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THE FULL-HYBRID POWERTRAIN OF THE NEW BMW ACTIVE HYBRID 5.
Aachen Colloquium ChinaBMW Group, 1st November 2011
THE NEW BMW ACTIVE HYBRID 5. DR. CHRISTOPH LUTTERMANN
DR. FRIEDRICH RABENSTEIN, DR. MANFRED KLÜTING, FRANK KESSLER, JAN KRETSCHMER, CLAUS-OTTO GRIEBEL, ELMAR HOCKGEIGER
BMW ACTIVE HYBRID 5.INTRODUCTION.
220
CO2-Emissions of the BMW Group Automobiles in Europe.
VALVETRONIC High Precision Injection
200
180
160
CO
2[g
/km
]
210
190
170
VALVETRONIC High Precision Injection
EfficientDynamics
TwinPower Turbo,8HP
1995 - 2008:
- 25 %
Page 2The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
140
160
150
130
12095 97 98 99 0700 05 06040301 02 08 09 1096 11 20
2008 - 2020:
- 25 %Downsizing / UpgradingHybrid TechnologyE-Mobility
BMW ACTIVE HYBRID 5.ENGINEERING TARGETS.
Significant reduction of CO2 emissions.(compared to standard powertrain).
Distinctive electric driving experience.(sufficient agility in urban driving conditions, high availability).
ConnectedDrive meets EfficientDynamics.(intelligent use of onboard navigation data).
Create a modular solution:- Scalable from Mild Hybrid to Plug-In Hybrid.- Compatible with all BMW vehicles.- Maximize synergies with standard powertrain
Page 3
- Maximize synergies with standard powertrain(e.g. combustion engine, gearbox).
- In-house development and production of HV battery.
Preserve the Character of the BMW 5-Series:BMW-adequate driving dynamics and vehicle character of the BMW 535i.
� Concept Decision: full hybrid design with P2 architecture.
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5.SYSTEM OVERVIEW.
Power Electronics Hybrid Control Unit DC/DC Converter
8-SpeedAutomaticTransmission
E-Motor Li-Ion HV-Battery
Battery Control Unit SME
Transmission Control UnitEGSDC/DC Converter Transmission
Engine ControlUnit DME
EGS
12V-Batteryfor Starter
System
Combustion Engine N55
Page 4
Starter SystemSGR
Electrified Ancillary Units Brake Vacuum Pump, Power Steering Pump
Engine N55
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
El. Air ConditioneKMV
6-Cylinder inlineTwinPowerTurbo: Starter
BMW ACTIVE HYBRID 5.COMBUSTION ENGINE N55.
TwinPowerTurbo:
Max. Torque: 400 Nm @ 1200-5000 min-1
Max. Power: 225 kW @ 5800-6400 min-1
Starter integrated in Belt Drive
Belt tensioner
Page 5
Gasoline Direct Injection in combination with VALVETRONIC
Twin scroll Turbotensioner
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5.STARTER SYSTEM.
Additional starter system integrated in belt drive.
Superior start comfort (acoustics, vibration).
12 V Starter/Generator Unit
Superior start comfort (acoustics, vibration).
Starter function is independent from electrical driving � no torque reserve necessary in HV system.
Page 6
Belt tensioner
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5. HYBRID 8-SPEED AUTOMATIC TRANSMISSION.
E-Machine Separatingclutch K0
TV damper
Integrated start-upelement
clutch K0
Page 7The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
Mechatronics Electrical Oilpump
Modular and scalable transmission concept.
High synergies with non-hybrid transmission
BMW ACTIVE HYBRID 5. HYBRID 8-SPEED AUTOMATIC TRANSMISSION.
High synergies with non-hybrid transmission(Gearsets, Clutches, TCU, Package, Interfaces).
E-Machine replaces torque converter.
Technical Data:
Max. input torque capacity
Max. input speeds
700 Nm
7,200 rpm
Page 8
Max. input speeds
Ratio spread
Full hybrid functionality(Engine start-stop, Electrical drive, Recuperation, e-Coasting)
7,200 rpm
7.071
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5. ELECTRIC DRIVE SYSTEM.
E-Machine:PSM
Power Electronics:DC/DC converter (HV to 12 V)
Electric A/C compressor
PSM40 kW / 210 Nm max.Water cooled
DC/DC converter (HV to 12 V)Inverter for EM controlHV supply for A/CElectronic Control UnitWater cooled
Page 9
12 V Electrical system+-
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5. LITHIUM ION HV BATTERY SYSTEM.
BMW In-house Development and Production Power Oriented Design
Stable Aluminium Housing
Page 10
Connector Panel- HV Connector- Cooling
Holder with Mounting Device
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5. LITHIUM ION HV BATTERY SYSTEM.
Battery - System
Housing and Structural Elements
Cells CoolingBattery Management(Functions, Diagnostics)
Electric/Electronic,Hardware
Page 11
317 V
200... 385 V
4 Ah
1,350 Wh
43 kW
Producer
No. of cells
No. of modules
Weight
Volume
BMW Group
96
8
< 46 kg
approx. 40 l
Voltage, nominal
Voltage range
Capacity, nominal
Stored energy, nominal
Max. discharge power
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5. SYSTEM PERFORMANCE.
300500
450450 Nm @ 1000-5000 min-1
250 kW @ 5800-6400 min-1
Out
put [
kW]
100
200
Torq
ue [N
m] 300
400
200
150
150
250
450
350
250
250 kW @ 5800-6400 min-1
Page 12
0
Engine speed [1/min]
0800060005000400030002000
100
0
150
50
50
70001000
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
Hybrid System performanceTwinPower Turbo engine
BMW ACTIVE HYBRID 5. DYNAMIC RESPONSE.
Electric Overboost
Acce
lera
tion
@ ti
p-in
Electric OverboostDynamic
Response
Page 13The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
Time [s]
BMW ACTIVE HYBRID 5. FUEL ECONOMY AND PERFORMANCE.
175
180
BMW 535iA MSA
160
170
NED
C C
O2
[g/k
m]
175
165
155
Full HybridCompetitor
Full HybridCompetitor
Fuel economy benefit: 16 %
Page 14
145
5.0
0-100km/h [s]
150
1408.57.57.06.56.05.5 8.0
BMW ActiveHybrid 5 BMW 520iA MSA
Full HybridCompetitor
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5.HYBRID SYSTEM FUNCTIONS.
6.4 l/100 km
1925 kg (+ 150 kg to BMW 535i)
Fuel consumption @ NEDC:
Vehicle weight (EU): 1925 kg (+ 150 kg to BMW 535i)
EU 5, ULEV II, Japan Green Car 4 Star
60 km/h
160 km/h
3-4 km
Vehicle weight (EU):
Emission levels:
Vmax e-drive*:
Vmax e-coast:
e-drive range*:
Comfort engine start stop function
Page 15
Comfort engine start stop function
Intelligent State-of-Charge Control
ActiveHybrid Damping function
Navigation-based hybrid operating strategy(*on a level track)
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
Load step in 1st gear
BMW ACTIVE HYBRID 5. ACTIVE HYBRID DAMPING.
0.60.6
Torq
ue
-0.2
0.4
Acce
lera
tion
[g]
4
0.2
Active Damping on1 2 53
Torq
ue
0.0
-0.2
0.4
Acce
lera
tion
[g]
4
0.2
0.0
Active Damping off1 2 53
0.0
0.0
Page 16
Use of the E-Machine for active vibration damping.Significant improvement in comfort for dynamic response situations.
AHD
Tor
que
4t [s]
1 2 53
AHD
Tor
que
4
0.0
t [s]1 2 53
0.0
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5. CONNECTED DRIVE MEETS EFFICIENT DYNAMICS.
Use Case: downhill gradient.
- Start discharge by load reduction of
Beginning of slope.
-
-
Battery fully charged.
Shift to normaloperating strategy.
A
B
-
Page 17
First-time use of route data from navigation system in hybrid operating strategy. Optimized adjustment to driving situation.
load reduction of combustion engine.
Maximize eDrive limits.
-
-
End discharge.
No load shifting.C
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
Use Case: slow driving zone.
BMW ACTIVE HYBRID 5. CONNECTED DRIVE MEETS EFFICIENT DYNAMICS.
A
B
-
-
Start load shifting.
Reduction eDrive limits.
-
-
End charging of HV battery.
Maximize eDrive limits.
Page 18
Increased availability of e-drive.Improved fuel economy.Similar functionality for target zone.Battery cooling strategy is also adapted.
C- Shift to normal
operating strategy.
The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
BMW ACTIVE HYBRID 5. SUMMARY.
Future-oriented fuel economy combined with the BMW-typical vehicle character.
Significant CO reduction of 16 % without compromise in driving dynamics.Significant CO2 reduction of 16 % without compromise in driving dynamics.
Distinctive electric driving experience, enhanced by intelligent connection of vehicle systems.
The ActiveHybrid 5 is another important milestone in the EfficientDynamics strategy.
Page 19The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.
THE FULL-HYBRID POWERTRAIN OF THE NEW BMW ACTIVE HYBRID 5.
Aachen Colloquium ChinaBMW Group, 1st November 2011
THE NEW BMW ACTIVE HYBRID 5.
THANK YOU FOR YOUR ATTENTION.