Development and Test of MAGSPLIT Dedicated Hybrid ......•Dedicated hybrid transmission for passenger cars, buses and trucks ... Simple Concept • One input shaft and one output

#LCV2019 @LCV_Event

Development and Test of MAGSPLIT

Dedicated Hybrid Transmission (DHT) for

Vehicles Cross-Platform ApplicationGboyega Oshin

Project Manager – Magnomatics

LCV2019 Event Sponsor:

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COMMERCIALLY CONFIDENTIAL

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3Confidential

DEVELOPMENT AND TEST OF MAGSPLIT

DEDICATED HYBRID TRANSMISSION (DHT) FOR

CROSS-PLATFORM APPLICATION

Gboyega Oshin, Stuart Calverley, Jeff Birchall

Magnomatics Ltd, UK

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4Confidential

John Boyega

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5Confidential

MAGSPLIT Dedicated Hybrid Transmission Unit

MAGSPLIT - Combining engine and electrical power to provide highly efficient powertrain

• Dedicated hybrid transmission for passenger cars, buses and trucks

• Low cost, high efficiency transmission

• Simple, proven and flexible

Innovate UK sponsored project – Magnomatics Limited, Romax Technology, Changan UK, CMCL

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6Confidential

Simple Concept

• One input shaft and one output shaft, with electronic ratio control

• Magnetic interaction of the input rotor, output rotor and the stator changes speed ratio of

input/output

Input rotor

Output rotor

Electronic ratio control

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7Confidential

Typical Powersplit Architecture

• Magsplit replaces planetary gear and a motor/generator in a typical powersplit

• There is still a need to add electrical power boost into the drivetrain using a second electrical motor

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8Confidential

Cross-Platform Application

• Machines sized to meet requirements for performance (Vmax, 0-50 kph and 0-100 kph) and

gradeability for both HEV and EV modes

• Transmission sized for two vehicles: C/D segment passenger and Sports Utility Vehicle platforms

• Engine and transmission assessed for sport, mid-range and entry level, PHEV and HEV variants

EADO

CS75

√ √ √

√√ √

√ with ERAD

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9Confidential

Concept Evaluation – Coaxial vs Parallel Layout

Coaxial:

• Simpler machine with fewer parts

• Larger traction motor diameter

• Packaging more challenging

Parallel axis:

• Separate gear stage allows for

smaller and faster traction

motor

• Easier to package

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10Confidential

Concept Selection additional considerations

• Packaging

• Fuel consumption

• Durability

• Complexity

• Cost

Parallel axis with 1-speed offered the best trade-off

4

4.5

5

5.5

6

6.5

7

7.5

NEDC WLTP Artemis

Co

rrect

ed

fu

el co

nsu

mp

tio

n

(lit

res/

100 k

m)coaxial 1-speed

coaxial 2-speed

parallel 1-speed

parallel 2-speed on TM

parallel 2-speed on final drive

Fuel Consumption

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11Confidential

Detail Design - Analysis

Magnet rotor structuralTransmission modal analysis

Drivetrain structural Pole Piece rotor structural

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12Confidential

Detail Design - Analysis

Mesh analysis of oil flow network

Coolant flow CFD

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13Confidential

Brass Board Testing and Controller Development

Engine

Magsplit Traction

motor

Torque

transducer

• Magsplit DHT system separated into main

components for brass board testing

• Torque transducer between system components

and current shunts connected to electric machine

informs the power flow between components

• SIL, HIL and brass board testing used for

controller development

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14Confidential

Transmission build

Stators and sleeves in case Geartrain Dry BuildMAGSPLIT Input and

output rotor assembly

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15Confidential

Sub-system Testing – Gearbox

Lubrication system testing

Gearbox drag loss testing

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16Confidential

Sub-system Testing – Traction Motor

• Back-to-back testing allows full range

testing of traction motors (14,500 rpm and

225 Nm)

• Thermal mapping; heat soak test

• Oil distribution and coolant flow rate

• Machine loss map at two temperatures

TM rotor TM in case for sub-system

testing

• Very capable EV mode – high power

density and high efficiency

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17Confidential

Testing Results

• Factory Acceptance Tests

• Loss measurements

• Thermal Performance

80oC225 Nm

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18Confidential

Transmission Assembly

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19Confidential

Transmission Cost and Fuel Economy Walk

Full BOM costed by FEV (Europe)

High volume manufacture at European labour and material rates

“Equivalent” DCT costed using the same assumptions on quantities, labour, etc

MAGSPLIT DHT cost 20% lower than equivalent hybrid DCT

DCT Magsplit

20%