Hybrid System Development IAV – The Partner for Electrification
Contents A Partner for the Paradigm Shift
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System Architecture Definition
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Powertrain Systems Design
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Electrical System Engineering
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Hybrid and Electric Drive Control and Calibration
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Integration Engineering
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About IAV
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As an industry partner, IAV has supported the integration of electrified technologies into the vehicles of today and tomorrow
A Partner for the Paradigm Shift IAV brings to the automotive industry a full spectrum of hightech engineering services in electronics, powertrain and vehicle development. Drawing on a complete vehicle system approach, IAV leverages company-wide expertise to supply the customer with the optimal, most efficient, cost effective and reliable solution. Since the early 1990s, IAV has been at the forefront of hybrid and electric drive development. Beginning with the design, build and development of concept vehicles and carrying through to the development of production applications, IAV continues to bring innovative solutions to the vehicle market. IAV offers industry-proven expertise in the development of hybrid and electric drive vehicles and methods, from full vehicle simulation during the concept phase using IAV's VeLoDyn for performance and fuel consumption optimization, to methods used for creating optimal hybrid and electric drive transmission systems with IAV’s in-house transmission synthesis tool and processes. Continuously striving to lead the charge toward the development of the ‘vehicle of the future’, IAV invests in technologies such as advanced battery management systems for lithium-ion and future cell chemistries.
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IAV applies a top-down holistic development approach for the entire vehicle
System Architecture Definition The introduction of electric machines to the powertrain provides an opportunity to increase operating efficiency and performance. To realize this opportunity, care must be taken in the selection of system architecture to ensure all vehicle requirements are achieved, especially component and total system cost. Furthermore, requirements for t he specific component must be defined, e.g., e-machine, inverter, high-voltage battery, cooling system, IC engine, transmission, brake system, etc. Whether the powertrain is being designed entirely from scratch or adapted to include the features of an HEV, concepts have to be evaluated early in the development phase to quantify the fuel consumption, efficiency, emission and drivability requirements to be achieved. Through the use of in-house and commercially available simulation tools, e.g., IAV’s VeLoDyn and Gamma Technologies GT-Drive, and backed by many man-years of experience, IAV quickly and accurately defines the system topology and technologies required to meet vehicle requirements. This includes system and sub-system requirements definition, supplier selection and validation. All completed in the context of 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
Powertrain Systems Design IAV hires and trains the very best hybrid powertrain system
possible permutations of powerflow through both planetary
design engineers specializing in the design of all Hybrid Electric
gearset and layshaft type transmissions. Using customer driven
Vehicle sub-systems, including the electric machine housing
criteria, the best possible architecture layout is selected for the
with its mounting, cooling and power-supply, high and low
customer‘s HEV application. To achieve optimal fuel economy
voltage harnesses, inverters and power-electronics, the energy
and reduced CO2, IAV’s architecture synthesis toolset includes
storage battery system, and control modules. By specifying and
transmission system hybridization via integration of electric
designing the required low-temperature cooling systems, IAV
machines.
employs design best practices to manage system intergration issues such as electro-magnetic interference. Throughout the development of the design, IAV deploys quality processes including DFMEA, GD&T, DFM/DFA, value analysis and cost management. Concentrating on efficiency and technical capability, IAV‘s degree-qualified design engineers take complete design and release responsibility for their components and assemblies. By carrying out the required specification, design calculations, digital modeling, design packaging, construction and design release with subsequent supplier management, IAV‘s design engineers ensure that all hybrid system and component requirements are considered and met. In effect, IAV design engineers become the total component project engineers. IAV has perfected an in-house transmission architecture synthesis toolset that is used to mathematically model all
A typical electric machine concept design
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IAV designs and integrates the powertrains of tomorrow
Electrical System Engineering The increasing scope of functionality provided by the electrical system and the high degree of cross-coupling of these systems require the E/E architecture to be designed with meticulous detail to meet automotive industry requirements. Increasing complexity forces new technology and changes the methods used in vehicle development. Many challenges are highlighted with the presence of high-voltage and current, especially safety. The functional safety of the electrified vehicle must be an integral part of the complete development process. IAV has demonstrated expertise in meeting these challenges in many of the production HEVs available today. In addition to production know-how, IAV has developed its own technologies, such as an intelligent battery management system for lithiumion cells, prototype inverters and DC-DC converters.
Topics covered: u
High-voltage battery
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Battery management systems
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Power electronic design
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High-voltage wiring
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Electric machine design and development
Prototype and production high-voltage battery systems
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Optimal performance is achieved by using robust control and calibration methods
Hybrid and Electric Drive Control and Calibration IAV specializes in the design, development and calibration of the control systems for proof of concept and production of electrified powertrains. The IAV team focuses on designing operating strategies to exploit the benefits of the electric drive in the presence of system constraints such as the battery’s SOC and powerlimits, e-machine torque and speed limits while maintaining a transparent driving experience. To support these activities, IAV has developed specialized tools, methods and processes to augment engineering expertise and expedite development while ensuring robustness and high quality levels.
Topics covered: u
Energy management
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Battery management systems
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Regenerative braking
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Enhanced stability systems
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Electric machine control
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Engine management
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Engine start/stop
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Driveline management
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Functional safety
IAV designs and calibrates the energy management system to exceed
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Diagnostics
customer requirements
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After HEV architecture definition, IAV engineers execute detailed design, integration, testing, validation and calibration
Integration Engineering Well over fifty percent of IAV’s powertrain system engineers around the world are dedicated to the package integration, functional development, control and calibration of automotive hybrid electric systems. This includes the mounting and s ervices integration for electric machines, hybrid battery systems, power electronics modules and the low temperature cooling system. IAV engineers are also specialists in the design and packaging of low and high voltage power and signal distribution harnesses, including design for electromagnetic compliance. In-house capabilities and experience span the derivation of system requirements with the customer to develop completely new HEV system architectures, from the design and integration of the hybrid electric sub-systems, to the electro-mechanical calibrations and OBD required for saleable production. IAV engineers have extensive hybrid electric cross-platform experience spanning light-duty front-wheel drive passenger cars, to rear-wheel drive premium sports cars, to light- and
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medium-duty commercial vehicles. IAV has not only integrated new hybrid electric systems, but also successfully converted production vehicles to create new hybrid electric variants.
Typical automotive hybrid electric system architectures
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IAV's new Technical Center – North America
About IAV IAV Group is a leading global automotive engineering service provider, employing more than 3,000 personnel throughout Europe, Asia and the Americas. Founded in 1998 as the North American subsidary of IAV GmbH, IAV Automotive Engineering Inc. develops breakthrough concepts and technologies — from powertrain design and development to controls and electronics — for future vehicle generations. Clients include leading automotive manufacturers and
London Detroit
Berlin Chemnitz Gifhorn Friedrichshafen Lenting Ludwigsburg Munich Neckarsulm Regensburg Ruesselsheim Weissach
Shanghai Seoul
Kaluga Paris
component suppliers, all of whom rely on the knowledge of IAV’s engineers to help them design and develop some of the industry’s most advanced engines and powertrains. The IAV Technical Center North America is now open in
Tokyo
São Paulo Pune
Northville, MI. The technical center includes four state-ofthe-art development/test cells. With this exciting new facility, IAV’s engineering capabilities have expanded to include full service projects, further cultivating the inventive
Excellence in automotive research and development —
spirit, enthusiasm and commitment to success for which the
a concept IAV applies across the globe
IAV Group is known.
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0 1 0 2 / 3 0 D : e v i t c e f f e , e c i t o n t u o h t i w e g n a h c o t t c e j b u S
IAV Automotive Engineering Inc. · 15620 Technology Drive · Northville, MI 48168 · USA · Tel. +1 734 233-3300 · Fax +1 734 233-3320 ·
Excellence in Automotive Research & Development
· www.iav.com
