Volvo's new plug-in XC90 is really a tri-motor

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Unusually for an OEM, Volvo Cars is being a bit modest about its new XC90
plug-in hybrid, describing it as the T8 Twin Engine. But technically the 2016
PHEV is, in aerospace parlance, a tri-motor, having a 2.0-L gasoline engine, an
electric motor, and a starter-generator.
We could say triple," admitted Lars Lagstrm, the vehicle's Project Leader and
Product Manager, "because we have a 34-kw motor between the engine and
main electric motor. But we have sufficient power without mentioning that!
In fact the extra 34 kW (45 hp) is used to help fill torque gaps and smooth
shift changes when the IC engine is engaged, and to give an extra boost when
required.
The new hybrid, part of the XC90 model plan from its inception and based on
its Scalable Product Architecture (SPA), arrives eight months after the
conventional models entered production. Volvo decided that time would be well
spent maturing the plug-in cars software to provide those ultra-smooth shifts.

The hybrid was conceived at a difficult time for Volvo, explained Lagstrm: It
was in 2008 and we knew we were no longer wanted by Ford [which owned
Volvo at the time] and we had to create our own future. We needed to be
independent. We had our own engine plant and we did not want to pay any
licensing fees or be part of a collaborative project with another producer.
The company became part of Geely Group in 2010 but Volvo has retained a
high degree of independence within the Chinese OEM, further broadening its
engineering expertise and application.
Seven drive modes
The hybrid T8 called for a wholly new electrical system, which was a challenge,
said Lagstrm. We knew what we needed but not how it was to be achieved
there were so many standards to consider and of course, we were looking to
the future, he said. The electrics were essentially an in-house development
with specialist input from both Siemens and LG Chem.
Key decisions for the PHEV included developing an energy dense 2.0-L 4
cylinder engine (all XC90s now have 2.0-L units) driving the front wheels
through an Aisin 8-speed auto gearbox and an Electrical Rear Axle Drive
(ERAD), which comprises the electric motor, single-speed gearbox, clutch,
differential and driveshafts.
Deciding not to use an off-the-shelf electric motor, Volvo engineers chose
Siemens to design the T8s 64-kW (86-hp) unit. It provides regenerative
braking capability to help add power to the cars 400-V battery, supplied by LG
Chem. The battery is tucked into the spine of the car, between the front seats
rearwards, in what would be for a conventional vehicle the prop shaft.
Plug-in recharging via a 16-A fast charge cable can be achieved in 2.5 h; using
a domestic plug takes between 3.5 h at 10A, or six hours at 6A.
Extracting maximum power from the ICE resulted in a supercharged and
turbocharged solution with a target output of 210 kW (281 hp). This was
upped by a further 26 kW (35 hp) during development. Total twin engine
output is 299 kW (401 hp) but that little starter generator boosts this to a
somewhat theoretical 333 kW (446 hp). The engine, with claimed peak torque
of 400 Nm (295 lbft), was developed in-house and is manufactured at Volvo's
Skvde plant.
The new 4-cylinder range is 30 to 90 kg lighter (66 to 199 lb) than predecessor
units. Friction losses have been minimized, including use of roller-bearing
camshafts, and Lagstrm is particularly proud that crankshafts of the 2.0-L
engines can be turned by hand; quite a feature.
The engine gives the XC90 hybrid a very rapid performance of 0-100 km/h
(0-62 mph) in a claimed 5.6 s. Vmax is 230 km/h (143 mph). Official
combined fuel consumption calculated on the NEDC basis is 2.1 L/100 km for
emissions of 49 g/km. Pure electric range is up to 43 km (27 mi).

The T8 has seven drive modes: Pure, Hybrid, Power, Save, AWD, Off-road, and
Individual. Pure mode uses electric as much as possible at speeds up to 125
km/h (78 mph). Hybrid is the default mode. The car can operate in front-,
rear- or all-wheel drive.
The challenge has been achieving the smoothness needed when switching
from pure electric into ICE, stated Lagstrm. Occupants should not sense
engagement of disengagement of the systema claim that the author
confirmed during a test drive. Added Lagstrm: Our test program was as
thorough for the Twin Engine as it is for all our models but with a much wider
scope.
GKN Automotive has launched what it describes as "the world's first
disconnecting eAxle on a premium SUV" for the T8. The eAxle is tucked into a
263 x 310 x 293-mm (10.3 x 12.2 x 11.5-in) package weighing 15 kg (33 lb).
GKN engineers noted that the design simplifies integration into global PHEV
vehicle platforms.
Volvos V60 PHEV, which preceded the XC90, uses a diesel engine but Volvo
decided the SUV T8 needed a gasoline ICE to meet the needs of global
markets, notably the U.S. and China.
The PHEV mass burden
Volvos electrification program is to strengthen further, said Lagstrm. In 2019
we plan to have a pure electric model based on the SPA platform that will have
a range of 500 km, he said. The SPA took four years to develop and is
described by Volvo as a cornerstone of its ongoing $11 billion product
development plan.
Battery weight remains a problem for all hybrid vehicle producers. The XC90
PHEV is 225 kg (496 lb) heavier than a comparable conventional version of the
car. The battery pack alone weighs 115 kg (253 lb), and associated controls
and electrical system weigh 100 kg (220 lb). According to Lagstrm the new
car has a favorable for handling rear:front bias of 47:53. Weight of the
conventional XC90 was reduced by up to 125 kg (275 lb) compared to the
previous XC90, which helps to offset the PHEV's additional mass.
Hot-formed steel comprises some 40% of the cars total body weight, claimed
by Volvo as representing the highest percentage of this type of alloy used in
the industry.
Lagstrm foresees improvements in electric motor efficiency and power output,
provided higher temperatures can be efficiently controlled. In a related
development, Volvo is working with Microsoft to jointly develop advanced
design technology. Microsoft HoloLens, described by the company as the
worlds first fully untethered holographic computer, could be used by customers
to configure cars in 3D. Holograms are mixed into the physical world. Other
auto applications are also possible.