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VDI-Wissensforum GmbH - DRITEV – Drivetrain for Vehicles 2021

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VDI-Wissensforum GmbH (ed.)

DRITEV – Drivetrain for Vehicles 2021

Series: VDI-Berichte

Volume 2381 2021

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S. Hönicke, K.-F. Wittwer, J. Liebold High-voltage composite test bench for component testing of battery-electric vehicles S. 395-398

„… „Road-to-Rig-Strategie“ bezeichnet. High-voltage composite test bench for component testing of battery-electric …” „… vehicles High-voltage component test of battery electric vehicles? Only in a system context! Sven Hönicke …” „… high-voltage compound test bench that allows all relevant components to be tested before they are integrated …”

D. Morgenweck, M. Großmann, W. Fakler, M. Lamke, F. Bitzer ZF E-Mobility Software Functions for Commercial Vehicles S. 703-718

„… distribution of all high voltage components and the EV-Gearbox controls the transmission. All components are …” „… software and controlled HV components. VDI-Berichte Nr. 2381, 2021 713 to the vehicle’s high voltage …” „… schematic overview of the vehicle. The positions of the aforementioned high voltage components are marked …”

N. Mueller Electrification of heavy commercial vehicles from the perspective of a bodybuilder S. 555-560

„… available system voltage does not match the supply of the existing electrical or electronic components. A …” „… power requirements for rotating the drum while driving is 15 - 20 kW. Much higher power is required …” „… motor powered by a DC source such as a battery. This setup of the aforementioned components creates a …”

B. Krüger, G. Filomeno, D. Dennin, P. Tenberge Holistic Design of All-Wheel Drive Electric Powertrains Using a Multi-Objective Optimization Algorithm S. 377-394

„… . In this investigation, the voltage level and the component temperature are assumed to be constant …” „… optimization parameters related to the EM are the nominal power, the voltage level, the nominal speed and the …” „… BEVs towards maximum performance, performance reproducibility, high energy efficiency and low …”

A. Bagh, D. Magnor, J. Kneiber, F. Löhe eTransport – Application of axle-integrated e-drive in urban LCV and MD trucks S. 637-652

„… high-voltage battery from direct to alternating current by power electronics on the one hand and driving a …” „… wheel of Tmax = 3,290 Nm. The system voltage amounts to UDC = 400 V and two high voltage batteries …” „… characterized by compact design, high power density, improved manoeuvrability as well as payload neutral …”

R. Kockisch, J. Müller, Erik Schneider Modular transmission systems for future BEV platform applications S. 11-22

„… be promoted and allow spending higher component costs therefore. In our case, this will be possible …” „… are required to cover an entire vehicle fleet with a minimum of system components. 1. INTRODUCTION …” „… powertrain configuration for a certain vehicle fleet with high modularity and VDI-Berichte Nr. 2381, 2021 11 …”

J. Shutty, A. Moser, D. Gajowski Analysis of propulsion system architectures across vehicle segments and markets S. 23-34

„… impacts the total drive cycle energy by 0.5%. For high voltage SiC based PE, this effect is even smaller …” „… these larger categories are multiple configuration options. These include voltage level (48V, 400V …” „… (eMotors, thermal systems, power electronics, battery systems, control systems, engine components …”

K. Hirano E-Axle with multi driving modes for BEV & Mild HEV P4 – The 3 in 1 e-Axle for EV requiring a wide range of driving force S. 229-240

„… conducted. Expansion to commercial vehicles and sports cars requiring higher output under high voltage …” „… consumption and high driving performance at the same time, together with an improvement of vehicle …” „… possible. In other words, a package design with lower power consumption, higher driving performance, and …”

T. Kaufhold, F. Schneider, O. Groneberg, A. Moser Modular Starting and Damping System integrated in 48V Hybrid Architectures – Efficient Starting System for Hybrid Vehicle Architectures S. 347-360

„… in comparison to High-Voltage (HV) applications, [1]. In addition, the pure electric driving range …” „… and high-voltage hybrid systems, in combination with a PES are discussed. 1.1. ICE Starting …” „… comfortable start High efficiency and low mechanical losses 1.2. PES Introduction The permanently …”

C. Schörghuber, M. Ortner, J. Pell, S. Pretsch Holistic system design and operation of a fuel cell truck based on an innovative energy management S. 685-700

„… cooling system. All systems have to operate together in an optimal way which is controlled on high level …” „… by the energy management. Due to the special properties of the components and the limited …” „… addition to the zero emission target, the powertrain must be operated with highest efficiencies. Important …”

C. Schmidt, H. Dhejne, J. Karlsson High Efficient 2 speed e-Axle – Highly efficient and shiftable under load S. 145-158

„… a state of the art SiC inverter. The system voltage of the e-drive is 800V. The higher voltage is …” „… High Efficient 2 speed e-Axle Highly efficient and shiftable under load Christian Schmidt …” „… , Sweden ABSTRACT: The vehicle architectures for SUV and LD-BEV’s come with higher performance …”

P. Geskes, J. Treier, M. Moser MAHLE 48V Battery for Truck applications S. 581-592

„… wise advantages in comparison to high-voltage applications. Their lower voltage, however, means that …” „… the expected currents are extremely high. MAHLE provides a modular 48-volt mild hybrid drive system …” „… system or can be fed back to the powertrain under high loads. Braking energy can be stored temporarily …”

D. Lechleitner, M. Hofstetter, M. Hirz, C. Gsenger, K. Huber Parking Lock Integration for Electric Axle Drives by Multi-Objective Design Optimization S. 303-318

„… ) c) d) VDI-Berichte Nr. 2381, 2021 305 and thus impose high loads on the mechanical components (e.g …” „… velocities and while driving downhill, VDI-Berichte Nr. 2381, 2021 303 leading to high loads on the e-drive …” „… components. These loads depend on the mounting position of the parking lock and have to be considered in the …”

G. Gao, D. Schöneberger, S. Rinderknecht Development of an innovative and modular test bench to analyse gear shifts in electrified powertrains S. 415-436

„… powertrains Design approach, realization and use cases of the component test bench Guanlin Gao, M.Sc …” „… . In addition to the model-based development and optimization of powertrains or its components …” „… bench components and sensors, as well as the control of the unit under test. In addition, the test …”

S. Kaimer Power to the Wheels – Challenges and Benefits of Electrified AWD for EVs and Hybrid vehicles S. 117-124

„… . High voltage ‘mid’ and ‘high’ axle drives will improve dynamics and CO2 reduction further, the high …” „… components. In addition to lower costs for the OEM, this approach allows for offering end customer-specific …” „… voltage ‘TV’ drive allowing for active torque vectoring between the rear wheels. In principle, there …”

J. De Landtsheere TREMEC HYbrid DRive Axle – HYDRA – Hybridization enables RWD dynamics in a FWD car S. 125-144

„… towards a performance-oriented application. The high voltage e-machine is a permanent magnet, radial flux …” „… leading manufacturer in the North American market for manual transmissions for high performance passenger …” „… high performance DCT’s in recent years, with applications in C8 Corvette, Ford Mustang GT500 and …”

Titelei/Inhaltsverzeichnis S. I-XVI

„… Testing High-voltage composite test bench for component testing of battery-electric vehicles …” „… components for hybrids and e-drives Simulation and AI-supported design in development Plenary speeches …” „… conventional and electrifi ed drives Latest test methods for the validation of components Expectations of the …”

G. Brudeli, B. Vestgård, S. Bjørkgård, L. Bjørkhaug Sustainable drivetrain architecture for hybrid and electric trucks S. 567-580

„… up from: base chassis which is same for all 3 variants, the driveline and the high voltage battery …” „… Investment and operating cost for various drivelines Base chassis (no driveline) Driveline High voltage battery Total cost/km VDI-Berichte Nr. 2381 …” „… still at high cost. The BGM modular hybrid aims at making a scalable, affordable, and fuelefficient …”

F. Langhammer, A. Kappes, A. Viehmann, S. Rinderknecht Novel “Two-Drive-Transmission for Long-Range” Powertrain: Ecology and Efficiency meet Driving Comfort S. 207-228

„… high voltage applications, the power of the drive units and also the number of totally available …” „… require large battery capacities of more than 70 kWh. These high capacities have a high energy …” „… requirement in production phase and, due to their large mass, lead to a higher electrical energy consumption …”

W. Sackl Sustainable Powertrain Solutions – the new role of the powertrain at Magna S. 1-10

„… systems for 48V and High Voltage applications. These 3 blue building blocks are the core elements of …” „… are reduced. Main functions are increasingly tied to high level software and controls – following …” „… and individualized. This means electric powertrains will need to have a high level of hardware …”

S. Idler, C. Bünder Scaling the functionality of a DCT-based DHD to segmentspecific requirements – The new high torque DHD Plus S. 241-254

„… (HDT) 7HDT300/400 and ends up at high voltage hybrid powertrains with a dedicated hybrid drive (DHD …” „… dualclutch transmissions as well as 48V and high-voltage variants: this family approach allows for a smart …” „… Scaling the functionality of a DCT-based DHD to segmentspecific requirements The new high torque …”

doi.org/10.51202/9783181023815

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OPE Journal

Browse Volumes: OPE Journal

OPE Volume 12 (2022) Issue 40 ISSN Online: 2366-8040

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Peter Andersson Ersman, Jessica Åhlin, Kathrin Freitag, Marie Nilsson, Ulrika Boda, Robert Brooke, Valerio Beni, Mats Sandberg Versatility of screen printed electrochromic displays on flexible susbstrates S. 12-14

„… thickness, are an additional advantage of electrolyte-based components.A convenient material Poly(3,4 …” „… aiding simplified manufacturing processes for a variety of printed electronic components and systems with …” „… components, to create a functional system, often increases the number of layers and materi-als that need to …”

doi.org/10.51202/2366-8040-2022-40

VDI Wissensforum GmbH - ELIV-MarketPlace 2022

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VDI Wissensforum GmbH (ed.)

ELIV-MarketPlace 2022

Series: VDI-Berichte

Volume 2405 2022

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A. Berger An Advanced High-Efficiency Inverter with High Switching Frequencies to Improve Powertrain Efficiency and Performance S. 85-98

„… )• Aging of the componentsDevelopment of unique in-house feedback sensorsLower computational burdenHigh …” „… overshoot protects devices, reduces ringing significantly, go to higher voltage with 1200V devices (i.e …” „… An Advanced High-Efficiency Inverter with High Switching Frequencies to Improve Powertrain …”

S. Suo Future of Electrified Powertrain in the era of Software Defined Vehicles and Service Oriented Architecture S. 79-84

„… applicationsTo achieve the benefits, EV Power system requires consolidation of high voltage power electronics …” „… Computer Unit (CCU)Vehicle Level Power & Energy Management Controls SW ComponentsEV Power Transfer …” „… Component/ECUs in Electrified Powertrain systemBMS: Battery Management SystemInverter: E-Drive Traction …”

Manuel Gärtner, Nadia Lecci New STi2GaNTM technology for ultra-fast switching automotive applications S. 121-132

„… loop stray inductancecauses higher voltage spikes and limits switching speedLower switching lossesLower …” „… 123Gallium Nitride (GaN) technology 3GaN vs Silicon:• Higher critical electrical field• Higher …” „… • Higher power density• Higher operating frequency• Enabling system miniaturizationSTi2GaN Solutions enable …”

M. Raimann New GaN based DC-DC converter concept for future fuel cell and charging applications S. 331-338

„… Raimann, ZF Friedrichshafen AG, Friedrichshafen Abstract High voltage to high voltage (HV-HV) DC-DC …” „… passenger cars high power density requirements and low cost are a major driver for innovation. For …” „… commercial vehicles higher efficiency of the converter enables lower total cost of ownership (TCO) in typical …”

Florian Pampel, M. Stapelbroek, I. Hazanavicius Tailored battery systems for entry level up to high performance applications Challenges in battery development S. 99-108

„… the highest package efficiency.Source: FEVVehicle integrationComponentChassis + battery …” „… Tailored battery systems for entry level up to high performance applicationsChallenges in battery …” „… meet the high safety requirements for use in partially or fully automated vehicles. Battery systems …”

doi.org/10.51202/9783181024058

VDI Wissensform GmbH - Drivetrain Solutions for Commercial Vehicles

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VDI Wissensform GmbH (ed.)

Drivetrain Solutions for Commercial Vehicles

Series: VDI-Berichte

Volume 2421 2023

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T. Jonsson, S. Balaji, G. Sivaraman, V. Ravindran, J. Engström Effects of PWM on losses and comparison of calculation approaches S. 47-58

„… distorted modulated voltage due to switching, contains within itself higher-order time harmonics in addition …” „… voltage input contributes to higher losses in comparison to sinusoidal input. The harmonic content in the …” „… voltage drives harmonic currents and associated fluxes in the electric machine, leading to higher losses …”

L. Vassieux, A Diop Valeo hybrid solutions for Commercial Vehicle – 48V and HV hybrid solution S. 93-108

„… . This presentation is focused on two optimized architectures for hybrid trucks: 48V and High Voltage …” „… consequence, to increase the drivetrain efficiency. In addition, the High Voltage solution allows zero …” „… the coasting phase (Eco-Roll). The second level is the High Voltage P2.5 & P3 (Figure 2) concept with …”

G. Wiche Voith Central Drive Concept for HD Trucks S. 181-190

„… , Voith has developed a high-voltage drive system in a modular approach tailored to the drivability of HD …” „… comprises three main components: the high-speed EVO motor, the Future Inverter Platform (FIP), and the …” „… purpose vehicle platform. The main components of the developed powertrain are 1) a four-speed AMT with …”

M. Eisele, M. Kohler Modular Electric Driveline Platform for Commercial Vehicles – Central Drives and Electric Axles Built up From Standardized and Scalable Components S. 37-46

„… Built up From Standardized and Scalable Components Markus Eisele, Markus Kohler, ZF Group …” „… the electric axle. They are more suitable for standard truck applications with high volumes, where a …” „… applications matrix, where the effort for e-axle integration might be too high. VDI-Berichte Nr. 2421, 202338 …”

M. Trahand Drivetrain architectures and vehicle integration: The evolution and advantages of in-wheel propulsion for heavy-duty commercial vehicles S. 123-134

„… to maintain high-voltage systems. In North America, many fleets also feature refrigerated trailers …” „… compact, is managing the higher risks of over-heating motors and the complexity of managing high voltage …” „… innovations in development include in-wheel motors for assets and routes with high energy demand, along with …”

H. Heimes, A. Kampker, M. Kehrer, S. Hagedorn, P. Euchner Packaging concepts for fuel cell commercial vehicles – From practical to application-oriented designs S. 13-28

„… , and its powertrain are shown. Fig. 3: The eActros and its powertrain [5] The high voltage battery …” „… M.Sc., Chair of Production Engineering of E-Mobility Components (PEM) of RWTH Aachen Zusammenfassung …” „… components, known as "Packaging." Initially, manufacturers used "Conversion Design" to leverage existing …”

doi.org/10.51202/9783181024218

VDI Wissensforum GmbH - Dritev – Drivetrain For Vehicles 2019

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VDI Wissensforum GmbH (ed.)

Dritev – Drivetrain For Vehicles 2019

Series: VDI-Berichte

Volume 2354 2019

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M. Bahne, A. Wiesebrock Flexible oil management for dual-clutch transmissions S. I-447-I-454

„… even more obvious: Within one vehicle platform, the whole range from 48-V to high voltage hybrid drives …” „… component-specific data. Today´s prediction model accuracy is quite precise, because there is comprehensive …” „… approach ensures safety margins for use cases like regular trailer operation, high heat, humidity …”

J. Grabowski, A. Colognese 48V to 12V Converters for xEV Applications – Managing the headaches of dual voltage automotive architectures S. II-45-II-54

„… produce the power required for the many hybrid features, a higher voltage battery system is required. The …” „… 48V battery provides the higher power required while still maintaining a safe-to-handle voltage …” „… withstanding high transient voltages (up to 60V in some cases). In order to address the problem, three …”

B. Müller, C. Angrick, M. Fritz New concepts for electrical drive trains for high power density S. II-55-II-66

„… high-voltage drives with regards to the installation space and electric output. Fig. 6: Example of a …” „… high-voltage technology), it has been shown that a targeted approach is able to cover a very broad application …” „… New concepts for electrical drive trains for high power density Bruno Müller, Carsten Angrick …”

M. Elshaer, C. Chen Wide-Band-Gap (WBG) power semiconductor switches for automotive HV battery chargers – Opportunities & challenges S. II-1-II-14

„… effect transistor (MOSFET) has been a key component in high voltage and high frequency switching power …” „… . Tihanyi, and H. Weber, “A new generation of high voltage MOSFETs breaks the limit line of silicon,” in …” „… technology for high voltage power MOSFETs,” in Proc. 12th Int. Symp. Power Semiconductor Device ICs, 2000 …”

M. Kruse, H. Decker, Sebastian Eulert Optimisation of electric motor acoustics of a hybrid dual clutch gearbox using virtual methods S. II-111-II-124

„… acoustic functions in the inverter, which apart from torque-forming voltage components of the inverter …” „… AG Group Components, Kassel Zusammenfassung Das von der Audi AG und Volkswagen AG Komponente …” „… Components, has been used since 2018 in the A6 and Q5 model series from Audi. In addition to the demands on …”

H. Schäfer System impacts to the electrical drive by using SIC-power semiconductors S. II-15-II-28

„… advantages like, higher reverse voltages, higher switching frequencies, lower switching – and conducting …” „… SIC-module is much lower. But the voltage drop related to the nominal current is higher. Besides the lower …” „… switching losses the high board thermal capacity of the SIC-components is also a further advantages …”

M. Stulrajter, M. Pacha Challenges of sensorless high-speed drives with PM motors S. II-29-II-44

„… signal is applied on the high-side switches and back-EMF voltage has to be sampled during the PWM …” „… Challenges of sensorless high-speed drives with PM motors Ing. Marek Stulrajter, Ph.D, Ing …” „… high speed area, and to introduce tips and tricks how to extend the speed operating range. 1 …”

P. Lück, K. Bennewitz, J. Tousen Volkswagen’s electric drivetrains of the new modular e-drive kit (MEB) S. I-515-I-530

„… with a flat high-voltage battery built into the floor, the electric drive with power inverter and …” „… systematically intermeshed. The high-voltage battery, a high-performance lithium-ion system, is located into the …” „… maximum rotational speed of 16,000 rpm. The PSM is a system component with a high power density and high …”

A. Kinigadner, T. Biermann Schaeffler eAxle family – future solutions for the electric drivetrain S. I-567-II-VIII

„… a look at high-voltage electric machines here. In addition to the different types of asynchronous …” „… aufweisen. Abstract Electrified cars are expected to reach high quantities during the current decade …” „… system-oriented approach. Future system concepts have a high degree of mechanical, electrical, and electronic …”

A. Alkan Human/machine readable language representation method in HEV drivetrain testing S. II-125-II-140

„… tested by HEV system test: High Voltage Drivetrain: Electric Drive includes the motor for hybrid and …” „… supplies both the electric motor as well as the high voltage battery with electricity. [1] Fig. 1 …” „… : High Voltage Drivetrain [1] Power Electronics: includes an inverter and a DC/DC converter. The …”

C. Möser, T. Märkle, K. Hornung Effective acoustic development of electrified powertrains – Combination of simulation and evaluation methods S. I-329-I-348

„… ]. Nevertheless, high-voltage electrification imposes new demands (see first chapter) on the adopted components …” „… high-voltage electrification. Powertrain Acoustics Development, as part of Audi’s Overall Vehicle Development …” „… tronic dual-clutch gearbox featuring a high-voltage electric motor, which Audi uses for plug-in hybrid …”

T. Pullen Integrated eDrive system for various performance classes S. I-287-I-294

„… . While keeping the interface architecture, a high voltage separator module adjusts the connection to …” „… ratio and a high volumetric power density. Due to the smart and optimized GKN design a scalability of …” „… between the electric motor, high-performance electronics and transmission are consistently transferred to …”

K. von Rueden, C. Danzer, J. Liebold, T. Mueller, T. Hirschbeck 1, 2 or 3 – how much it would be? Evaluating the need of multispeed electric drives coming from different perspectives S. I-227-I-254

„… the multispeed drives increase due to the higher number of mechanical components. In the illustrated …” „… individual powertrain components, particularly in hybrid powertrains with high levels of electrification as …” „… complexity of the goals, requirements and boundary conditions are so high that optimization by means of …”

O. Simon, W. Heubner Triple wet clutch module and actuation system, shift cylinders and park lock for modern hybrid transmissions – Architecture and technical description of a triple wet clutch unit and the related active... S. I-471-I-482

„… TWC with CSC, having a connection to an off-line 48 V or high voltage E-motor realized by a gear set …” „… relative to actuation type. The triple clutch module is still connected to a 48V or high voltage E-motor …” „… central power packs, which are generated by their constant high pressure level and leakages in the spool …”

Y. Le Neindre Great Wall Motors’ 2nd generation of Pi4 platform – A high performance PHEV for premium SUV in China S. II-99-II-110

„… Generation) • High voltage Belt Starter Generator, connected to the engine Front End Accessory drive, which …” „… conditions • Add-on of High Voltage PTC (compared to Fuel Heater in previous generation) to enable more …” „… Great Wall Motors’ 2nd Generation of Pi4 Platform A high performance PHEV for Premium SUV in …”

T. Basbous, J. Mortal Electric driveline adaptation from passenger-car application to Light & Medium Truck application – A competitive, efficient, compact and light solution S. III-19-III-28

„… comply with these restrictions, but also commercial vehicles while these have a very high diesel take …” „… electric truck launches, going further towards higher weight categories as seen in Fig. 1. Fig. 1 …” „… high-volume production passenger cars is one way to achieve these cost targets, as opposed to developing …”

P. Janssen, R. Keizer, T. Rosen Optimization of multi-motor electric drive systems – What is the optimum combination in terms of efficiency and cost? S. I-255-I-264

„… used successfully (e.g. by Tesla, Renault). In vehicles in the mid to high-power range also the use of …” „… (Asynchronous Motor) and EESM (Externally Excited Synchronous Motor) are used. In high power and SUV …” „… different components. The measurements were then scaled to the needed levels. The electric motor was scaled …”

M. Özbek, J. Trommer, K. Akiyama, Y. Yamada Nidec next generation electric traction motor S. II-77-II-84

„… for hybrid and electric vehicles. Nidec’s next generation electric traction motor shows a high power …” „… stator slots. This gives a high fill factor of the copper inside the slots as well as low coil ends …” „… round wire windings. Furthermore, the permanent magnet rotor design results in a high efficiency and …”

A. Gehring, M. Beringer, M. Özdemir Overview of stator technologies motors for electro mobility in passcars – The right technology for each application S. II-67-II-76

„… powertrain: From 42V in the beginning of the millennium over high voltage hybrid powertrain without the …” „… stator represents from the cost point of view one of the A- components of an electric traction drive …” „… development of electric motor technologies, amongst others higher efficiency, increased power density and …”

S. Demmerer Efficiency of electric axle drive systems – Potential of multi-speed-drives S. I-279-I-286

„… reduction gearset with a constant ratio. Two-speed transmissions are then in discussion, if higher maximum …” „… speeds and high starting torques should be achieved at the same time. This is often the case for sports …” „… performance demand on the one hand and higher efficiency on the other. E-mobility seams to offer a solution …”

C. Schoerghuber, I. Müller, H. Wiener Dedicated hybrid transmission for commercial vehicle applications – Mechanical layout, system analysis and simulation of a dedicated hybrid transmission for commercial vehicles S. III-29-III-48

„… with overdrive gear ratio (OD-mode) can be selected. If there is a failure within the high voltage …” „… integrated, high-speed e-motors as its drive sources. With the help of a sophisticated but comparatively …” „… simple transmission con- VDI-Berichte Nr. 2354, 2019 29 cept, high efficiencies, low product costs and a …”

A. Viehmann, J.-E. Schleiffer, S. Rinderknecht Evaluation of the dedicated range-extender transmission powertrain concept DE-REX regarding efficiency, costs and complexity – Comparative assessment of electric and hybrid powertrain configurations b... S. I-21-I-48

„… powertrain architecture for BEVs is a combination of one high-power electric motor (EM) with a fixedspeed …” „… gear ratio for high speed operation leads to a reduced launch torque. Therefore, it would be desirable …” „… to choose the gear ratio as high as possible, because then the torque and accordingly the power …”

doi.org/10.51202/9783181023549

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