2015 12 GETRAG Lecture Modular Hybrid Transmission Kit

Modular Hybrid Transmission Kit
for GETRAGs new PowerShift Generation

Uli Christian Blessing, Senior Manager & Chief Engineer Hybrid, GETRAG
GETRAG, 2015, 14th International CTI Symposium December 2015, Berlin
Ready for the CO2-Challenge
Agenda
1.
Motivation
2.
DCT Transmission Family
3.
Hybrid Transmission Kit
4.
48 V Comparison
5.
Plug-In Hybrid Solutions
6.
Conclusion and Summary
14th International CTI Symposium Germany 2015, Berlin | Senior Manager & Chief Engineer Hybrid, GETRAG | Uli Christian Blessing
Motivation
CO2 Improvements
High efficient powertrain

Power on demand actuation
Extended sailing functionality
Pure electric driving
Downsized engines
Customer/OEM Needs
Hybrid as must-have option

New driving functionalities
Easy scalability
Easy adaptation
No serviceability
Real world fuel savings
Automated driving
Costs
Transmission kit
Volume of scale
Reduce rare earth materials
Fun 2 Drive
Increased launch performance

Boosting
Immediate reaction
Functionality
Shift-by-Wire
Park-by-Wire
In-a-box solution
Integrated hybridization
Looking for the Swabian CO2-Champion

Situation Today Near Future:
Various concepts (minor to medium volumes)
Various hybrid power levels:
Mild hybrid (48 V with 15 kW) with significant volume demand
Full hybrid (220 V with 50 kW)
Plug-in hybrid (>360 V with 80 kW)
Very high diversity on OEM requirements

High costs (for piece price and development) due to low overall volumes
Target: One hybrid transmission kit, that can cover most of the needs

7DCT300
Input torque up to 320 Nm
7-speed + R with a gear ratio span of up to 8.5
Center distance of 188 mm and 197 mm
Dry weight of 67 kg
6DCT200
Input torque up to 230 Nm
6-speed + R with a gear ratio span of up to 8.0
Center distance of 183 mm
Dry weight of 61 kg
Common Hardware
Wet nested double clutch
TCU mounted to housing
Electronics
Sensors
BLDC motors
Clutch actuation and clutch cooling
Others
Global manufacturing footprint
Common software architecture
Key Features
Torquesplit architecture
Scalable power level:
48V hybrid up to 16 kW
Plug-in hybrid more than 80 kW
E-machine:
Integrated and high-speed
Oil-cooled
Pre-assembled as tested unit
Adjustable cooling flow (using the same electric

cooling pump as the clutch cooling)
Assembly of e-machine and inverter at GETRAG
Hybrid Transmission Kit Overview of Hybrid Functions
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 48 V Mild and Plug-in version
10
Hybrid Transmission Family

7HDT300 - 48V
Based on 7DCT300
E-machine connected to sub-transmission 2
Additional weight of 21 kg
Up to 1800 Nm output torque
6HDT200 48V
Based on 7DCT300
E-machine connected to sub-transmission 2
Additional weight of 22 kg
Up to 1500 Nm output torque
11
7HDT300 Package Comparison of DCT vs HDT

Key Features
No transmission length increase
Minimized overall hybrid package
Same interfaces as DCT
7DCT300
12
7HDT300
7HDT300 Latest Design for 48 V

Shiftdrum 2 motor
E-machine
48 V inverter
Shiftdrum 1 motor
Clutch1/2 actuation motor
13
48 V Comparison
48 V Comparison: Belt vs. Flanged vs. Integrated Solution
Belt Solution
Flanged Solution
Integrated Solution
Key Facts
Key Facts
Key Facts
Air-cooled claw pole EM

Belt-connection to ICE
Integrated inverter
Water-cooled EM
Flanged to transmission
Stand-alone inverter
Oil-cooled EM
Integrated in gearbox
Stand-alone inverter
Remark: For simplicity reasons, only these three main-stream examples

have been chosen
15
Belt Solution
Flanged Solution
Integrated Solution
Max. torque
up to 50 Nm
up to 50 Nm
up to 50 Nm
Max. power
12 - 14 kW
up to 18 kW
up to 18 kW
Cont. power
2,5 - 3,5 kW
up to 8 kW*
up to 13 kW*
up to 85%
up to 94%
up to 95%
NEDC
10 - 12%
17 - 20%
19 - 22%
WLTP
7 - 9%
12 - 14%
14 - 16%
EM-Performance
Efficiency
Fuel Efficiency
*depending on battery performance
16
Belt Solution
Flanged Solution
Integrated Solution
not possible
possible*
possible*
limited
possbile
possbile
Generator
possbile
diff. gears
diff. gears
Drivability
limited improvement
strong improvement
strong improvement
Package
easy
challenging
possible
Efficiency
belt-drive
efficient
very high
Hybrid Modes
El. creep/drive
Boosting
Others
17
Integrated Solution offers much better el. Driving Performance

Continuous Power of Belt vs. Integrated Solution
T in Nm
T in Nm
Integrated Solution
Belt Solution
100
100
Drag torque range of typical

combustion engines
50
50
0
0
2.000
4000
6000
n in rpm
2.000
4000
Remark: The Flanged Solution is close to the Integrated Solution

18
6000
n in rpm
Easy Scalability
Easy Scalability: From 48 V Mild up to 360 V Plug-In Hybrid
48 V System
360 V System
Max. torque
up to 50 Nm
up to 150 Nm
Max. power
up to 21 kW
up to 110 kW
Cont. power
up to 13 kW*
up to 35 kW*
Efficiency
up to 95%
up to 96%
Max. speed
18.000 rpm
18.000 rpm
Max. phase
current
350 A
450 A
EM-Performance
20
Changed stator windings

and power connectors
ensure easy scalability
48 V System
360 V System
El. creep/drive
limited (20 - 30km/h)
possible (>130 km/h)
Boosting/Generator
possible (diff. gears)
possible (diff. gears)
medium
high (battery!)
NEDC
19 - 22%
26 - 80%
WLTP
14 - 16%
19 - 68%
Hybrid Modes
Cost
Fuel Efficiency
21
Summary & Outlook
Modular Hybrid Transmission Kit for DCTs

Summary
23
Hybrid transmission kit established for new DCT transmission family
Easy scalabilty from 48 V up to Plug-In Hybrid
Modular integrated high-speed e-machine
Integrated 48 V system offers best ratio of cost vs. CO2 improvements
Significant fuel efficiency improvements can be achieved
Modular Hybrid Transmission Kit also useable for MTs

Outlook
The same hybrid transmission kit can also be used for MT
Hybrid set-up:
MT gearbox with e-clutch
Integrated high-speed e-machine
Flanged 48 V Inverter
Hybrid functionalities:
Pure el. driving
Boosting, Recuperation
Charging @ Standstill
Restart of the internal combustion engine
Fuel efficiency improvements up to 18%
24

2015 12 GETRAG Lecture Modular Hybrid Transmission Kit

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2015 12 GETRAG Lecture Modular Hybrid Transmission Kit

Uploaded by

Copyright:

Available Formats

Modular Hybrid Transmission Kit

for GETRAGs new PowerShift Generation

Ready for the CO2-Challenge

DCT Transmission Family

Hybrid Transmission Kit

Plug-In Hybrid Solutions

Conclusion and Summary

Ready for the CO2-Challenge

High efficient powertrain

Hybrid as must-have option

Increased launch performance

Ready for the CO2-Challenge

Looking for the Swabian CO2-Champion

Very high diversity on OEM requirements

DCT Transmission Family

Ready for the CO2-Challenge

DCT Transmission Family

Ready for the CO2-Challenge

DCT Transmission Family

Clutch actuation and clutch cooling

Hybrid Transmission Kit

Ready for the CO2-Challenge

Hybrid Transmission Kit

Adjustable cooling flow (using the same electric

Ready for the CO2-Challenge

Hybrid Transmission Kit Overview of Hybrid Functions

Remark: Hybrid modes identical for 48 V Mild and Plug-in version

Ready for the CO2-Challenge

Hybrid Transmission Family

Ready for the CO2-Challenge

7HDT300 Package Comparison of DCT vs HDT

Ready for the CO2-Challenge

7HDT300 Latest Design for 48 V

Clutch1/2 actuation motor

Ready for the CO2-Challenge

48 V Comparison: Belt vs. Flanged vs. Integrated Solution

Air-cooled claw pole EM

Remark: For simplicity reasons, only these three main-stream examples

Ready for the CO2-Challenge

48 V Comparison: Belt vs. Flanged vs. Integrated Solution

*depending on battery performance

Ready for the CO2-Challenge

48 V Comparison: Belt vs. Flanged vs. Integrated Solution

Ready for the CO2-Challenge

Integrated Solution offers much better el. Driving Performance

Drag torque range of typical

Remark: The Flanged Solution is close to the Integrated Solution

Ready for the CO2-Challenge

Easy Scalability: From 48 V Mild up to 360 V Plug-In Hybrid

Changed stator windings

Ready for the CO2-Challenge

48 V Comparison: Belt vs. Flanged vs. Integrated Solution

limited (20 - 30km/h)

possible (>130 km/h)

possible (diff. gears)

possible (diff. gears)

Summary & Outlook

Modular Hybrid Transmission Kit for DCTs

Hybrid transmission kit established for new DCT transmission family

Easy scalabilty from 48 V up to Plug-In Hybrid

Modular integrated high-speed e-machine

Integrated 48 V system offers best ratio of cost vs. CO2 improvements

Significant fuel efficiency improvements can be achieved

Ready for the CO2-Challenge