Optimal and prototype dimensioning of 48V P0+P4 hybrid drivetrains
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ORIGINAL PAPER
Optimal and prototype dimensioning of 48V P0+P4 hybrid drivetrains Matthias Werra1 · Axel Sturm1 · Ferit Küçükay1 Received: 27 November 2019 / Accepted: 3 September 2020 © The Author(s) 2020
Abstract This paper presents a virtual toolchain for the optimal concept and prototype dimensioning of 48 V hybrid drivetrains. First, this toolchain is used to dimension the drivetrain components for a 48 V P0+P4 hybrid which combines an electric machine in the belt drive of the internal combustion engine and a second electric machine at the rear axle. On an optimal concept level, the power and gear ratios of the electric components in the 48 V system are defined for the best fuel consumption and performance. In the second step, the optimal P0+P4 drivetrain is simulated with a prototype model using a realistic rulebased operating strategy to determine realistic behavior in legal cycles and customer operation. The optimal variant shows a fuel consumption reduction in the Worldwide harmonized Light Duty Test Cycle of 13.6 % compared to a conventional vehicle whereas the prototype simulation shows a relatively higher savings potential of 14.8 %. In the prototype simulation for customer operation, the 48 V hybrid drivetrain reduces the fuel consumption by up to 24.6 % in urban areas due to a high amount of launching and braking events. Extra-urban and highway areas show fuel reductions up to 11.6 % and 4.2 %, respectively due to higher vehicle speed and power requirements. The presented virtual toolchain can be used to combine optimal concept dimensioning with close to reality behaviour simulations to maximise realistic statements and minimize time effort. Keywords Virtual development methods · Hybrid drivetrains · 48 V · Fuel consumption · Mobility
1 Introduction Fuel consumption reduction is one of the key objectives of today’s vehicle development. In this regard, the drivetrain electrification is one of the most important development. A broad field emerges between low voltage concepts with 48 V and high voltage battery electric vehicles with voltages up to 800 V. At this point, 48 V electrification offers an optimal compromise between low costs in combination with very high savings potential [1]. Low costs are achieved by avoiding great technical effort for high voltage safety precautions [2, 3]. Compared to the 12 V power supply, the 48 V level allows higher electric power of the electric machine (EM) and battery. * Matthias Werra m.werra@tu‑braunschweig.de Axel Sturm a.sturm@tu‑braunschweig.de Ferit Küçükay iffzg@tu‑braunschweig.de 1
Institute of Automotive Engineering, TU Braunschweig, Hans‑Sommer‑Str. 4, 38106 Brunswick, Germany
State-of-the-art 48 V hybrid systems are capable of all hybrid functionalities, e.g. recuperation, electric driving and coasting while engine is off. This ultimately increases the overall system efficiency and accordingly reduces fuel consumption. With the 48 V power supply a reasonable electric power of up to 30 kW can be realised [4–6]. Even higher power is possible but i
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