATTERY

ELECTRICMACHINE

ELECTRICMACHINE

MARINE BOX

GEAR BOX

SPLIT POWERDRIVE

SPLIT POWERDRIVE

CLUTCH

I.C.ENGINEELECTRIC MODE ELECTRIC MODE

BOOSTER MODE BOOSTER MODE

ENGINE MODE ENGINE MODE

EPS Industrial

The EPS (ELECTRIC PROPULSION SYSTEM) provides innovative electric propulsion through the combination of standard Transfluid products. Integrating standard components and adhering to SAE standards produces a new product which easily interfaces with any user and application.When used with commercial vehicles, the EPS system includes an automatic “Powershift” RANGERMATIC or REVERMATIC transmission. For marine propulsion the REVERMATIC marine gear uses the reliable RBD coupling.Both transmissions can be installed with Transfluid’s permanent magnets electric motor. This improves the operations of the vehicle or boat by using the efficiency and performance of the electrical machine.

Electric motor that operated through frequency drive

Spin-on oil filter

Torqueconverter

The innovative concept of EPS consists of an automatic RANGERMATIC “Powershift” transmission coupled to a permanent magnet electric motor. This optimizes the driving experience of the vehicle and enhances the performance of the motor. The RANGERMATIC reduction ratios allow the user to select the optimal ratio according to the operating conditions. The addition of the DROP BOX DP280 on the output of the EPS system provides additional gear ratios to enhance the electric motor performances. Additionally, the drop box is available with two outputs for four-wheel drive applications. This provides identical use and driving of the EPS system to those of a combustion engine.The use of batteries, indispensable for the supply of the electric machines, allows the recovery of kinetic energy during deceleration and braking (Kinetic Energy Recovery System) storing energy that would otherwise be lost, increasing the autonomy of the vehicle.

EPS industrial system

Electric PropulsionSystem

EPS MarineElectric motor that operated through frequency drive

Spin-on oil filter

Elasticcouplings

Three speed forward, onespeed reverse Powershift

Transmission


Oil-water cooler


Forward-Reverse Powershiftmarine gear

Axial thrust assembly

The innovative concept of the marine EPS REVERMATIC11-700 RBD marine gear coupled to the electric motor allows you to maximize the maneuverability of the boat and to increase the performance of the electric motor. The reduction ratio of the marine gear allows the user to size the propeller of the boat to demand the maximum power delivered by the electric motor, fully exploiting the motor power and speed. The reverse function is performed by the REVERMATIC11-700 RBD marine gear. This protects the electrical components from transient current peaks.In addition, the EPS Marine system can be used as an extra drive system on large power engines by connecting the output of the EPS system to the PTO (commonly called PTI in marine transmission).To optimize the performance of the motor a DROP BOX DP280 can be mounted on the output of the

EPS marine system

SIZE

MO

TOR

Out

put m

echa

nica

lpo

wer

kW

(hp)

3000

rpm

MO

TOR

curr

ent

DC B

US

side

GEN

ERAT

ION

curr

ent

DC B

US

side

Nom

inal

torq

ueN

m (l

b-ft

)

(att

erie

s)Vd

c

GEN

ERAT

OR

Out

put e

lect

ricpo

wer

kW

3000

rpm

DC B

US

B.E.

M.F

Vrm

s +/

- 10%

MO

TOR

Nom

inal

cur

rent

Arm

s

MO

TOR

20

35

50

75

20 (27)

35 (48)

50 (68)

75 (102)

63 (47)

110 (81)

160 (118)

238 (176)

15

27

38

57

65

220

220

220

210

110

150

220

96

300

300

300

235

134

190

287

160

95

130

195

EPS system, before to PTI, to provide additional gear ratios optimizing the motor torque output.An example:By using a compact EPS system weighting only 220 kg, powered at 300 V dc, it is possible to obtain on the PTI a torque of 2750 Nm, a very interesting value for the propulsion of large boats.

EPS-I35 including: • E-machine EM290-35 • Frequency drive TYPE 75 powered at 300 V dc • MPCB-5R Management system w/display and software • Electronic control system for single engine • Powershift transmission REVERMATIC and RANGERMATIC

EPS-I50 including: • E-machine EM290-50 • Frequency drive TYPE 75 powered at 300 V dc • MPCB-5R Management system w/display and software • Electronic control system for single engine • Powershift transmission REVERMATIC and RANGERMATIC

EPS-I75 including: • E-machine EM290-75 • Frequency drive TYPE 75L powered at 300 V dc • MPCB-5R Management system w/display and software • Electronic control system for single engine • Powershift transmission REVERMATIC and RANGERMATIC

Ratio available for powershift REVERMATIC or RANGERMATIC: • Single speed 11-700 ratio: 0.86 or 1.04 or 1.45 or 1,88 or 2,25 and

• Three speed 31-700 ratio 0.865 - 1.882 - 2.75 and 1,882 reverse gear

Electric traction system integrated withREVERMATIC 11-700 or RANGERMATIC 31-700 or 21-700 or 22-700

reverse gear

EPS-M35 including: • E-machine EM290-35 • Frequency drive TYPE 75 powered at 300 V dc • MPCB-5R Management system w/display and software • Electronic control system for single engine • Marine gear REVERMATIC or RANGERMATIC

EPS-M50 including: • E-machine EM290-50 • Frequency drive TYPE 75 powered at 300 V dc • MPCB-5R Management system w/display and software • Electronic control system for single engine • Marine gear REVERMATIC or RANGERMATIC

EPS-M75 including: • E-machine EM290-75 • Frequency drive TYPE 75L powered at 300 V dc • MPCB-5R Management system w/display and software • Electronic control system for single engine • Marine gear REVERMATIC or RANGERMATIC

Ratio available for powershift REVERMATIC or RANGERMATIC: • Single speed model 11-700 ratio: 1.45 or 1.88 or 2.25 + reverse gear • Double speed model 31-700 ratio 1.88 and 2.75 + 1,88 reverse gear

Marine electric propulsion system integrated with single speed marine gear REVERMATIC 11.700RBD or two speed marine gear RANGERMATIC 21-700 RBD.

EPSData Collection

Reference catalogs of the products we use in hybrid & electric technology

ITALYTRANSFLUID S.p.A.Via Guido Rossa, 4

21013 Gallarate (VA)Ph. +39.0331.28421

Fax [email protected]

CHINATRANSFLUID BEIJING TRADE CO.LTD

101300 BeijingPh. +86.1060442301-2Fax [email protected]

FRANCETRANSFLUID FRANCE s.a.r.l.

38110 RochetoirinPh. +33.9.75635310Fax [email protected]

GERMANYTRANSFLUID GERMANY GmbH

D-48529 NordhornPh. +49.5921.7288808Fax [email protected]

RUSSIATRANSFLUID OOO143100 Moscow

Ph. +7.495.7782042Mob. [email protected]

U.S.A.TRANSFLUID LLCAuburn, GA 30011

Ph. +1.770.8221.777Fax +1.770.8221.774

[email protected]

December 2016

www.transfluid.euwww.buy-transfluid.com

Remote monitoring - Fast serviceSafe - Reliable - Timely

Annual subscription for remote monitoring and service of Hybrid or Electric System

Gift box with emergency spares kitDelivery of spares sparts to the nearest service center within 72 hoursAdvance notice for maintenanceOnline monitoring

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hybrid & electric technology - transfluid · lipo/lifepo4 battery complete with battery...

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