P2 On and Off-axis Efficient Hybrid Concepts

2019-05-09

P2 On and Off-axis

Efficient Hybrid Concepts

Tim Olsson

© BorgWarner Inc. 2

eDM Architectures – P2


P2 On-axis


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


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


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


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


What is an S-wind stator?


Why an S-wind stator?


HV SW270-45 Performance Curve325Vdc


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


P2 Off-axis


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


P2 Off-axis General Layout

MGi 48V

EM 400V

AC

Compressor

Pressure

Sensor

Piston Unit and DMFGen VI Actuator Pump

AC Compressor


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


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


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


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


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


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


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


-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


-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


System comparisons


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


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


16%Less emissions

Driving what’s next

Boost TorqueElectric DriveCO2 Savings

16%Less emissions


Thank you!

P2 On and Off-axis Efficient Hybrid Concepts

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