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DCEA Hybrid Eng Challenges Han

The document discusses engineering challenges for a 2-mode hybrid powertrain system. It provides an overview of the 2-mode hybrid motivation to offer full hybrids across multiple vehicle classes without compromising drive quality or fuel economy. It then describes the mechanics of the 2-mode system, including its planetary gears, clutches, motor specifications, and advantages over other hybrid systems. Finally, it discusses control challenges for the 2-mode system related to fuel economy optimization, control architecture, electro-hydraulic control, thermal protection, and hardware-in-loop validation.

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Ed Han
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100 views10 pages

DCEA Hybrid Eng Challenges Han

The document discusses engineering challenges for a 2-mode hybrid powertrain system. It provides an overview of the 2-mode hybrid motivation to offer full hybrids across multiple vehicle classes without compromising drive quality or fuel economy. It then describes the mechanics of the 2-mode system, including its planetary gears, clutches, motor specifications, and advantages over other hybrid systems. Finally, it discusses control challenges for the 2-mode system related to fuel economy optimization, control architecture, electro-hydraulic control, thermal protection, and hardware-in-loop validation.

Uploaded by

Ed Han
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Hybrid Powertrain

Engineering Challenges
2-Mode Explored

Ed Han
Manager – Controls Development, Val, & RLM
GM Hybrid Powertrain Engineering
Hybrid Powertrain Engineering Challenges
Agenda - Exploring 2-Mode Hybrid System
– “No Compromise” Hybrid Motivation
– 2-Mode Mechanics
• Stick & Lever Diagram
• Powerflow advantages
– Challenge of 2-Mode Controls
• Fuel Economy Walkup
• Control Architecture
• Electro-hydraulic Control
• Thermal Protection
• Hardware-in-Loop & Torque Security Validation
– Critical Skills for Hybrid Controls
• SAE Career Fair (April 14-16)
Motivation for the 2-Mode Hybrid

– Achieve superior drive quality of Powersplit


Hybrids but present the customer with no
compromises:
• Offer a choice of vehicle classes for Full Hybrids
– Package and Drive Trucks, Crossover SUVs, Sports Sedans

– Improve Fuel Consumption in the Real World


• Highway / Suburban Commute
– Increase Continuous Duty for Towing
– Increase Speed Range for High Speed Cruise
GM 2-Mode Advantage
– Length ~ 700mm (Fits 6L70E envelope)
– Wet Weight – 167 Kg (368 lbs)
– Torque – V8 Compatible
– 3 Planetary Gears/4 Clutches
• 4 Gears: 3.692/1.705/1/0.738
• EVT M1: 1.705 to infinite
• EVT M2: 0.738 to 1.705
– Traction Voltage Interconnects
– MG1/MG2: 60/60 kW Motors
• Towing > 6000 lbs

• RX400H:
– MG1/MG2/MGR: 109/123/50 kW Motors
• Towing 3500 lbs
2ML70 Stick Diagram

C4 C12R

C234
C13
Lever Analogues for Several Types of EVTs
A E
– Input Split
B
Engine
A E
– Output Split

A E Engine B

– Compound
Split
Engine A “Generator”

B B “Motor”
2ML70 Lever Diagram
86:44 86:44
Motor
C12
“A” 105:39

1.95 1.95

2.95 C234
Main Final
Shaft Drive
1.0

Engine
C13

3.82
2.82

C4
Motor
“B”
2 Mode Reduces Electric Power and
Fixed Gears Add Parallel Hybrid Functionality

City
Electric Power (relative to engine)

Highway
100%
Typical transmission ratio range
80%

60%
Output Split Input Split
40%

20%

0%
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
-20%
Compound Split
-40%

-60%
Fixed Gears Available
-80%
EVT Example
-100%
Overall Transmission Ratio (input speed/output speed)
FE Improvement Analysis

Vehicle Load, Mass, and Accessory Power Reduction

Engine Technology (LIVC, DOD)

Enable Electric Only Operation at Low Power

Enable Electric Launch

Enable Regenerative Braking

Opportunity Charging

Turn Engine Off During Decel

Turn Engine Off at Idle

Improved Accessory Power Generating Efficiency

Enable 2-mode

Hybridization of Accessory Power

Added Mass of Hybridization

Base Vehicle

20 25 30 35 40
City Label Fuel Economy (miles per gallon)

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