48V: How much hybridization is possible with the …

1 48V: How much hybridization is possible with the new vehicle power? 14th International VDI Congress, Friedrichshafen Uli Christian Blessing Chief Engineer Hybrid Agenda Base Transmission Hybrid Transmission V Comparison Hybrid Solutions and Summary 2 Ready for the CO2-Challenge June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing Motivation Ready for the CO2-Challenge June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014.

2 Uli Blessing CO2 IMPROVEMENTS COSTS CUSTOMER/OEM NEEDS FUN 2 DRIVE FUNCTIONALITY 3 Motivation Ready for the CO2-Challenge June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing FUNCTIONALITY shift-by-Wire park-by-Wire in-a-box solution integrated hybridization CO2 IMPROVEMENTS high efficient powertrain power on demand actuation extended sailing functionality pure electric driving downsized engines COSTS transmission kit volume of scale reduce rare earth materials CUSTOMER/OEM NEEDS high efficient hybridization hybrid as must-have option new driving functionalities easy scalability easy adaptation no serviceability real fuel efficiency improvement FUN 2 DRIVE

3 Increased launch performance boosting immediate reaction 4 COSTS Motivation Ready for the CO2-Challenge June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing FUNCTIONALITY shift-by-Wire park-by-Wire in-a-box solution integrated hybridization CO2 IMPROVEMENTS high efficient powertrain power on demand actuation extended sailing functionality pure electric driving downsized engines transmission kit reduce rare earth materials CUSTOMER/OEM NEEDS high efficient hybridization hybrid as must-have option new driving functionalities easy scalability easy adaptation no serviceability real fuel efficiency improvement FUN 2 DRIVE increased launch

4 Performance boosting and immediate reaction 5 Ready for the CO2-Challenge Situation Today - Near Future: Various concepts (minor to medium volumes) Various hybrid power levels: Mild Hybrid (48V with 15 kW) with significant volume demand Full Hybrid (~220V with 50 kW) Plug-In Hybrid (>360V more than 110 kW) Very high diversity on OEM requirements High costs (for piece price and ED+T) due to low overall volumes Rare earth materials should be avoided if possible Increasing CO2 targets with benefits for pure electric driving ( EU / China / US /.)

5 Goal: One Hybrid Transmission kit, that can cover most of the needs Looking for the Swabian CO2-Champion 6 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing Base Transmission 7 DCT300 Ready for the CO2-Challenge Key Facts: Input torque up to 300 Nm 7-speed + R with a gear ratio span of > Wet nested dual clutch with electrical on-demand cooling Electro mechanical gear and electro hydraulic clutch actuation Start/stop and extended sailing functionality Mechanical park lock Options.

6 Park-by-Wire AWD Hybrid 7 DCT300 Base Transmission 8 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing Ready for the CO2-Challenge Carry over of key components TCU with electric actuation for clutch and shift Wet clutch with electrical on-demand cooling Modular Software Architecture 7 DCT300 Transmission Kit for various solutions 9 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing 6 DCT150 6-Speed PowerShift 7 HDT300 7-Speed Hybrid 7 DCT300 7-Speed PowerShift Hybrid Transmission 7 HDT300 Ready for the CO2-Challenge Key Facts: 7 HDT300 based on 7 DCT300 GETRAG torque split concept Carry-over of key components from DCT transmission kit High-speed e-machine One common oil circuit for cooling and lubrication Electrical park lock system (w/o add.)

7 Actuator) Integrated e-machine with different power levels mild hybrid (48 V, 21 kW) plug-in hybrid (up to > 360 V; >110 kW) 7 HDT300 Hybrid Transmission 11 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing Ready for the CO2-Challenge Additional Components for Hybrid E-machine (as tested-unit) Intermediate gear set Connectors for EM Bidirectional cooling flow pump (using same electric cooling pump as clutch cooling) Assembly of e-machine and inverter at GETRAG 7 HDT300 Hybrid Transmission 12 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing Ready for the CO2-Challenge Hybrid Modes: Pure electric driving Extended sailing Recuperation Boosting Generator-mode / load-shift Charge@standstill Restart of internal combustion engine with Torquesplit effect Remark.

8 Hybrid modes identical for 48V and Plug-In version 7 HDT300 Hybrid Transmission 13 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing Ready for the CO2-Challenge Overall Optimization: More compact package Less material and amount of parts 7 HDT300 Consequent Evolution 14 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing 2013 2014 Higher overall efficiency Same power and torque levels Ready for the CO2-Challenge 7 HDT300 Latest Design for 48V (Integrated Solution)

9 15 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing differential c/o DCT TCU c/o DCT Transmission mount Inverter cooling water Inverter 48V Bat. Connection Inverter CAN & 12V 48V Comparison 17 Ready for the CO2-Challenge June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing Key Facts: Air-cooled claw pole EM Belt-connection to ICE Integrated inverter Key Facts: Oil-cooled EM Integrated in gearbox Stand-alone inverter Key Facts: Water-cooled EM Flanged to transmission Stand-alone inverter 48V Comparison: Belt vs.

10 Flanged vs. Integrated Solution Belt Solution Integrated Solution Flanged Solution Remark: For simplicity reasons, only these three main-stream examples have been chosen Ready for the CO2-Challenge 48V Comparison: Belt vs. Flanged vs. Integrated Solution 18 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing EM-Performance Max. torque Max. power Cont. power Efficiency Fuel Efficiency NEDC WLTP Belt Solution Integrated Solution Flanged Solution up to 50 Nm up to 21 kW up to 13 kW * up to 95 % 10 12 % 7 9 % 19 22 % 14 16 % up to 50 Nm 12 14 kW 2,5 3,5 kW up to 85 % up to 50 Nm up to 18 kW up to 8 kW * up to 94 % 17 20 % 12 14 % * depending on battery performance Ready for the CO2-Challenge 19 June 25, 2014 GETRAG, 14th International VDI Congress, Drivetrain for Vehicles, Friedrichshafen June 2014, Uli Blessing Hybrid Modes El.