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

      Optimized Efficiency of Hybrid Transmissions

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      Designed for future CO2 limit values

      The transmission has a major influence on how quickly the tank empties and on how much CO2 a car emits per kilometer. IAV has developed a high-power, high-torque eight-speed hybrid dual-clutch transmission that is capable of reducing fuel consumption by up to 18 percent over a conventional six-speed dual-clutch transmission on account of its high number of speeds and integrated hybrid function. A further advantage of the IAV 8H-DCT450 lies in its extremely small package requirement.

      Maximum efficiency at all operating points and in all driving situations: that was the brief for developing the eight-speed hybrid dual-clutch transmission. The high number of speeds plays a key part here. “It makes optimum use of the map range when the combustion engine is the main source of propulsion”, says Dr. Jörg Müller, head of the Transmission, E-Motor and Hybrid Systems department at IAV. “This alone cuts fuel consumption in the New European Driving Cycle (NEDC) by 4.3 percent over a six-speed transmission.”

      In addition, hybridization contributes to this effect: delivering a continuous power output of 30 kilowatts and maximum torque of 300 newton meters, the efficiency-optimized e-motor can provide all of the drive power necessary over some distance. It is also designed to minimize the overall transmission package needed – with a total installed length of 370 millimeters, it takes up no more space than a comparable transmission without hybrid functionalities. Hybridization alone reduces fuel consumption in the NEDC by 13.8 percent.

      The two separate hydraulic circuits also help to provide the high level of efficiency of IAV’s in-house development. A circuit working at a low pressure of 5 bar cools the clutch and e-motor. A second circuit operating at a high pressure of up to 50 bar is responsible for actuating the clutches and shift elements.

      Suitable for compact and upper standard class

      “All told, this produces a potential fuel saving of 18.1 percent as compared with a conventional six-speed transmission”, Müller says. With its maximum torque of 450 newton meters, the eight-speed hybrid dual-clutch transmission is suitable for use in vehicles from the compact to upper standard class and even the SUV segment.

      Various IAV development methodols were used in the development process. The transmission synthesis tool identified the transmission’s optimum structure from millions of possibilities under the given boundary conditions. It provides a high level of development certainty because all possible variants can be taken into consideration. IAV’s e-motor synthesis tool delivers electric drive systems that combine a high level of efficiency with minimum dimensions. Combining both tools made it possible to package the hybrid transmission’s functionalities in an extremely small amount of space.

      The eight-speed hybrid dual-clutch transmission is a well-developed solution that can be tailored to specific customer demands and used straight away as the starting point for production-ready development.

      Gear set

      • Gear set optimized in structure with IAV transmission synthesis
      • Intelligent multiple use of gear set components to reduce gear planes and axial package
      • Maximum transmission input torque of 450 Nm
      • Eight well-stepped forward speeds with variable overall spacing from 7.0 to 10.0
      • Number of gear set components similar to that of conventional six-speed dual-clutch transmissions
      • Weight approx. 85 kg

      E-motor

      • Permanent magnet synchronous motor with buried magnets
      • Continuous power output of 30 kW at 300 Nm torque
      • Coaxial arrangement to transmission input
      • Realization of hybrid functions: electric driving, boosting, regenerative braking, start-stop, coasting, as well as combustion engine load-point shifting
      • Design optimized using IAV’s optimization tool for maximum efficiency
      • On-demand oil cooling
      • Weight approx. 20 kg

      Mechatronics

      • Energy-efficient powerpack for transmission actuation and cooling
      • On-demand provision of power from an electrically operated twin pump for high and low-pressure circuit
      • Pressure accumulator for covering output peaks in the high-pressure circuit to provide a high level of efficiency
      • Suitable for all typical full-hybrid functions
    • 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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