GETRAG HybridDrive 7HDT300 The Optimized Hybridization

© GETRAG, GETRAG Drivetrain Forum, 2012-09-25, Cologne

GETRAG HybridDrive 7HDT300The Optimized HybridizationUli Christian Blessing, Chief Engineer Hybrid TransmissionsGETRAG


GETRAG HybridDrive 7HDT300 - The Optimized Hybridization

Agenda

Key features of GETRAG HybridDrive 7HDT300– Level of hybridization– Schematic overview of the TorqueSplit hybrid– Functionality– Packaging options

Details of the e-machine– Optimized integration of the stator and rotor– Cooling Concept

Modularity

Comparion of GETRAG HybridDrive vs. competitors

Summary


Gearset– 7HDT300 based on 7DCT300– Torque range, up to 300 Nm – Adaptable EM-ratio

Wet nested clutch – Electro hydraulic actuation

Electro mechanical shift actuation

Electrical on-demand cooling for clutch and e-machine

Electrical park lock system (w/o additional actuator)

Ready for Start/Stop & Hybrid (w/o additional hardware)

Integrated e-machine with different power levels– Plug-In Hybrid (up to > 360 V)– Mild Hybrid (48 V)

Key Features of the GETRAG HybridDrive 7HDT300



Level of Hybridization of the GETRAG HybridDrive 7HDT300

0%Micro

Mild

Plug-Into

Full

100%

Fuel

redu

ctio

n

Conventional CarGETRAG PowerShift 7DCT300 offers Start/Stop + extended sailing w/o hardware change

Integrated 48 V e‐machinewith dedicated oil‐cooling

Integrated High‐Power e‐machine with dedicatedoil‐cooling

Fuel Efficiency Improvement in the NEDC



Schematic Overview of GETRAG HybridDrive 7HDT300

2,4,6,R

clutch 2

clutch 1

sub transmission 2

sub transmission 1

1,3,5,7

engine

PCUe-machine

scalable functionality by using different e‐machine lengths



Hybrid Modes and Functionalities of GETRAG HybridDrive 7HDT300

Hybrid Modes Electric driving Sailing Recuperation Boosting Generator-mode / Load-Shift Charge@Standstill

Hybrid Functionalities Starter of the internal combustion engine not necessary

– Restart with Torquesplit effect– Cold Cranking– Impulse Start



Hybrid Modes - Restart of Internal Combustion Engine


2,4,6,R

1,3,5,7

PCU

2.000 rpm

800 rpm250 Nm

2,4,6,R

1,3,5,7

PCU

2.000 rpm

100 Nm00EM speed

nmax

EM to

rque

nEM

Reduced restart duration compared to parallel hybrid

Higher torque of EM available for electric driving

Restart possible at very low vehicle speeds

torque reserve for engine cranking


Hybrid Modes - Restart of Internal Combustion Engine

GETRAG HybridDrive 7HDT300 - The Optimized Hybridizationa C

ar in

m/s

2Sp

eed

in 1

/min

Restart with 12V Starter

nVM nTG1 nTG2

TEMTK1 TK2

nVM nTG1 nTG2

Electric Driving G2Torquesplit Restart G3

nVM nTG1 nTG2

TEMTK1 TK2 TEMTK1 TK2

Electric Driving G6Parallel Restart G6

Torq

ue in

Nm


Packaging Options of GETRAG HybridDrive 7HDT300

E-machine Front Version E-machine Rear Version



Hybrid Drivability requirements from Mild to Plug-In Hybrid

Drivability requirements for electric driving (Plug-In Hybrid) max. speed: up to 130 km/h (w/o torque interruption) max. wheel torque: > 2100 Nm continuous power: 30 kW (@ max. speed) peak power: 70 kW (@ 250Vdc; 420Arms)

Drivability requirements for electric driving (Mild Hybrid) max. speed: up to 50 km/h (w/o torque interruption) max. wheel torque: > 1800 Nm continuous power: 8 kW (@ max. speed) peak power: 15 kW (@ 48Vdc; 350Arms)



Comparison of GETRAG HybridDrive 7HDT300 vs. Competitors


7HDT300 Hybrid AT Hybrid CVT

48 Volt System High-Speed EM,El. Driving possible

Only via crankshaftmounted version

Only via crankshaftmounted version

Mild-Hybrid High-Speed EM,El. Driving possible

High-Torque PSM High-Torque PSM

Full-Hybrid High-Speed EM + ASM possible

High-TorquePSM mandatory

High-TorquePSM mandatory

Plug-In Hybrid Side-by-side EM enables packaging

Increase oftransmission length

Increase oftransmission length

Efficiency Very low losses, noaux. system

Auxilliary systemnecessary

High losses, auxsystem necessary

Costs No add. actuation, High-speed EM

Add. oil-pump, High-Torque PSM

Add. oil-pump, High-Torque PSM

Functionality No 12V starternecessary

No torque converter,Low-Speed Driving

No torque converter,Low-Speed Driving


Modularity of Hybridisation

Hybridisation with axial parallel e-machine is also possible on– 7DCT500– 6DCT150

Modularity is based on – Active parts of e-machine (at least same diameter)– Oil-cooling– Bidirectional electric cooling pump– Integration of the e-machine– Hybrid SW functionality



Summary

GETRAG HybridDrive 7HDT300 offers a scalable hybridisation from Mild toPlug-In Hybrid

Integrated high-speed e-machine with oil-cooling

All hybrid functionalities are available (48 V / Mild option offers pure electricdriving)

No additional actuation needed for hybridisation of 7DCT300

Wide operational area of TorqueSplit Hybrid is outstanding compared to otherconcepts

Modular approach enables usage of same e-machine kit for– 7DCT500– 6DCT150



GETRAG HybridDrive 7HDT300The Optimized HybridizationUli Christian Blessing, Chief Engineer Hybrid TransmissionsGETRAG

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GETRAG HybridDrive 7HDT300 The Optimized Hybridization