THE FULL-HYBRID POWERTRAIN OF THE NEW BMW ACTIVE HYBRID … · 2019. 2. 12. · BMW ACTIVE HYBRID...

THE FULL-HYBRID POWERTRAIN OF THE NEW BMW ACTIVE HYBRID 5.

Aachen Colloquium ChinaBMW Group, 1st November 2011

THE NEW BMW ACTIVE HYBRID 5. DR. CHRISTOPH LUTTERMANN

DR. FRIEDRICH RABENSTEIN, DR. MANFRED KLÜTING, FRANK KESSLER, JAN KRETSCHMER, CLAUS-OTTO GRIEBEL, ELMAR HOCKGEIGER

BMW ACTIVE HYBRID 5.INTRODUCTION.

220

CO2-Emissions of the BMW Group Automobiles in Europe.

VALVETRONIC High Precision Injection

200

180

160

CO

2[g

/km

]

210

190

170

VALVETRONIC High Precision Injection

EfficientDynamics

TwinPower Turbo,8HP

1995 - 2008:

- 25 %

The Full-Hybrid Powertrain of the New BMW ActiveHybrid 5, BMW Group, Christoph Luttermann, 1st November 2011.

140

160

150

130

12095 97 98 99 0700 05 06040301 02 08 09 1096 11 20

2008 - 2020:

- 25 %Downsizing / UpgradingHybrid TechnologyE-Mobility

BMW ACTIVE HYBRID 5.ENGINEERING TARGETS.

Significant reduction of CO2 emissions.(compared to standard powertrain).

Distinctive electric driving experience.(sufficient agility in urban driving conditions, high availability).

ConnectedDrive meets EfficientDynamics.(intelligent use of onboard navigation data).

Create a modular solution:- Scalable from Mild Hybrid to Plug-In Hybrid.- Compatible with all BMW vehicles.- Maximize synergies with standard powertrain

- Maximize synergies with standard powertrain(e.g. combustion engine, gearbox).

- In-house development and production of HV battery.

Preserve the Character of the BMW 5-Series:BMW-adequate driving dynamics and vehicle character of the BMW 535i.

� Concept Decision: full hybrid design with P2 architecture.


BMW ACTIVE HYBRID 5.SYSTEM OVERVIEW.

Power Electronics Hybrid Control Unit DC/DC Converter

8-SpeedAutomaticTransmission

E-Motor Li-Ion HV-Battery

Battery Control Unit SME

Transmission Control UnitEGSDC/DC Converter Transmission

Engine ControlUnit DME

EGS

12V-Batteryfor Starter

System

Combustion Engine N55

Starter SystemSGR

Electrified Ancillary Units Brake Vacuum Pump, Power Steering Pump

Engine N55


El. Air ConditioneKMV

6-Cylinder inlineTwinPowerTurbo: Starter

BMW ACTIVE HYBRID 5.COMBUSTION ENGINE N55.

TwinPowerTurbo:

Max. Torque: 400 Nm @ 1200-5000 min-1

Max. Power: 225 kW @ 5800-6400 min-1

Starter integrated in Belt Drive

Belt tensioner

Gasoline Direct Injection in combination with VALVETRONIC

Twin scroll Turbotensioner


BMW ACTIVE HYBRID 5.STARTER SYSTEM.

Additional starter system integrated in belt drive.

Superior start comfort (acoustics, vibration).

12 V Starter/Generator Unit

Superior start comfort (acoustics, vibration).

Starter function is independent from electrical driving � no torque reserve necessary in HV system.

Belt tensioner


BMW ACTIVE HYBRID 5. HYBRID 8-SPEED AUTOMATIC TRANSMISSION.

E-Machine Separatingclutch K0

TV damper

Integrated start-upelement

clutch K0


Mechatronics Electrical Oilpump

Modular and scalable transmission concept.

High synergies with non-hybrid transmission

BMW ACTIVE HYBRID 5. HYBRID 8-SPEED AUTOMATIC TRANSMISSION.

High synergies with non-hybrid transmission(Gearsets, Clutches, TCU, Package, Interfaces).

E-Machine replaces torque converter.

Technical Data:

Max. input torque capacity

Max. input speeds

700 Nm

7,200 rpm

Max. input speeds

Ratio spread

Full hybrid functionality(Engine start-stop, Electrical drive, Recuperation, e-Coasting)

7,200 rpm

7.071


BMW ACTIVE HYBRID 5. ELECTRIC DRIVE SYSTEM.

E-Machine:PSM

Power Electronics:DC/DC converter (HV to 12 V)

Electric A/C compressor

PSM40 kW / 210 Nm max.Water cooled

DC/DC converter (HV to 12 V)Inverter for EM controlHV supply for A/CElectronic Control UnitWater cooled

12 V Electrical system+-


BMW ACTIVE HYBRID 5. LITHIUM ION HV BATTERY SYSTEM.

BMW In-house Development and Production Power Oriented Design

Stable Aluminium Housing

Connector Panel- HV Connector- Cooling

Holder with Mounting Device


BMW ACTIVE HYBRID 5. LITHIUM ION HV BATTERY SYSTEM.

Battery - System

Housing and Structural Elements

Cells CoolingBattery Management(Functions, Diagnostics)

Electric/Electronic,Hardware

317 V

200... 385 V

4 Ah

1,350 Wh

43 kW

Producer

No. of cells

No. of modules

Weight

Volume

BMW Group

96

8

< 46 kg

approx. 40 l

Voltage, nominal

Voltage range

Capacity, nominal

Stored energy, nominal

Max. discharge power


BMW ACTIVE HYBRID 5. SYSTEM PERFORMANCE.

300500

450450 Nm @ 1000-5000 min-1

250 kW @ 5800-6400 min-1

Out

put [

kW]

100

200

Torq

ue [N

m] 300

400

200

150

150

250

450

350

250

250 kW @ 5800-6400 min-1

0

Engine speed [1/min]

0800060005000400030002000

100

0

150

50

50

70001000


Hybrid System performanceTwinPower Turbo engine

BMW ACTIVE HYBRID 5. DYNAMIC RESPONSE.

Electric Overboost

Acce

lera

tion

@ ti

p-in

Electric OverboostDynamic

Response


Time [s]

BMW ACTIVE HYBRID 5. FUEL ECONOMY AND PERFORMANCE.

175

180

BMW 535iA MSA

160

170

NED

C C

O2

[g/k

m]

175

165

155

Full HybridCompetitor


Fuel economy benefit: 16 %

145

5.0

0-100km/h [s]

150

1408.57.57.06.56.05.5 8.0

BMW ActiveHybrid 5 BMW 520iA MSA



BMW ACTIVE HYBRID 5.HYBRID SYSTEM FUNCTIONS.

6.4 l/100 km

1925 kg (+ 150 kg to BMW 535i)

Fuel consumption @ NEDC:

Vehicle weight (EU): 1925 kg (+ 150 kg to BMW 535i)

EU 5, ULEV II, Japan Green Car 4 Star

60 km/h

160 km/h

3-4 km

Vehicle weight (EU):

Emission levels:

Vmax e-drive*:

Vmax e-coast:

e-drive range*:

Comfort engine start stop function

Comfort engine start stop function

Intelligent State-of-Charge Control

ActiveHybrid Damping function

Navigation-based hybrid operating strategy(*on a level track)


Load step in 1st gear

BMW ACTIVE HYBRID 5. ACTIVE HYBRID DAMPING.

0.60.6

Torq

ue

-0.2

0.4

Acce

lera

tion

[g]

4

0.2

Active Damping on1 2 53

Torq

ue

0.0

-0.2

0.4

Acce

lera

tion

[g]

4

0.2

0.0

Active Damping off1 2 53

0.0

0.0

Use of the E-Machine for active vibration damping.Significant improvement in comfort for dynamic response situations.

AHD

Tor

que

4t [s]

1 2 53

AHD

Tor

que

4

0.0

t [s]1 2 53

0.0


BMW ACTIVE HYBRID 5. CONNECTED DRIVE MEETS EFFICIENT DYNAMICS.

Use Case: downhill gradient.

- Start discharge by load reduction of

Beginning of slope.

-

-

Battery fully charged.

Shift to normaloperating strategy.

A

B

-

First-time use of route data from navigation system in hybrid operating strategy. Optimized adjustment to driving situation.

load reduction of combustion engine.

Maximize eDrive limits.

-

-

End discharge.

No load shifting.C


Use Case: slow driving zone.

BMW ACTIVE HYBRID 5. CONNECTED DRIVE MEETS EFFICIENT DYNAMICS.

A

B

-

-

Start load shifting.

Reduction eDrive limits.

-

-

End charging of HV battery.

Maximize eDrive limits.

Increased availability of e-drive.Improved fuel economy.Similar functionality for target zone.Battery cooling strategy is also adapted.

C- Shift to normal

operating strategy.


BMW ACTIVE HYBRID 5. SUMMARY.

Future-oriented fuel economy combined with the BMW-typical vehicle character.

Significant CO reduction of 16 % without compromise in driving dynamics.Significant CO2 reduction of 16 % without compromise in driving dynamics.

Distinctive electric driving experience, enhanced by intelligent connection of vehicle systems.

The ActiveHybrid 5 is another important milestone in the EfficientDynamics strategy.


THE FULL-HYBRID POWERTRAIN OF THE NEW BMW ACTIVE HYBRID 5.

Aachen Colloquium ChinaBMW Group, 1st November 2011

THE NEW BMW ACTIVE HYBRID 5.

THANK YOU FOR YOUR ATTENTION.

THE FULL-HYBRID POWERTRAIN OF THE NEW BMW ACTIVE HYBRID … · 2019. 2. 12. · BMW ACTIVE HYBRID...

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