IAV at the 38th Vienna Engine Symposium

Towards Smart Powertrains

      Concepts and Technologies for Minimum Emissions and Maximum Efficiency

      IAV is paving the way to zero-emission driving – with state-of-the-art exhaust gas aftertreatment and hybrid systems as well as all-electric drives. A modified topology for the exhaust gas aftertreatment system in conjunction with IAV’s new hybrid transmission is helping to cut emissions while enhancing driving dynamics. For all-electric vehicles, IAV has developed a modular electric drive unit that permits local zero-emission driving.

      We presented all three solutions at the Vienna Engine Symposium on April 27 and 28.

      Innovative Close-Coupled Exhaust Gas Aftertreatment

      Diesel engines will only be capable of meeting the EU6 standard if exhaust gas aftertreatment (EAT) continues to be improved. To this end, IAV is moving the EAT system closer to the engine and positioning some or all of its components upstream of the turbocharger, leaving exhaust gas in DOC and SCRF between 100 and 150 degrees kelvin hotter than with the classic approach of positioning EAT downstream of the turbocharger. This shortens the time the exhaust gas aftertreatment system takes to reach optimum operating temperature – and the vehicle complies with emission requirements in all situations. (...) More

      Optimized Efficiency of Hybrid Transmissions

      Adding a modern hybrid transmission further reduces fuel consumption. IAV has developed a hybrid eight-speed dual-clutch transmission guaranteeing maximum combustion engine efficiency in all driving situations and across the operating map. Factoring in the benefit from hybridization and innovative hydraulic system produces a potential fuel saving of 18.1 percent over a conventional six-speed transmission. (…) More

      Modular, electric drive concept

      The new generation of electric drive units from IAV provides the key to an all-electric car. The modular concept comprises an electric motor and transmission with one to three gear speeds. This solution delivers a high level of torque over a wide speed range, while also taking up little package and permitting cost-efficient volume production. The modular electric drive unit provides high hill-climbing ability in conjunction with maximum efficiency. It can also be used flexibly and lends itself to a variety of powertrain configurations, e.g. for battery-powered electric or fuel cell vehicles. (…) More

      Modular, electric drive concept

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      IAV presented the new version of its modular electric drive concept. Combining e-motor and transmission, it provides up to three speeds and, because of its modular concept, can be made to suit various vehicle platforms and demands. The aim is to combine a high level of ride comfort, efficiency and compact package at competitive cost.

      Long-term, electric drive systems will play a key part in mobility because they permit zero-emission mobility and are not reliant on fossil energy. Besides the environmental aspect, manufacturers also need to consider their customers’ demands on ride comfort.

      At the same time, consumers expect top efficiency to give them maximum traveling range, good hill-climbing performance, high vehicle speed and good acceleration on one battery charge.
      Many of today’s electric drives use a combination of an e-motor and transmission with fixed gear ratio.

      Although solutions of this type are relatively simple in terms of structure, they cannot meet all of the demands made on them at the same time. For instance, high hill-climbing performance and maximum efficiency demand very different transmission ratios. It is for this reason that IAV has chosen a modular concept based on an e-motor and a transmission with one to three speeds.

      “As a result, we can match the electric drive unit to different vehicle platforms and demands”, explains Mathias Krause, head of the Cylinder Head/Crankcase department in IAV’s Powertrain System Development division. “Our solution delivers a high level of torque across a wide vehicle speed range.”

      Suitable for various powertrain configurations

      IAV’s solution is also flexible in terms of use – as the main drive for battery-powered electric vehicles, for fuel cell vehicles or as a component of plug-in hybrids. Its power output is sufficient for vehicles from classes A (subcompact car), B (compact car), C (standard size) and D (upper standard size). It represents a further development of a solution IAV presented back in 2010.
      In the modular electric drive unit, an e-motor developed by IAV delivers a continuous power output of 50 kilowatts and maximum power of 80 kilowatts. It generates constant torque of 150 newton meters which can be increased to 300 newton meters for short periods of time. It was designed using IAV’s e-motor synthesis tool which finds the optimum solution for the given application from an almost unlimited number of potential variants.

      Providing a maximum of three speeds, the planetary transmission is installed at the side of the e-motor and is capable of generating output torque levels of up to 3,000 newton meters. At the same time, this makes it possible to limit the motor’s maximum speed to 8,000 revolutions per minute. The differential is accommodated in the e-motor, making optimum use of limited package.

      Traveling range increased by up to ten percent

      “Our modular electric drive unit meets the demands on torque with more speeds than comparable solutions”, says Jens Liebold, Technical Consultant for Electromechanical Drive Systems at IAV. “Instead of a multiple-speed transmission, these use a larger motor with means they need more package and encounter problems because of the higher motor speeds involved, such as with NVH.” Solutions with a fixed transmission ratio also come with efficiency drawbacks, IAV’s solution increases traveling range by five to ten percent.

      Developing the casing also presented a particular challenge. Compact design, a high level of functional integration and temperature management have been combined to provide additional benefits. With IAV’s solution, for example, the power electronics are accommodated in the casing to reduce costs from copper wiring, ensure good EMC shielding as well as include the power electronics in the electric motor’s cooling circuit. “In our case, we use the stator’s circuit to control the temperature of the power electronics because we can bring it into contact with a large area of the casing’s cooled sections”, Krause says. “The transmission lubrication system, in turn, also cools the e-machine’s rotor.”

      Besides this, the project also placed exacting demands on the casing’s structural stiffness. “Otherwise there is a risk of getting problems with acoustic behavior”, Liebold explains. “So the casing had to be as stiff as possible to avoid vibration but also to absorb forces and transfer them to the vehicle.” In developing the casing, IAV’s experts cooperated closely with Nemak, a globally operating aluminum casting specialist. This has resulted in a casing that combines compact size, high stiffness, a high level of functional integration and competitive costs.

      Drive unit

      • Suitable for vehicle classes A to D
      • Hill-climbing ability: maximum of 30 percent
      • Top speed: 160 km/h (continuous) / 185 km/h (maximum)
      • Acceleration 0 – 60 km/h in 4 seconds, 0 – 100 km/h in 10 seconds

      E-motor

      • Power output: 50 kW (continuous) / 80 kW (maximum)
      • Torque: 150 Nm (continuous) / 300 Nm (maximum)

      Transmission

      • Maximum of three speeds
      • Torque: 3,000 Nm (maximum)
    • Kongresszentrum Hofburg

      Heldenplatz,
      1010 Wien

      Site plan

      Venue

      Congress Center Hofburg, Heldenplatz, 1010 Vienna/Austria

      Event times

      Thursday, April 27, 7.30 a.m. – 6.30 p.m.
      Friday, April 28, 8.00 a.m. – 6.00 p.m.

      Site plan

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