Investigation of the power losses of the hybrid transmission DE-REX based on modeling and measurement

Abstract

Electric and hybrid powertrains are developed to reduce the energy and fuel consumption of vehicles. Recently, multi-speed transmission systems were discussed for further reduction of the energy consumption of electric vehicles. Therefore, analyzing the power losses of such transmissions is of interest. In this paper, the novel powertrain concept DE-REX (Two-Drive-Transmission with Range-Extender) and the experimental investigation of its overall power losses is first introduced. A method is then developed to model and analyze the power losses of this hybrid transmission based on experimental data. After the validation of the method, the overall power loss model is eventually applied to estimate the power losses of the transmission at other driving modes, which were not measured on the test rig. The method is used to understand the characteristics of power losses inside the transmission in a hybrid powertrain and to optimize powertrain power losses in future.

Keywords

Electric vehicles fuel efficiency/economy hybrid hybrid vehicles transmission vehicle chassis

Get full access to this article

View all access options for this article.

References

Delprat

Lauber

Guerra

, et al. Control of a parallel hybrid powertrain: optimal control. IEEE T Veh Technol 2004; 53: 872–881.

Tribioli

Energy-based design of powertrain for a re-engineered post-transmission hybrid electric vehicle. Energies 2017; 10: 918.

Velex

Ville

Diab

Investigations on power losses in high-speed gears. Proc IMechE, Part J: J Engineering Tribology 2006; 220: 191–198.

Banerjee

Kane

TR.

Modeling and simulation of rotor bearing friction. J Guid Control 1994; 17: 1137–1139.

Proctor

Kumar

Delgado

IR.

High-speed, high-temperature finger seal test results. J Propul Power 2004; 20: 312–318.

Molari

Sedoni

Experimental evaluation of power losses in a power-shift agricultural tractor transmission. Biosyst Eng 2008; 100: 177–183.

Szweda

TA.

An experimental study of power losses of an automotive manual transmission. PhD Thesis, The Ohio State University, Columbus, OH, 2008.

Rinderknecht

König

Schleiffer

. Modularity aspects for hybrid electric powertrains on the example of the two-drive-transmission. In: VDI Getriebekongresshttp://tubiblio.ulb.tu-darmstadt.de/65689/

Shen

Liu

Rinderknecht

. Modelling of power losses of transmission synchronizers in neutral position. In: WCX world congress experience. SAE International, https://doi.org/10.4271/2018-01-1228

10.

Niemann

Winter

Maschinenelemente: Band 2: Getriebe allgemein, Zahnradgetriebe-Grundlagen, Stirnradgetriebe. Berlin: Springer-Verlag, 2013.

11.

Shen

Rinderknecht

Hoppert

General modelling method of power losses in transmission with parameter identification. Forsch Ingenieurwes 2017; 81: 117–123.

12.

Development of a generalized mechanical efficiency prediction methodology for gear pairs. PhD Thesis, The Ohio State University, Columbus, OH, 2005.

13.

Changenet

Velex

A model for the prediction of churning losses in geared transmissions—preliminary results. J Mech Design 2007; 129: 128–133.

14.

Heingartner

Mba

Determining power losses in helical gear mesh: case study. In: ASME international design engineering technical conferences and computers and information in engineering conference, Chicago, IL, 2–6 September 2003, pp.965–970. New York: ASME.

15.

Dawson

Windage loss in larger high-speed gears. Proc IMechE, Part A: J Power and Process Engineering 1984; 198: 51–59.

16.

Eastwick

Johnson

Gear windage: a review. J Mech Design 2008; 130: 034001.

17.

SKF. SKF-Hauptkatalog: das Wälzlager-Handbuch für Studenten (Katalog 5000 G). Schweinfurt: SKF Group, 2004.

18.

Michaelis

Höhn

Hinterstoißer

Influence factors on gearbox power loss. Ind Lubr Tribol 2011; 63: 46–55.

19.

Huang

Zhu

Guo

Thermal analysis of high-speed SMC motor based on thermal network and 3-D FEA with rotational core loss included. IEEE T Magn 2009; 45: 4680–4683.

20.

ISO14179: 2001. Gear—thermal capacity—part 2: thermal load carrying capacity.

21.

De-Peng

Shou-xiang

Global sensitivity analysis of occupant egress safety model. Procedia Engineer 2011; 11: 179–184.

22.

Jurkschat

Otto

Lohner

, et al. Bestimmung des Verlustverhaltens und der Wärmebilanz von Wäzlagern. Forschung im Ingenieurwesen 2018; 82: 149–155.

23.

Fernandes

Marques

Martins

, et al. Gearbox power loss. Part I: losses in rolling bearings. Tribol Int 2015; 88: 298–308.

24.

Bard

Nonlinear parameter estimation. Cambridge, MA: Academic Press, 1974.

25.

Shacham

Brauner

Application of stepwise regression for dynamic parameter estimation. Comput Chem Eng 2014; 69: 26–38.

26.

Refaeilzadeh

Tang

Liu

Cross-validation. Berlin: Springer, 2009.