HyperHybrid- High efficient and low cost serial hybrid system for passenger vehicles

Starting point / motivation

Based on the EU standard EC443/2009 the European automotive manufacturer are forced to fulfill new standards for the emission of passenger vehicles. This standard defines an overall fleet CO² emission value of 130g/km for 2015 and 95g/km for 2020 and a penalty fee is defined for the OEM´s (Original Equipment Manufacturer) if the defined values will be exceeded.

This forces the OEM´s to investigate and research on new and alternative power train technologies because the optimization potential on common combustion power train systems is not high enough to fulfill the standard targets. So the hybrid system seems to be one of the most sufficient system to reach these emission targets. For this new technology different hybrid systems from micro hybrid to full hybrid and parallel to serial hybrid systems are available and under investigation.

To be successful with the future hybrid system it has to fulfill the emission targets and additionally the system has to be cost competitive (or on slightly higher cost) and the system reliability has to be comparable with common state of the art power train systems.

Contents and goals

The innovative focus is on the optimization of the power train system and its components regarding:

• efficiency
• performance
• size (packaging)
• noise and costs
• innovative and trend setting hybrid control strategies and vehicle dynamics

Methods

Based on the compact components the described hybrid system (HyperHybrid) shall be able to be packaged in the existing engine compartment of common vehicles without vehicle design adaptations. Based on the application and performance optimized design of the components and system we are able to build up the system within the same weight and cost range of an existing diesel engine (with gear box).

The HyperHybrid system will be primarily powered by a 8kW Li-Io battery. The battery will be mainly charged by the grid as a “Plug-In” system. If the battery will be discharged during operation the power supply will be ensured by an application specific developed high efficient combustion engine with integrated generator (development funded by FFG base program) called HICE (High Efficient Internal Combustion Engine).

Based on the drive load independent HICE operation of a serial hybrid system a partial load operation of the combustion engine can be prevented which results in a high efficient operation of the engine with a specific fuel consumption in the range of 220g/kWh. The driving power will be supplied by an electric motor with integrated transmission and mechanical differential.

Results and Conclusions 

Based on the innovative hybrid control strategy the system shall be able to operate within a range of 50km with fully electric drive at a speed range up to 60-80km/h. Above this focused speed range the system will be powered by the high efficient HICE. Target of the project is:

• the construction of a test vehicle with comparable overall weight (to benchmark vehicle)
• a better driving dynamic (acceleration 0-100km/h) 
• a full electric range of nearly 50km 
• an overall range comparable with the benchmark system (vehicle with diesel engine)
• dramatically reduced fuel consumption (up to 30%) especially in the range of a vehicle velocity below 100km/h 

Furthermore we will develop an efficient simulation tool which shall enable us to simulate the Hyperhybrid system for various vehicles to determine values like: 

• vehicle dynamic
• fuel consumption 
• thermal management values 

Besides the tools shall be the baseline tool for the development, optimization and verification of our efficient hybrid controller strategy.

• Ing. Martin Graz - Obrist Powertrain (Projektleitung)
• Dr. Anton Fuchs - Kompetenzzentrum - Das virtuelle Fahrzeug, Forschungsgesellschaft mbH
• Dr. Stephan Schmidt - Forschungsgesellschaft für Verbrennungskraftmaschinen und Thermodynamik mbH

Obrist Powertrain
Ing. Martin Graz
Tel.: +43 (5577) 62370-2
E-mail: office@obrist.at