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 rule-based 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.
Highlights
Fuel consumption reduction is one of the key objectives of today’s vehicle development
The Equivalent Consumption Minimization Strategy (ECMS) approach is the comparison of petrochemical energy from the tank ETank with the electrochemical energy from the battery EBattery with the aim to minimize an equivalent fuel consumption according to: EEquivalent = ETank + (k1 + k2 ⋅ SOC) ⋅ EBattery
A virtual toolchain for the optimal concept and prototype dimensioning of 48 V hybrid drivetrains has been presented
Summary
Fuel consumption reduction is one of the key objectives of today’s vehicle 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]. For higher electric power the current is high what leads to bigger wire cross-sections and has an impact on the costs, weight and installation space It affects the size and the thermal management of the EM as well as the 48 V battery which has to provide the electric power. The result is an optimal—in terms of fuel consumption and performance—48 V hybrid P0+P4 drivetrain with an optimal electric power of the P0 and P4 electric machines, 48V battery capacity and gear ratio for the electric machines in the Worldwide harmonized Light Duty Test Cycle (WLTC). Statements in terms of model differences between the two simulation models are possible
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