100329 Hybrid System Development Us WEB

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Hybrid System DevelopmentIAV The Partner for Electrification


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Contents

A Partner for the Paradigm Shift 4

System Architecture Definition 6

Powertrain Systems Design 8

Electrical System Engineering 10

Hybrid and Electric Drive Control and Calibration 12

Integration Engineering 14

About IAV 16


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As an industry partner, IAV has supported the integration of electrified technologies into the vehicles of today and tomorrow


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5 4

A Partner for theParadigm Shift

IAV brings to the automotive industry a full spectrum of high-tech engineering services in electronics, powertrain and vehicledevelopment. Drawing on a complete vehicle system approach,IAV leverages company-wide expertise to supply the customerwith the optimal, most efficient, cost effective and reliablesolution.

Since the early 1990s, IAV has been at the forefront of hybridand electric drive development. Beginning with the design, buildand development of concept vehicles and carrying through to thedevelopment of production applications, IAV continues to bringinnovative solutions to the vehicle market.

IAV offers industry-proven expertise in the development ofhybrid and electric drive vehicles and methods, from full vehiclesimulation during the concept phase using IAV's VeLoDyn forperformance and fuel consumption optimization, to methodsused for creating optimal hybrid and electric drive transmission

systems with IAVs in-house transmission synthesis tool andprocesses. Continuously striving to lead the charge toward thedevelopment of the vehicle of the future, IAV invests intechnologies such as advanced battery management systems forlithium-ion and future cell chemistries.


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IAV applies a top-down holistic development approach for the entire vehicle


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System Architecture Definition

The introduction of electric machines to the powertrainprovides an opportunity to increase operating efficiency andperformance. To realize this opportunity, care must be taken inthe selection of system architecture to ensure all vehiclerequirements are achieved, especially component and totalsystem cost.

Furthermore, requirements for the specific component must bedefined, e.g., e-machine, inverter, high-voltage battery, coolingsystem, IC engine, transmission, brake system, etc. Whether thepowertrain is being designed entirely from scratch or adaptedto include the features of an HEV, concepts have to beevaluated early in the development phase to quantify the fuelconsumption, efficiency, emission and drivability requirementsto be achieved.

Through the use of in-house and commercially availablesimulation tools, e.g., IAVs VeLoDyn and Gamma TechnologiesGT-Drive, and backed by many man-years of experience, IAV

quickly and accurately defines the system topology andtechnologies required to meet vehicle requirements. Thisincludes system and sub-system requirements definition,supplier selection and validation. All completed in the contextof cost and timing objectives. Design to achieve transparent operating objectives

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A Hybrid-Electric 8-Speed Transmission designed using IAV's Architecture Synthesis toolset


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Powertrain Systems Design

IAV hires and trains the very best hybrid powertrain systemdesign engineers specializing in the design of all Hybrid ElectricVehicle sub-systems, including the electric machine housingwith its mounting, cooling and power-supply, high and lowvoltage harnesses, inverters and power-electronics, the energystorage battery system, and control modules. By specifying anddesigning the required low-temperature cooling systems, IAVemploys design best practices to manage system intergrationissues such as electro-magnetic interference. Throughout thedevelopment of the design, IAV deploys quality processesincluding DFMEA, GD&T, DFM/DFA, value analysis and costmanagement.

Concentrating on efficiency and technical capability, IAVsdegree-qualified design engineers take complete design andrelease responsibility for their components and assemblies. Bycarrying out the required specification, design calculations,digital modeling, design packaging, construction and designrelease with subsequent supplier management, IAVs design

engineers ensure that all hybrid system and componentrequirements are considered and met. In effect, IAV designengineers become the total component project engineers.

IAV has perfected an in-house transmission architecturesynthesis toolset that is used to mathematically model all

possible permutations of powerflow through both planetarygearset and layshaft type transmissions. Using customer drivencriteria, the best possible architecture layout is selected for thecustomers HEV application. To achieve optimal fuel economyand reduced CO 2, IAVs architecture synthesis toolset includestransmission system hybridization via integration of electricmachines.

A typical electric machine concept design


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Electrical System Engineering

The increasing scope of functionality provided by the electricalsystem and the high degree of cross-coupling of these systemsrequire the E/E architecture to be designed with meticulousdetail to meet automotive industry requirements. Increasingcomplexity forces new technology and changes the methodsused in vehicle development. Many challenges are highlightedwith the presence of high-voltage and current, especially safety.The functional safety of the electrified vehicle must be anintegral part of the complete development process.

IAV has demonstrated expertise in meeting these challenges inmany of the production HEVs available today. In addition toproduction know-how, IAV has developed its own technologies,such as an intelligent battery management system for lithium-ion cells, prototype inverters and DC-DC converters.

Topics covered:

u High-voltage batteryu Battery management systemsu Power electronic designu High-voltage wiringu Electric machine design and development Prototype and production high-voltage battery systems


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IAV specializes in the design, development and calibration of thecontrol systems for proof of concept and production of electrifiedpowertrains. The IAV team focuses on designing operatingstrategies to exploit the benefits of the electric drive in thepresence of system constraints such as the batterys SOC andpowerlimits, e-machine torque and speed limits while maintaining atransparent driving experience.

To support these activities, IAV has developed specialized tools,methods and processes to augment engineering expertise andexpedite development while ensuring robustness and high qualitylevels.

Topics covered:

u Energy managementu Battery management systemsu Regenerative brakingu Enhanced stability systemsu Electric machine controlu Engine managementu Engine start/stopu Driveline managementu Functional safetyu Diagnostics

Hybrid and Electric DriveControl and Calibration

IAV designs and calibrates the energy management system to exceedcustomer requirements

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After HEV architecture definition, IAV engineers execute detailed design, integration, testing, validation and calibration


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Integration Engineering

Well over fifty percent of IAVs powertrain system engineersaround the world are dedicated to the package integration,functional development, control and calibration of automotivehybrid electric systems. This includes the mounting and servicesintegration for electric machines, hybrid battery systems, powerelectronics modules and the low temperature cooling system.IAV engineers are also specialists in the design and packaging oflow and high voltage power and signal distribution harnesses,including design for electromagnetic compliance.

In-house capabilities and experience span the derivation ofsystem requirements with the customer to develop completelynew HEV system architectures, from the design and integrationof the hybrid electric sub-systems, to the electro-mechanicalcalibrations and OBD required for saleable production.

IAV engineers have extensive hybrid electric cross-platformexperience spanning light-duty front-wheel drive passengercars, to rear-wheel drive premium sports cars, to light- and

medium-duty commercial vehicles. IAV has not only integratednew hybrid electric systems, but also successfully convertedproduction vehicles to create new hybrid electric variants. Typical automotive hybrid electric system architectures

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IAV's new Technical Center North America


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IAV Group is a leading global automotive engineering serviceprovider, employing more than 3,000 personnel throughoutEurope, Asia and the Americas. Founded in 1998 as theNorth American subsidary of IAV GmbH, IAV AutomotiveEngineering Inc. develops breakthrough concepts andtechnologies from powertrain design and devel opment tocontrols and electronics for future vehicle generations.

Clients include leading automotive manufacturers andcomponent suppliers, all of whom rely on the knowledge ofIAVs engineers to help them design and develop some ofthe industrys most advanced engines and powertrains. TheIAV Technical Center North America is now open inNorthville, MI. The technical center includes four state-of-the-art development/test cells. With this exciting newfacility, IAVs engineering capabilities have expanded toinclude full service projects, further cultivating the inventivespirit, enthusiasm and commitment to success for which theIAV Group is known.

About IAV

Excellence in automotive research and development a concept IAV applies across the globe

Detroit

So Paulo

London

BerlinChemnitzGifhornFriedrichshafenLentingLudwigsburgMunichNeckarsulmRegensburgRuesselsheimWeissach

ShanghaiSeoul

Pune

Tokyo

KalugaParis

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