Highly Efficient All-wheel Drive for Cars of Tomorrow
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Highly Efficient All-wheel Drive for Cars of Tomorrow Compared to single-axle-driven vehicles, all-wheel-drive vehicles offer better traction and greater driving safety. This applies in particular to on-demand all-wheel drive technology, which was previously reserved for premium models and is now increasingly being used in lower-priced passenger cars. GKN and RWTH Aachen University have developed an all-wheel drive for significant CO2 savings as well as a 48-V hybrid module. The usual extra fuel consumption of an AWD system is reduced to one third with the highly efficient all-wheel drive components.
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AUTHORS
Dipl.-Ing. Sven Herber is Program Manager Advanced Engineering ePowertrain at GKN Driveline International GmbH in Lohmar (Germany).
Dipl.-Ing. Theo Gassmann is Director Advanced Engineering at GKN Driveline International GmbH in Lohmar (Germany).
Dipl.-Ing. Jan Haupt is Manager Advanced Engineering ePowertrain at GKN Driveline International GmbH in Lohmar (Germany).
Dipl.-Ing. Christoph Chatenay is Program Manager Advanced Driveline Concepts at GKN Driveline International GmbH in Lohmar (Germany).
INFLUENCE ON THE CO 2 FLEET BALANCE
Today’s All-wheel Drives (AWDs) cause additional fuel consumption compared to single-axle passenger cars, which puts a burden on the CO2 fleet balance. This consumption disadvantage can be significantly reduced by temporarily switching off AWD components that are not required, although this involves a certain amount of additional design work [1]. The development of highly efficient CO2-reducing future technologies is ATZ worldwide 10|2020
being funded by the German Federal Ministry of Economics and Energy (BMWi) [2]. For this reason, the aim of the here presented and also BMWi funded project AWD2020 [3] was the realization of a highly efficient all-wheel drivetrain for the compact SUV vehicle class with a transversely mounted combustion engine, which is cost-neutral in comparison to systems that are commonly used today. In order to be able to demonstrate further optimization potential in the future, it should also be possible to add a 48-V hybrid module to the power-
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C OVER STORY El ectric Mobilit y
FIGURE 1 Sectional view of the PTU (left) and RDU (right) (© GKN)
train. In this case, a vehicle equipped with such a module offers the user additional functions such as electric boosting, electric crawling, parking, electrically assisted sailing and thus further reduction of energy consumption. The benchmark for this project was a modern all-wheel drivetrain of the latest generation with a corresponding installation space. The two project partners GKN and the Institute of Electrical Machines (IEM) of the RWTH Aachen University developed the hardware and software components presented in this article, which were finally integrated into the all-wheel drivetrain shown in the title figure.
FIGURE 2 Proportional PTU drag losses (© GKN)
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DESIGN OF THE DRIVETRAIN
As a classic “on-demand” AWD, the highly efficient powertrain has a Power Transfer Unit (PTU
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