#LCV2019 @LCV_Event Development and Test of MAGSPLIT Dedicated Hybrid Transmission (DHT) for Vehicles Cross-Platform Application Gboyega Oshin Project Manager – Magnomatics LCV2019 Event Sponsor:
#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%