1、 Ricardo plc 2016 8th TM Symposium Beijing, PR China April 2016 Tony ONeill Rob Parkinson Tobiasz Jackman Low Cost Transmission Concepts for New Energy Vehicles Ricardo plc 2016 第 8届 变速器专题讨论会 中国北京 2016年 4月 Tony ONeill Rob Parkinson Tobiasz Jackman 新能源汽车 低成本变速器概念 3 Ricardo plc 2016 April 2016 Unclass
2、ified - Public Domain Introduction to Ricardo 4 Ricardo plc 2016 April 2016 Unclassified - Public Domain 里卡多简介 5 Ricardo plc 2016 April 2016 Unclassified - Public Domain Design of a New Energy Vehicle (especially HEV and PHEV) is often constrained by a need to modify an existing, complex and expensi
3、ve automated transmission (AT, DCT or CVT) With sales of such vehicles expected to increase significantly there is an increasing place for the use of DHTs (Dedicated Hybrid Transmissions) which lower BOM cost and enable improved efficiency and functionality from the hybrid system With a focus on low
4、 cost, Ricardo has developed a range of hybridisation concepts based on manual transmission manufacturing and AMT actuation technology The resulting modular, low cost family of transmissions can be used across a range of BEV, REEV, HEV and PHEV vehicles In this presentation we will introduce these c
5、oncepts and explain their potential benefits to New Energy Vehicles Introduction 6 Ricardo plc 2016 April 2016 Unclassified - Public Domain 新能源 汽车 (尤其 是 HEV和 PHEV)的设计往往受限于 需要 对现有复杂 且 昂贵 的 自动变速器 (AT、 DCT或CVT)进 行修改 预计 此类车辆销售额 将 大幅增加 ,DHT(混动 专用变速器 )的用途 将 越来越广泛 ， 它能够降低 BOM成本 ，提 升混动系统 效率和功能 以 低 成本 为 关注 点
6、 ， 里卡多基于手动变速器制造和 AMT的执行机构 技术 ， 开发了一系列混合动力概念 由此 开发的 模块化 、 低成本变速器系列可用于多种 BEV、 REEV、 HEV、 PHEV车辆 在本演示文稿中 ,我们将介绍这些 方案 并解释它们对于新能源汽车的潜在优势 介绍 7 Ricardo plc 2016 April 2016 Unclassified - Public Domain Another DHT designed and developed by Ricardo featured:- Compact DHT using AMT technology Small number of
7、transmission speeds with 2 electrical machines Ricardo responsible for Mechanical design Actuation Software Large number of prototypes Full test programme In production since 2014 Ricardo first developed a DHT in 2000, this featured:- 2 x 32kW electrical machines 6 speed dual clutch transmission wit
8、h dog clutch engagement synchronisation was achieved by control of the electrical machines no reverse gear reverse was achieved with electric motor drive A/C compressor on the transmission and could be driven by the IC engine or by either of the two e-machines later smaller version of the same trans
9、mission developed with 2 x 24kW electrical machines Successful rig and vehicle test programme Ricardo DHT Case Study History Ricardo has a long history in the successful development of DHTs and other transmissions for all kinds of New Energy Vehicles 8 Ricardo plc 2016 April 2016 Unclassified - Publ
10、ic Domain 里卡多设计和开发 的 另一款 DHT， 其功能包括 : 使用 AMT技术的紧凑 DHT 集成 2个电机 和少量档位 里卡多卡负责 机械设计 执行机构 软件 大量 样机 完整测试方案 自 2014年投产 在 2000年 ,里卡多 首次 开发了一款 DHT， 其功能包括 : 2台 32kW电机 6速双离合器变速器 ， 使用滑套换挡 电机 调速 实现同步 无倒档 -倒档通过电机传动实现 空调压缩机位于变速器上 ， 可由内燃机或两个电机之一驱动 后期小型化的产品 采用 2台 24kW电机 成功 完成了台架 和 整车 开发 里卡多 DHT案例研究历史 里卡多在成功开发 DHT和各种类
11、型的 新能源汽车 的 变速器方面 有 着悠久 历史 9 Ricardo plc 2016 April 2016 Unclassified - Public Domain A Hybrid Electric Vehicle (HEV) is a vehicle which uses a combination of power sources, normally a liquid fuelled conventional Internal Combustion Engine (ICE), in conjunction with electrical power. Operating in a b
12、roadly electrical charge sustaining mode, it requires limited electrical storage capacity and is focussed around improving overall liquid fuel efficiency of the vehicle A Plug-in Hybrid Electric Vehicle (PHEV) is a similar configuration, but with significantly more electrical power storage which can
13、 be also be externally refuelled. It operates mainly in an electrical charge depleting manner to minimise liquid fuel consumption What are HEV/PHEVs? What functions do they provide / enable? 10 Ricardo plc 2016 April 2016 Unclassified - Public Domain 混合动力电动汽车 (HEV)是一种使用多种能量来源的车辆 ， 通常是 使用 液体燃料 的 常规内燃
14、机 (ICE)加上电 能 。 可在 多种 的充电续航模式下 运行 ,对电池容量的需求有限 ， 关注改善车辆的整体液体燃油ICE效率 插电式混合动力电动汽车 (PHEV)采用类似 配置 ,但 电池容量 更大 ,也可从外部加注燃料 或充电 。 它主要 以 电能 消耗模式 运行 ， 以 最大程度降低液体燃油的消耗量 什么是 HEV/PHEV？ 它们提供 /实现什么功能 ? 11 Ricardo plc 2016 April 2016 Unclassified - Public Domain (P)HEV powertrain arrangements Hybrid Configurations P1
15、 Motor fixed to engine P2 Motor fixed to transmission input P3 Motor fixed to transmission output P4 Motor fixed to axle (input or output) P1/P4 Motors fixed to engine and axle (input or output) P1/2b Motor fixed either to engine or transmission input The diagrams below outline various modular (P)HE
16、V powertrain configurations currently produced Whilst positions of each part differ, each configuration consists of similar conventional components 12 Ricardo plc 2016 April 2016 Unclassified - Public Domain (P)HEV动力传动系布置 混合动力结构 P1 电机固定在发动机上 P2 电机固定在变速器输入轴上 P3 电机固定在变速器输出轴上 P4 电机固定在车桥 (输入或输出 )上 P1/P4
17、 电机固定在发动机和车桥 (输入或输出 )上 P1/2b 电机固定在发动机或变速器输入轴上 下图列出了当前生产的各种模块化 (P)HEV动力系的结构 虽然每个零件的位置不同 ,每种 配置 包括的常规零部件基本类似 13 Ricardo plc 2016 April 2016 Unclassified - Public Domain Looking in detail at the P2 hybrid configuration below, many redundant components can be seen Using a powerful electric motor, the co
18、mplexity of the powertrain can be reduced. This can lead to reduced cost and improved efficiency Modular (P)HEV powertrain arrangements have high BOM cost Parts Added Parts Removed Electric Motor EM Clutch Clutch Actuation System Battery and Power Electronics Parts Added Parts Removed Electric Motor
19、 x2 Dual Clutch Unit Battery and Power Electronics Dual Clutch Actuation System Planetary Gear Set 3.5 Synchronisers and Actuation Many gears, shafts and bearings 6 speed DCT with P2 Hybrid Architecture Dedicated Hybrid Transmission (Toyota Prius) 14 Ricardo plc 2016 April 2016 Unclassified - Public
20、 Domain 仔细查看下面的 P2混合动力结构 ,可以看到很多冗余零部件 使用 高性能 电机 ， 可以降低动力系的复杂程度 。 从而 降低成本 ,提高效率 。 模块化 (P)HEV动力传动系布置增加了 BOM成本 增加的零件 拆下的零件 电动机 EM 离合器 离合器 执行机构 蓄电池和电源电子 系统 增加的零件 拆下的零件 电动机 2个 双离合器装置 蓄电池和电源电子 系统 双离合器 执行机构 行星齿轮组 3.5套 同步器和 选换挡执行机构 很多齿轮、轴和轴承 带有 P2混合动力结构的 6速 DCT 专用混合动力变速器 (丰田 Prius) 15 Ricardo plc 2016 April
21、 2016 Unclassified - Public Domain Dedicated Hybrid Transmissions (DHT) are a new category of transmission defined as; “a transmission requiring an electric machine/s in the drivetrain to undertake its desired functions” DHT architecture / transmission technology is not prescriptive and could be bas
22、ed on DCT, AMT, AT, or EVT arrangements with any number of speeds, modes or torque sources (electric, ICE etc.) MT or CVT based DHT arrangements seem unlikely DHTs are the right choice for future strongly electrified, ICE based powertrains What are Dedicated Hybrid Transmissions (DHT)? Good for (P)H
23、EV? Cost Weight Package volume Complexity NVH Quality Required Functions for vehicle Base Transmission Efficiency Powertrain Efficiency Useable without electric Development Cost 0 0 0 0 0 0 0 0 0 0 0 0 N/A Conventional Transmission Dedicated Hybrid Transmission Conventional Hybridised Transmission 1
24、6 Ricardo plc 2016 April 2016 Unclassified - Public Domain 混合动力变速器 (DHT)是一种新型变速器 ， 定义为 ： “ 在传动 系统 中需要电动机 协 助其 执行功能的一类 变速器 ” DHT结构 /变速器技术并 无 规范 约束 ,可以基于 DCT、 AMT、 AT、 或 EVT结构 ， 采用任意数量的 档位数 、模式或扭矩来源 (电机 、 ICE等 ） 基于 MT和 CVT技术的 DHT看似不可能 DHT是未来 高度 电气化 ICE动力系的正确选择 什么是专用混合动力变速器 (DHT)?有利于 (P)HEV? 成本 重量 布置容量
25、 复杂程度 NVH质量 车辆所需功 能 基础变速器效 率 动力传动系 效率 可无电使 用 开发成本 0 0 0 0 0 0 0 0 0 0 0 0 N/A 传统 变速器 专用 混合动力 变速器 传统 混合动力 变速器 17 Ricardo plc 2016 April 2016 Unclassified - Public Domain An ICE provides a defined efficiency “sweet spot”, fuel efficiency significantly decreases outside this area Gear ratios are requir
26、ed to allow the “sweet spot” to be matched to many points in the vehicle torque / speed operating map Since an ICE can not provide high torque at zero or low RPM, it requires a launch device such as a clutch or torque converter An electric motor provides good efficiency across a much larger area of
27、its operating limits than an ICE, permitting fewer ratios As it also provides 100% torque at zero speed, no launch device is required Energy density / cost of current battery technology makes pure electric power expensive and heavy Transmission requirements for ICE and for BEV 18 Ricardo plc 2016 Ap
28、ril 2016 Unclassified - Public Domain ICE提供一个确定 的效率 “ 最佳 地带 ” ， 在这一区域以外燃油效率显著降低 齿 速 比 让 这一 “ 最佳 地带 ” 与车辆 阻力 /速度 运行图形上的很多点匹配起来 在零转速或低转速下 ICE无法提供高扭矩 ，它需要一种启动设备 ， 如离合器或液力变矩器 相对于 ICE， 电动机在其更大范围的运行限制内提供更高的工作效率 ， 可以降低齿 速数量要求 它在零转速下还提供 100%扭矩 ,不需要启动设备 目前蓄电池技术的能量密度 /成本使得纯电动汽车成本高昂 ， 重量大增 ICE和 BEV变速器要求 19 Ric
29、ardo plc 2016 April 2016 Unclassified - Public Domain By combining conventional and electric power sources a dedicated hybrid powertrain enhances the merits of both power sources Why can a DHT be more simple than a conventional transmission? Torque (Nm)Vehicle Speed km/h 1st 3rd 4th 2nd EM ratio 1 u
30、sed for launch and urban driving EM ratio 2 used for hybrid operation higher at higher vehicle speeds and gear shift torque support operation EV Mode/ Hybrid Mode Battery Charging Mode Hybrid Mode IC Engine Only Mode 20 Ricardo plc 2016 April 2016 Unclassified - Public Domain 通过结合传统和电 力动力源 ， 专用的混合动力
31、传动系增强了两种 动力类型 的优点 为什么 DHT要比传统型变速器更为简单 ? 转矩(Nm)车辆行驶速度 km/h 1档 3档 4档 2档 EM 速比 1 用于启动和城市驾驶 EM速 比 2 用于较高车速下的混合动力运行和换挡扭矩支持运行 EV模式 /混动模式 蓄电池充电模式 混合动力模式 内燃机模式 21 Ricardo plc 2016 April 2016 Unclassified - Public Domain Below are examples of a modular hybrid transmission and a DHT arrangement Dedicated Hybr
32、id Powertrains offer significant opportunities for reduced subsystem costs and complexities but they can not be iteratively developed from existing conventional systems How can the business case for a development investment in Dedicated Hybrid Powertrain be made more acceptable in the short term? DH
33、T, step change from conventional ICE, an investment conundrum 6 speed DCT with P2 Hybrid Architecture Dedicated Hybrid Transmission (Toyota Prius) 22 Ricardo plc 2016 April 2016 Unclassified - Public Domain 下面是模块化混合动力变速器和 DHT布置的示例 专用混合动力传动系提供了降低系统成本和复杂程度的重要机会 ,但不能 沿用 现有传统系统 进行二次开发 开发投资专用混合动力传动系的商业案例
34、在短期内如何能更加可接受 ? 传统 ICE的逐步演化 , DHT是一个投资难题 P2混合动力 架构 的 6速 DCT 专用混合动力变速器 (丰田 Prius) 23 Ricardo plc 2016 April 2016 Unclassified - Public Domain Option 1 A modular system for increased applicability to raise volumes where possible Option 2 A simple, multi-path DHT, aimed at a low cost, mass market vehicl
35、e Option 3 A DHT architecture which shares base transmission with conventional variant How to approach DHT introduction for an improved business case? These three options for developing a DHT will be discussed in more detail 24 Ricardo plc 2016 April 2016 Unclassified - Public Domain 方案 1 应用 模块化 结构
36、以 扩大 应用 范围 ，可能情况下增加 销量 方案 2 一 种简单 、 多路径 DHT， 旨在低成本 、 大众市场 车型 方案 3 - 采 用 与传统型式 变速器 相同的 技术基础的 DHT设计 推荐 DHT技术 ， 如何改进 商 业 案例 ? 下 文对 这三种 方案的 DHT进行更详细的介绍 25 Ricardo plc 2016 April 2016 Unclassified - Public Domain The option 1 approach to DHT breaks the powertrain in to 3 combinable sub-system modules in
37、order to maximise the (re)-use opportunity for each separate module These sub-systems can be variously configured to suit many powertrain architectures Each sub-system module could have limited configurable options for further increased flexibility, if desired Option 1 A modular system for increased
38、 applicability to raise volumes where possible This image shows all 3 sub-system modules arranged in a 2WD transverse arrangement 26 Ricardo plc 2016 April 2016 Unclassified - Public Domain 方案 1的 DHT方法把动力系分为 3个可合并的子系统模块 ,以便最大限度地提高每个单独模块 (重新 )使用的机会 这些子系统可以采用各种不同方式进行配置 ， 以满足多种传动系结构 必要时 ， 每个分系统模块可以具有有限
39、的可配置 性 ， 用于增加未来灵活性 方案 1 -应用模块化结构以扩大应用范围 ， 可能情况下增加销 量 此图显示了在 2WD横向布置变速 器 中使用的所有 3个分系统模块 27 Ricardo plc 2016 April 2016 Unclassified - Public Domain Option 1 Example modes of operation, various configurations EV only (BEV, REEV, HEV, PHEV) Boosted launch / Series hybrid (REEV, HEV, PHEV) Parallel hybr
40、id (HEV, PHEV) ICE direct (HEV, PHEV) Static charging / ICE start-stop (REEV, HEV, PHEV) Regenerative braking (BEV, REEV, HEV, PHEV) 28 Ricardo plc 2016 April 2016 Unclassified - Public Domain 方案 1 运行模式 ， 布置示例 EV模式 (BEV、 REEV、 HEV、 PHEV) 增强 启动 /串联 混合动力 (REEV、 HEV、 PHEV) 并联 混合动力 (HEV、 PHEV) ICE模式 (HE
41、V、 PHEV) 怠 速 充电 /ICE启 -停 (REEV、 HEV、 PHEV) 制 动能量回收 (BEV、 REEV、 HEV、 PHEV) 29 Ricardo plc 2016 April 2016 Unclassified - Public Domain Option 1 Example vehicle architecture options HEV 2WD PHEV 4WD REEV 2WD BEV 2WD These 3 sub-system modules can be combined in different configurations to produce at least 12 distinct vehicle powertrain architectures for BEV, REEV, HEV and PHEV 30 Ricardo plc 2016 April 2016 Unclassified - Public Domain 方案 1 - 车辆架构 方 案示例 HEV 2WD PHEV 4WD REEV 2WD BEV 2WD 这 3个子系统模块可以集成在不同的配置中 ， 用于为 BEV、 REEV、 HEV和 PHEV、 至少 12种不同的动力 架构
