From customer requirements to the optimal hybrid powertrain: High-performance hybrid transmission for future plug-in hybrid drives

摘要

This paper describes a way to right-size powertrain components (battery, e-motor(s), ICE, transmission) to fulfil today's customer requirements in a best possible way by using special IAV's tools for advanced development. Furthermore a new powerful hybrid concept will be derived which enables high performance vehicles with good driving performance and low fuel consumption. To define a suitable powertrain solution for future vehicles IAV uses an advanced development process which makes intensive use of systematic computer-aided development tools. The tool chain starts with the "Powertrain synthesis" which determines the initial boundaries for the following development steps. Further specialized tools like "Transmission synthesis" and "E-motor synthesis" find the right solutions which fulfil these requirements in a best possible way. The result of this investigation is a powertrain concept that bases on a gasoline engine combined with an electric motor which is connected to a 4-speed planetary automatic transmission. A first 3D-design of the transmission shows that it is possible to pack the electric motor and also the whole gear set into a housing of around 360 mm length. The target B-segment vehicle may accelerate in around 4 seconds from 0 to 100 kph and consume 4.0 l/100 km gasoline in the NEDC without using energy which was stored in the battery before the start of the drive cycle (charge-sustaining mode).