International VDI-Congress 2013 Friedrichshafen Dipl.-Ing.

ipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG GmbH & Cie KG
7HDT300 - How much electrical power does the
combustion engine need?
International VDI-Congress 2013 - Friedrichshafen
Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 2
Agenda
Motivation
Base Transmission 7DCT300
- key facts
- improvements
Hybrid Transmission 7HDT300
- key facts
- hybrid configuration
- e-machine cooling
- 48 V System
- 360 V Plug-In hybrid
Summary
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group
Motivation
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 4
Market Requirements
CO
2
IMPROVEMENTS
CUSTOMER/OEM NEEDS
FUNCTIONALITY
FUN 2 DRIVE
COSTS
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 5
Market Requirements
CUSTOMER/OEM NEEDS
FUNCTIONALITY
FUN 2 DRIVE
COSTS
CO
2
IMPROVEMENTS
high efficient transmission
high efficient e-machine
power on demand actuation
extended sailing functionality
pure electric driving
downsized engines
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 6
Market Requirements
CUSTOMER/OEM NEEDS
FUNCTIONALITY
COSTS
CO
2
IMPROVEMENTS
high efficient transmission
high efficient e-machine
power on demand actuation
extended sailing functionality
pure electric driving
downsized engines
FUN 2 DRIVE
increased launch performance
increased input speed
boosting
immediate reaction
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 7
Market Requirements
FUNCTIONALITY
COSTS
CO
2
IMPROVEMENTS
high efficient transmission
high efficient e-machine
power on demand actuation
extended sailing functionality
pure electric driving
downsized engines
FUN 2 DRIVE
increased launch performance
increased input speed
boosting
immediate reaction
CUSTOMER/OEM NEEDS
high efficient hybridization
hybrid as must-have option
new driving functionalities
easy scalability
easy adaptation
no serviceability
real fuel efficiency improvement
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 8
Market Requirements
FUNCTIONALITY
CO
2
IMPROVEMENTS
high efficient transmission
high efficient e-machine
power on demand actuation
extended sailing functionality
pure electric driving
downsized engines
FUN 2 DRIVE
increased launch performance
increased input speed
boosting
immediate reaction
CUSTOMER/OEM NEEDS
high efficient hybridization
hybrid as must-have option
new driving functionalities
easy scalability
easy adaptation
no serviceability
real fuel efficiency improvement
COSTS
transmission kit
volume of scale
reduce rare earth materials
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 9
Market Requirements
CO
2
IMPROVEMENTS
high efficient transmission
high efficient e-machine
power on demand actuation
extended sailing functionality
pure electric driving
downsized engines
CUSTOMER/OEM NEEDS
high efficient hybridization
hybrid as must-have option
new driving functionalities
easy scalability
easy adaptation
no serviceability
real fuel efficiency improvement
FUNCTIONALITY
shift-by-Wire
park-by-Wire
in-a-box solution
integrated hybridization
FUN 2 DRIVE
increased launch performance
increased input speed
boosting
immediate reaction
COSTS
transmission kit
volume of scale
reduce rare earth materials
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group
Base Transmission 7DCT300
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 11
Base Transmission 7DCT300
Key Features
input torque 300 Nm
dry weight 65 kg (w/o DMF)
7-speed + R with a gear ratio span of > 8.5
wet nested dual clutch with electrical on-demand cooling
electro mechanical gear actuation and electro hydraulic clutch actuation
start/stop functionality and extended sailing functionaltiy (no add. HW)
control unit (TCU) mounted to housing
mechanical park lock
Optional Features
HEV (Mild- to Plug-In)
AWD
integrated park-by-wire
integrated transmission cooling
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 12
Key Improvements of 7DCT300 compared to 6DCT250
improved launch performance:
- clutch primary inertia reduction of up to 70% dedicated for downsized
turbo charged engines
- thermal capacity increase by 300%
- higher input speed 7.000 rpm 7.500 rpm
higher fuel economy Overall improvement of up to 4% in NEDC
- gear ratio span 7.2 > 8.5
- low viscosity oil
- power-on-demand actuation
weight improvement: 72 kg 65 kg
global footprint
improved driveability:
- higher torque control accuracy of wet double clutch
NEXT Generation Benchmark Transmission
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group
Hybrid Transmission 7HDT300
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 14
Hybrid Transmission 7HDT300
Key Features
gearset
- 7HDT300 based on 7DCT300
- torque range, up to 300 Nm
- adaptable EM-ratio (rotor shaft to crank shaft)
one oil circuit for cooling and lubrication, fill for life
GETRAG Torque-Split

concept for hybridization

electrical park lock system (w/o add. actuator)
ready for Start/Stop & Hybrid (w/o add. hardware)
integrated e-machine with different
power levels (15 kW up to >110 kW)
- Mild Hybrid (48 V)
- Plug-In Hybrid (up to > 360 V)
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 15
7HDT300 Schematic Overview of Torquesplit Hybrid
2,4,6,R
clutch 2
clutch 1
sub transmission 2
sub transmission 1
1,3,5,7
engine
PCU
e-machine
scalable functionality by using different e-machine lengths
Key Modifications
e-machine integration of active parts in transmission housing
e-machine permanently connected to ST2
e-machine using resolver as speed sensor
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 16
7HDT300 Hybrid Features & Modes
General Hybrid Features
enable easy scalability from Mild- to Plug-In Hybrid (from 48 V up to > 360 V)
ensure low additional costs for hybridization including economy of scale
ensure high modularity with base transmission
side-by-side configuration of e-machine enables better vehicle packaging
Hybrid Modes
electric driving
extended sailing
recuperation
boosting
generator-mode / load-Shift
charge@standstill
restart of internal combustion engine with Torque-Split

effect
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 17
7DCT300 Hydraulic Overview
internal
cooler
Similar in GETRAG
Similar in Market
Pressure Sensor
Clutch Motor
Gerotor Pump
Wet Clutch
Stand-alone
TCU
Hydraulic Pistons
e-Pump
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 18
7HDT300 Hydraulic Overview
internal plus
optional
external
Similar in GETRAG
Hybrid Extension
Similar in Market
Pressure Sensor
Clutch Motor
Gerotor Pump
Wet Clutch
Stand-alone
TCU
Hydraulic Pistons
Reversing e-Pump
oil cooled
Hybrid EM
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 19
7HDT300 E-Machine Cooling Concept
Cooling Features
modular approach to enable different cooling levels up to 11 kW of
cooling power
optimized to achieve higher e-machine continuous power
Stator Cooling
Jacket
Stator Winding
Head Cooling
Rotor Shaft /
Inner Cooling
Rotor Axial
Surface Cooling
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group
48 V Solution
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 21
7HDT300 48 V Details
2,4,6,R
1,3,5,7
e-machine
engine
48 V Belt Solution
air-cooled claw pole e-machine
connected via belt to crankshaft
integrated power electronics
48 V Integrated Solution
oil-cooled e-machine (ASM/PSM)
integrated in transmission housing
stand alone power electronics
What is the value added ??
2,4,6,R
1,3,5,7
engine e-machine
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 22
7HDT300 48 V Comparison Belt vs. Integrated
Belt Solution Integrated Solution
el. creeping/driving
boosting
generator-mode
efficiency
extended sailing
driveability
costs
serviceability
not possible
limited
possible
medium
no electric accel.
limited improvement
low
average
possible (<20 km/h)
possible
possible (diff. gears)
high
inital electric accel.
add. features
medium
life-time
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 23
7HDT300 48 V Comparison Belt vs. Integrated
Belt Solution Integrated Solution
EM-Performance
max. torque
max. power
cont. power
efficiency
Fuel Efficiency
NEDC
WLTP
50 Nm
12 14 kW
2,5 3,5 kW
up to 85 %
10 12 %
7 9 %
up to 80 Nm
up to 16 kW
up to 8 kW
up to 92 %
19 22 %
14 16 %
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group
360 V Plug-In Hybrid Solution
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 25
7HDT300 Plug-In Hybrid
Key Features
pure el. driving up to more than 130 km/h
high-power density to enable vehicle package
high speed e-machine w/o rare earth eliminates risk of political dependancy
E-Machine Facts
phase current: 420 A 420 A
nominal voltage: 250 V 360 V
max. torque: 165 Nm 165 Nm
max. speed: 18.000 rpm 18.000 rpm
peak power: >80 kW >110 kW
continuous power: >30 kW > 35 kW
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 26
7HDT300 Comparison 48 V vs. Plug-In Hybrid
48 V Hybrid 360 V - Plug-In Hybrid
el. creeping/driving
boosting
generator-mode
costs
Fuel Efficiency
NEDC
WLTP
limited (<20 km/h)
limited
possible (diff. gears)
medium
19 22 %
14 16 %
possible (>130 km/h)
possible
possible (diff. gears)
high
26 80 %
19 68 %
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group
Summary
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group 28
Summary
Base Transmission and Hybridization Kit
base transmission is ready for hybrid w/o any additional actuation
scalable solution enables hybridization from 48 V to 360 V Plug-In hybrid
oil-cooling of e-machine improves continuous power
48 V Solution
integration of e-machine enables higher performance and better driveability
pure el. creeping/driving and extended sailing possible
integration delivers better fuel efficiency than belt version
360 V Plug-In Hybrid
high power e-machine with more than 110 kW guarantees superb el. driving
up to more than 130 km/h
high speed e-machine w/o rare earth eliminates risk of political dependancy
side-by-side configuration enables better vehicle package
International VDI-Congress 2013 Friedrichshafen Dipl.-Ing. Uli Christian Blessing, Chief Engineer Hybrid Transmissions, GETRAG Corporate Group
Thank you for your attention!