AVL 重卡电驱桥技术分享-2024-10-商用车

Heavy-DutyDrivelines

TheAVLHDE-AxleTechnologyShowcase

FelixBAYER

AVLListGmbHPublic

Today’sPresenters

FelixBayer

TechnicalExpertPowertrainSystems

felix.bayer@

+433167872685

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FelixBAYER|AVLTruck&Bus|15Oktober2024

Today’sAgenda

1

2

3

AboutAVL

IntroductionandTargetSetting

SystemDevelopment

4HardwareValidation

5ProductionAdaptions

6Q&A

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AboutAVL

Public

“Wearedrivenbyapassiontoexamine

thescience,mechanicsandphilosophyofmovement.Tohelpcreateaworldthatisclimate-neutralandonethatmakessafe,comfortable,greenmobilityareality

foreveryone.”

HelmutO.List

ChairmanandCEOAVLListGmbH

AVLataGlance

1948

Founded

75+

YearsofExperience

29

Countries

Represented

50+

GlobalTechand

EngineeringCenters

A

12,200

EmployeesWorldwide

68

EngineersandScientists

10%

OfTurnoverInvestedinInhouseR&D

2,200

GrantedPatentsinForce

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Truck&Bus

FocusAreas

ElectricVehiclePropulsion

SW,

Electrics&Electronics

Vehicle

ADAS/AD&Connectivity

Zero-ImpactEmission

NewTech-Center@Steyr

TotalAreaof15.000m2focusedonFlexibilityandMulti-Use

>99%WasteHeatRecovery

H2Storage

2x300kg

6Testbeds

Upto125kNm

Workshopforupto

6vehicles

SecuredPrototypeParking

Office

upto190workplaces

BatteryStorage

Upto5.000kWh

4.000m²Off-road

ProvingGround

ExternalBatteryContainer

HyperCharger

HillTrack

(8%and12%)

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Introductionand

TargetSetting

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Challenges

LegislativetargetswilldemandZEVforallCVs.e-Axlesaredemanded

forcompliancewithregulatorylimitsandpolicyinitiatives

Integratede-Axlescomewithhighinvestmentcosts-Modularityandvehiclesegmentswithhighsalesnumbersarekey

PackagingspaceforbatteriesandH2tanksneedsaholistice-Axle

developmentapproachtoensureacompacte-axlestructure

SpecificOEMneedswillrequire

customizedengineeringsolutions•Fleetstructure

•Timetomarket

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Introduction

AVLIsaOne-StopSolutionProviderfore-AxlesinAllVehicleClasses

2016

AVLR&D-MDeAxle

2020

AVLR&D-Veh.Integr.

2023

HDeAxle-cust.proj.

2019

AVLR&D-HDeAxle

Fullvehicleo

44tovehicleclass

Conceptdevelopment

800Vfullyintegrated

inverter

750V;2xdirectoilcoolede-motors

conversionto

electricpowertrain

2speed-148kWcont.16.000rpme-motor

2speed-360kWcont.9.000rpme-motors

eAxleandVCUintegration

…

Variousfamilyand

topologystudiesMarketstudies

14,5tovehicleclass

6todeliverytruck

1speed-60kWcont.15.000rpme-motor

GenericmodularASWSoftwareapproach

Integrationofoff-the-shelfe-Motorsand

MILproofedASWavailable

Inverters

2020

MDeAxle-cust.proj.

Troubleshooting

2020

eAxleASWdevelopment

2017

LDeAxle-cust.proj.

2016-2024

eAxle-cust.proj.

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Introduction

TargetSetting

MainVehiclePerformanceParameters

Derivedfromrealdrivecycle(4x2Truck)

Requiredcontinuouspower:400kW

20%@peakpower

3%@80kph

max.speed100kph

ConventionalAxlePackaging

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SystemDevelopment

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MultistepWorkflow

ExamplePowertrainSizing

Mechanicaldrivepower

Staticroughdimensioning

accordingkeyrequirements

e.g.:2%grade@80kph

Powersplitfor

batteryand

fuelcell

AVLCruiseM

AVLModelConnect

Dynamicdimensioningaccordingdrivingcycle

e.g.:Graz->WienerNeustadt->Graz

TestbedConnect

Detailed

evaluationof

limitations

Plantmodelgeneration

e.g.:detailedVTMSModel,detailedFCSmodel,batterymodel,ageing,…

Modelenhancement

e.g.:PredictiveEnergyManagement

Optimizationtheavailable

energy

of

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UtilizingPsoforFindingtheRighte-AxleTopology

InputData

Differente-axleswithdifferent

ratiofamilies.Ratiovariation

withineachfamilyconcept.

Differente-motorconcepts

withthreedifferentdiameters

each.Scalingofe-motor

power.

Differentdrivingcycles

(combinationfromEU+US)

withdifferentpayloads.

Powerscalingvariation

PayloadVariation

MDCycles

Em1

Em3

Em2

USCycles

HDCycles

Em4

Em5

Em6

EUCycles

USCycles

Differentmaximumspeed

EUCycles

Differentcornerpoint

Differentouterdiameter

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UtilizingPsoforFindingtheRighte-AxleTopology

Simulationmatrix

HDEU

StandaloneFamilyIIStandalone

…

Axle1

…

…

…

FamilyIIIFamilyI

Em2a

Ratiogear1-x(v1)

Ratiogear1-x(…)

Ratiogear1-x(v10)

Ratiogear1-x(v1)

Ratiogear1-x(…)

Ratiogear1-x(v10)

Ratiogear1-x(v1)

Ratiogear1-x(…)

Ratiogear1-x(v10)

Ratiogear1-x(v1)

Ratiogear1-x(…)

Ratiogear1-x(v10)

Ratiogear1-x(v1)Ratiogear1-x(…)

Em2b

Em2

Explanationofvariations

Eachoftheaxleshasdifferentratiovariations

−Standalone

−FamilyI–familyIII

Eachaxleandratiovariationiscombinedwiththedifferente-motors

−E-motorwithsamepower,butdifferentouterdiameter

Furthermore,eache-motor(withthedifferentouterdiameters)isalsoscaledinpower

Resultingnumberofoverallcalculatedvariants

Drivecycles

E-axle

Topologies

E-motor

types

(average)

E-motor

power

scaling

E-motordiameters

Gearratios

(average)

Gearratiofamilies

Overallvariants

14

5

2

3

3

~10

4

Overall

x

x

x

x

x

x

x

~50000

Pere-axle

x

x

x

x

x

~720

Perapplication

x

x

x

x

x

x

~3600

Explanation

+0%+10%+20%

123mm(a)

456mm(b)

789mm(c)

StandaloneFamilyI

FamilyIIFamilyIII

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UtilizingPsoforFindingtheRighte-AxleTopology

KPIPost-ProcessingviaMatlabApp

Choiceofgearfamily

Choiceofaxle

Choiceofe-motortype

Choiceofdrivecycle

ChoiceofKPIs

Choiceofe-motorChoiceofe-motor

diameterpowerscaling

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AVLHDe-AxleDevelopment

ModularityExample(MDtoHD)

Application

26t/6x2

42t/4x2

65t/6x4&8x4

49t/6x4&8x4

PPT

peakcontmax

360

240

30

kW

kW

kNm

PPT

peakcontmax

540

400

40

kW

kW

kNm

PPT

peakcontmax

540

400

60

kW

kW

kNm

PPT

peakcontmax

810

600

70

kW

kW

kNm

PPT

peakcontmax

270

200

30

kW

kW

kNm

EMA

EMA

EMA

EMB

EMB

EMA

EMA

EMA

EMA

EMA

EMA

HighSpec

LeadVariant

20t/4x2

PeakPower(total)

ContinuousPower(total)Max.torqueatwheels

E-motorA

PpeakPcont

270

200

kWkW

(E-motorB)

Ppeak180kW

Pcont120kW

EMA

EMA

LowSpec

e-axle270

derivedfromAVLHDE-AxleOptional:differenthousingsfordifferentaxleloads

AVLe-axle540oradaptationfor

offroadapplication

540

Optimizede-Axle

Optimizedvariantcanbereplacedbylowspecorhighspecvariant

(dependentonvehiclerequirements)

EMA

Conclusion:WideRangeofapplications

canbecoveredby2(3)e-Axles

EMA

EMA

(e-axle360)

derivedfromAVLHDE-Axle

540

EMB

EMB

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AVLHDe-AxleDevelopment

TechnologyDemonstrator(A-Sample)

Benefits:

HighestEfficiency

*withoutbrakesWeight<1.000kg*

PowershiftFunctionality

Flexible,ScalableandModularArchitecture

E-motors(PSM)

2x270kWpeakpower

2x200kWcontinuouspower

9.000rpmmax.rotationalspeed

Directoilcoolingforhighesttorquedensity

i1-1i1-2

EM1

TMout

EM2

i2-1

LongHaulDriveCycle

=>70%EM2

=highefficiency

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AVLHDe-Axledevelopment

FEASimulations

Strengthandlifetimeofhousings,chassispartsandothere-axlecomponents(e.g.differentialcase,planetarycarrier)

Variousloadcasestoensure

structuralstrengthandlifetime

ofe-axleandchassiscomponents

•Staticloads

•Dynamicloads

•Torqueloads

•Combinedloads

Checkofboltconnections

Checkofflangetightness

InputforNVHandCFDsimulations

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AVLHDe-AxleDevelopment

NVHOptimization

Reductionofstructurebornnoise

Optimizationofgearmicrogeometry(contactpattern)

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AVLHDe-AxleDevelopment

SimulationsforCoolingandLubricationSystem

Lubricationoftransmissioncomponents

Simulationofoildistribution

Validationontestrig

Definedlubricationoilflowstotransmissioncomponentsforhighreliabilityanddurability

Integrationinvehicle

3DCFDunderhoodsimulationofheattransferininstalledcondition

Reliablecoolingsysteminrealworkingconditions

Coolingsystem

Simulationoftemperaturedistribution

Highlyefficientdirectoilcoolingsystemforhighcontinuouse-motorpower

Nooverheatingofoilandcomponentsforhighlifetime&shortmaintenanceintervals

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AVLHDe-AxleDevelopment

ThermalVirtualValidation

ConjugateHeatTransferSimulation

virtual

Lossese-motor

Boundarycondition

Housing(HTC)

Boundarycondition

Boundarycondition

Lossesoftransmission

Boundarycondition

Cooling

Boundarycondition

Thermal3DCFDmodel

OILTEMPERATURE

1Dmodel

Oilsupply

channels

(HTC)

TemperaturedegC

real

lowhigh

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HardwareValidation

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AVLHDe-AxleDevelopment

LubricationTest

•••

•

Oildistributiontest

Pumpperformancetest

Pressurerelivevalveadjustment/functiontest

VF_OIL[dm³/min]T_OIL[°C]

P_OIL[kPa]

21

20

19

18

17

16

15

14

90

80

70

60

50

40

30

20

10

0

340

320

300

280

260

240

220

200

180

160

140

120

100

80

60

40

20

0

Deltapmeasurements

250005000075000100000125000150000175000200000225000

recorder_time[ms]

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AVLHDe-AxleDevelopment

BasicFunctionTest-NoLoad

•Resolveradjustment

•Invertermeasurements

•E-Motormeasurements

•Parametercheck

•SWCheck

•Shiftingfunctioncheck

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AVLHDe-AxleDevelopment

BasicFunctionTest-UnderLoad

•Shiftingbehaviormeasurement

•Resolveradjustment

•Invertermeasurements

•Temperaturebehavior(E-Motor,Inverter,System)

•Runin

•SWadjustments/checks

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AVLHDe-AxleDevelopment

ContactPatternTest

•Atnominaltorque(allgears,pullandcoast)

•Atpeaktorque(allgears,pullandcoast)

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AVLHDe-AxleDevelopment

VehicleIntegrationTests

Batterietests

E-Axletests

E-Motor/Invertertests

Thermal/coolingperformancetests

EMCpre-tests

SWtests

Communicationtests

Faultinjectiontesting

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