p2 on and off-axis efficient hybrid concepts
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2019-05-09
P2 On and Off-axis
Efficient Hybrid Concepts
Tim Olsson
© BorgWarner Inc. 2
eDM Architectures – P2
© BorgWarner Inc. 3
P2 On-axis
© BorgWarner Inc. 4
P2 On-axis Hybrid Module
Torsional
Vibration
Damper
Engine
disconnect
clutch
Housing
Traction
Motor
Clutch
Control
Module
Integrated launch clutch
(Optional)
Position
Sensor
High Voltage
Connector
© BorgWarner Inc. 5
Optimized integration of Dual
Clutch and Disconnect Clutch with
standard pressure actuation
Ø2
70
mm
Ø1
82
mm
138,4 mm
ICE Transmission
BW On-Axis P2 Triple Clutch - Standard Pressure
© BorgWarner Inc. 6
Cooling Concept
ICE Transmission
Design Example
C1, C2 cooling
C0 and Rotor cooling
Stator cooling
Stator Cooling
Optimized water jacket & sleeve
design for better heat extraction
Rotor Cooling
Oil fed through rotor carrier hub to
inner housing K0 and guided
directly to rotor lamination
Oil flow splits beneath rotor and is
guided towards the two ends of
the rotor
Exiting Oil flung off onto stator
end-turns for additional stator
cooling
Stator
Rotor
BW On-Axis P2 Triple Clutch - High Pressure
© BorgWarner Inc. 10
Electric Motor Overview
On-axis
High Voltage (350V)
SW270 (45 and 60mm, HEV and PHEV)
Low Voltage (48V)
Feasibility study on 48V SW270 in progress
Overview
Key Characteristics
270 mm OD stator with rectangular wire (Large rotor ID enables integrated clutches, etc.)
S-wind stator for minimum axial length and maximum continuous performance
Distributed-wound stator and skewed rotor to minimize NVH and torque ripple
95% Peak EfficiencySW270
© BorgWarner Inc. 12
What is an S-wind stator?
© BorgWarner Inc. 13
Why an S-wind stator?
© BorgWarner Inc. 16
HV SW270-45 Performance Curve325Vdc
© BorgWarner Inc. 21
BW On-Axis P2 Activities
P2 On-axis production launched for
Friction Packages
Disconnect Clutches
Hydraulic Disconnect Clutch Actuation
Controls
Numerous Series Programs for P2 Modules
BorgWarner P2 Car Demonstrator
Buick Regal AWD – Q4 2019
© BorgWarner Inc. 22
P2 Off-axis
© BorgWarner Inc. 23
EM
Gearb
ox
AC
ICE
Chain and Sprockets
Housing
K0, Wet Friction
Clutch & Actuator
K1, Transmission
Clutch
Damper & Absorber
MGi
40T
P2 Off-axis Conceptual Layout
© BorgWarner Inc. 24
P2 Off-axis General Layout
MGi 48V
EM 400V
AC
Compressor
Pressure
Sensor
Piston Unit and DMFGen VI Actuator Pump
AC Compressor
© BorgWarner Inc. 25
Damper/clutch
Axial lenght efficient
Default closed clutch nested inside DMF
Minimum axial installation space required
Torque up to 600Nm
Restricted by allowed axial force on crankshaft
Optional CPA
Speed up to 7000rpm
• Sprocket size depending on requested ratio
Ø 3
08
mm
55mm
© BorgWarner Inc. 26
Chain Drive
Primary chain for E-motor
Optional secondary chain for AC
No tensioner on primary chain to minimize losses. Pre-tensioned by pivot fixation of EM
Chains designed for vehicle life, no need for additional tensioning
Gravity fed lubrication – no pump
Oil thrown into reservoir – fed back to chain(s) and clutch
© BorgWarner Inc. 28
P2 Off-axis Drive ModesICE D C0 C1
T
EM ACCool Welcome
ICE D C0 C1
T
EM ACElectrical Driving
ICE D C0 C1
T
EM ACEngine Start
ICE D C0 C1
T
EM ACElectric Boost
ICE D C0 C1
T
EM ACRecuperation
ICE D C0 C1
T
EM ACCoasting
D = Dual Mass Flywheel T = Transmission Cx = Clutch
= BorgWarner P2 Off-axis content
= Power (electric, combustion or regeneration)
ICE D C0 C1
T
EM ACICE mode
ICE D C0 C1
T
EM ACRolling start
ICE D C0 C1
T
EM ACCharge mode
© BorgWarner Inc. 29
0
50
100
150
200
250
300
350
400
0 1000 2000 3000 4000 5000 6000 7000
Torq
ue
[N
m]
ICE Speed [rpm]
Vehicle Torque
TotalTorque 48V EMTorque ICE
Benefits
Performance and Drive-ability
Electric Boost
Electric Sailing
Electric Launch
Rapid and Silent S/S
48V and HV Modularity
Cool Welcome
Efficiency
Braking energy recovery
CO2 reduction
AC drive energy recovery
CO2 reduction
Assists downsizing and down speeding
CO2 reduction
Assists emissions control
NOx and Soot
Engine-off Sailing
CO2 reduction
© BorgWarner Inc. 30
Benefits continued
Cost Offsets
Starter & Alternator replaced
Engine can be downsized
Fits into existing bellhousing space
12.7 / 9.5 mm HYVO rocker chain
Narrower & More power than a belt
All components share the same oil
Spline or Flexplate output
© BorgWarner Inc. 31
Fuel savings
Typical P2 Control Algorithm
0
2
4
6
8
10
12
14
16
18
NEDC Petrol NEDC Diesel WLTC Petrol WLTC Diesel
Fuel savingsPercentage
Small
Large
SUV
© BorgWarner Inc. 32
0%
5%
10%
15%
20%
25%
Cautious Balanced Agressive
Fuel savings vs tuning and powerPercentage
Induction Machine
MGI 15kW
MGI 20kW
Fuel savings, cont.
0
2
4
6
8
10
12
14
16
18
NEDC Petrol NEDC Diesel WLTC Petrol WLTC Diesel
Fuel savingsPercentage
Small
Large
SUV
© BorgWarner Inc. 33
-30
-20
-10
0
10
20
30
40
50
60
70
0 20 40 60 80 100 120 140
Po
we
r [k
W]
Velocity [km/h]
EM power [kW]ICE power [kW]
Propulsion Energy – WLTC12V Baseline
© BorgWarner Inc. 34
-30
-20
-10
0
10
20
30
40
50
60
70
0 20 40 60 80 100 120 140
Po
we
r [k
W]
Velocity [km/h]
EM power [kW]ICE power [kW]
Propulsion Energy – WLTC15kW P2 Off-Axis
EV mode
“Free” energy
© BorgWarner Inc. 36
System comparisons
© BorgWarner Inc. 40
MGi - Electric Machine Design
PMSM – 38EH
High Volume Bar winding
WEG Jacket Cooling
Integrated Inverter
600A Peak Current
Magnets are glued into the rotor slots
Stator OD 130mm
Active Length 55-90mm
Optimized for P2 position
220 mm
55-90 mm
1
30
mm
© BorgWarner Inc. 43
MGi - 50/65/80 Nm - P2
0
5
10
15
20
25
30
35
0
10
20
30
40
50
60
70
80
90
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
Po
wer
(kW
)
To
rqu
e (
Nm
)
RPM
BorgWarner Modular Torque MGiw/o inverter - 48V
>6000rpm, torque same for all
variants due to power limitation
© BorgWarner Inc. 48
16%Less emissions
Driving what’s next
Boost TorqueElectric DriveCO2 Savings
16%Less emissions
© BorgWarner Inc. 49
Thank you!
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