Hybrids, Page 2
Bosch received first diesel-electric hybrid component production contract
Bosch was awarded the first production contract for a diesel-electric
hybrid but would not identify the automaker. Components include the engine
and hybrid controller and electric motor. Production should start by 2010.
Source: Dow Jones. June 12, 2007
GM awards advanced development battery contracts for Chevrolet Volt
GM
awarded two contracts for advanced lithium-ion battery development
from among 13 contenders for both range-extender gasoline electric and
fuel cell variants of the E-Flex architecture to speed up development
of the Volt. One contract was
given to Compact Power Inc. in Michigan, a subsidiary of LG Chem
of Korea using their lithium-ion polymer cells with manganese spinel
(LiMn2O4) based cathodes. Mercedes has been using manganese lithium-ion
batteries in the B-Class F-Cell fuel cell vehicle introduced in 2005
(earlier mention). The other contract
was awarded to Continental Automotive Systems, who recently announced
plans for lithium-ion batteries and who have been working with GM on
hybrids since 2003. Continental will integrate A123Systems lithium iron
phosphate (LiFePO4) cells.
June 5, 2007
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Mercedes to build Citaro G series hybrid bus prototype
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BMW steers away from hybrid powertrains - report
BMW revealed
to journalists in Britain hybrids will not be part of their range for
the forseeable future, although BMW codeveloped the two mode hybrid.
Instead BMW will focus on "Efficient Dynamics", a package of
technologies and energy management systems including automatic
stop-start and regenerative braking, which will be spread
through BMW's model range as it's renewed.
May 9, 2007
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BAE Systems Hybridrive to use A123Systems Li-Ion cells
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Siemens VDO update on Fuel Efficiency
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Saft adds new lithium ion technology to its product portfolio
Saft launches LiFePO4 for defense applications. Lithium
iron phosphate technology was licensed from the University
of Texas. While the performance is lower than their standard
LiNiCoAlO2 lithium ion cells, it has higher thermal stability.
According to Saft there are still some challenges ahead to
make LiFePO4 compatible with automotive applications.
April 25, 2007
Bosch receives first major gasoline-electric hybrid contract:
Touareg, Cayenne, Q7
During the wide ranging annual press conference Franz Fehrenbach
announced
Bosch had received a first major contract for a gasoline-electric hybrid,
with an expected fuel efficiency improvement of 25% in urban traffic
compared to conventional port injection systems. According to several
press reports it's for the VW Touareg, Porsche Cayenne and Audi Q7.
Series production should start late 2008 with an anticipated annual
volume of 30,000 to 40,000, and up to 100,000 units lateron.
April 25, 2007
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Magna Steyr shows HySUV electric 4 wheel drive (e4WD)
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Daimler PHEV Prototype |
New York Times to operate Sprinter Plug-in Hybrid
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PG&E Energizes Silicon Valley With Vehicle-to-Grid Technology
Pacifc Gas and Electric
showed a prototype plug-in hybrid which was converted in partnership
with the Bay Area Air Quality Management District and Energy CS, which
added a lithium ion battery to a traditional Toyota Prius. The additional
battery capacity increases the vehicle's ability to run completely on
electricity. In front of many of the Silicon Valley's industry and
governmental leaders, PG&E showed the reverse flow of energy from the
vehicle back to the outlet -- a first public showcase for any utility.
Once connected to the outlet, PG&E then ran several lights and appliances
to show how V2G could benefit its customers. "PG&E's V2G demonstration marks an important milestone for plug-in vehicle technology," said Felix Kramer, Founder of CalCars.org. "Using a grid-connected car's battery as distributed energy storage for homes or businesses expands the economic and environmental benefits of plug-in vehicles."
April 9, 2007
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Wrightspeed's X1 Electric Supercar Sparks Hybrid Dreams
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Daimler Expands Plug-in Hybrid Program to New Sprinter
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Palo Alto Daily News: Mayor kick off Plug-in Hybrid Drive
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Swatch negotiates hybrid license with car industry
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Mercedes is working on Automatic Stop-Start
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Standard Brake Energy Regeneration Debuts
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Mercedes might introduce two hybrid systems in 2009
BMW Daimler to Cooperate on Efficient Dynamics
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Südchemie to invest in lithium iron phosphate production
Südchemie
invests
in Quebec lithium iron phosphate production for use a new generation of
lithium-ion batteries. Phostech Lithium in Boucherville/Canada, an affiliate
of Süd-Chemie AG, Munich, has completed the construction of a production
line of 300 metric tons per year of lithium iron phosphate (LiFePO4).
Phostech Lithium cooperates with Bosch Power Tools to develop lithium-ion
batteries with iron phosphate cathodes, with an expected market launch in 2007.
February 10, 2007
China BAK Announces Plans for New Facility to Manufacture New Products
China BAK Battery announced plans for
a new advanced lithium ion battery cell production site in the
Tianjin Beichen Hi-Tech Industrial Park.
January 10, 2007
GM revives the electric car: Sleek Chevy Volt concept unveiled
The Volt has a 40 mile range on 16 kWh lithium ion batteries alone, and can
be recharged either by plugging into a standard 15A outlet, or using the
onboard 1 liter 3 cylinder turbocharged engine with generator set (genset)
rated at 53 kW in a series hybrid config, which extends the range to
640 miles on 12 gallons of fuel.
The Volt has some similarities with the Swatchmobile proposed by Nicolas Hayek in 1994.
GM plans to produce them once suitable batteries become available in
a few years. Since it's based on the E-Flex architecture the Volt
can also be adapted to hydrogen fuel cell
or all electrical power, says Nick Zielinski, chief engineer for the Volt.
Jan 7, 2007
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Johnson Controls-Saft and Cobasys A123Systems to design and
test GM plug-in hybrid battery
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Siemens VDO to acquire Ballard's Electric Drive Business
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Degussa, Volkswagen set up Lithium-Ion professorship
Degussa announced a new institute for Applied Materials Sciences for
Energy Storage and Conversion at Münster University, in cooperation with
Chemetall and Volkswagen. The intention is to focus on large format
lithium-ion battery technology for hybrids. Degussa writes: "The task in
this respect is to improve the energy and power density of batteries and
their safety and durability, all important prerequisites for significantly
lowering the costs of battery systems." Degussa makes the SEPARION®
flexible ceramic foils and also electrodes for lithium ion batteries.
Degussa SEPARION®
Oct 16, 2006
| Project White Star update
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FedEx puts 75 more hybrid delivery trucks into service
FedEx together with Eaton and Freightliner developed hybrid
delivery trucks and had been running 18 prototypes. More recently
a further 75 vans were built to go into service in New York City
and other cities by this summer. The Stanford Graduate School of
Business case study gives some background of the development process.
The W700 Step Vans use a 4.3 liter Mercedes OM904 inline 4 diesel
engine from the well established European 900 series known as the
MBE 900 in the USA and with an output of 125 kW (167 hp),
Eaton developed direct hybrid transmission, Li-Ion batteries and
are assembled by Freightliner Custom Chassis in Gaffney South Carolina.
FedEx was awarded the 2005 Blue Sky Award by CALSTART for "its
nearly single-handed placement of commercial hybrid trucks on the
map for corporate America. The FedEx and Environmental Defense
effort led the commercial truck market’s interest and efforts into
the hybrid market."
Stanford case study: FedEx and Environmental Defense: Building a Hybrid Delivery Fleet (pdf)
Heavy Hybrid Vehicle Commercialization Progress and Directions
The HTUF Process, CalStart/WestStart (pdf)
9/16/2006
Sprinter hybrid electric and plug-in hybrid electric drive
Inner-city delivery vans do most of their work in areas where emissions
are a major issue, therefore Daimler is intensively developing
alternative drive systems. Top right: ZF Sachs produces the strong
Sprinter electric motor with 70 kW placed between combustion engine
and transmission. The Sprinter hybrid was introduced at the IAA
commercial vehicles in Hannover in September 2004 as
mentioned earlier.
Sprinter info page
9/15/2006
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Johnson Controls-Saft awarded program for Li-Ion batteries
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Bosch video: Micro Hybrid Start Stop System (SES), Mild & Strong Hybrid
Bosch is getting up to speed. They updated their
webserver to include hybrid info, explaining the difference between
micro hybrid, mild and strong hybrid, including videos, and also
established the Bosch Hybrid System Project House in 2004.
9/5/2006
NO MBUSA two-mode hybrid plans
Paul Halata, MBUSA's parting CEO, says MBUSA plans no two
mode hybrid within a year after the Chrysler Group's and General Motors
hybrid SUVs debut. Daimler jointly developed the P1/2
transmission with GM and BMW. MBUSA plans to focus on turbodiesel
SUVs instead.
diesel page
8/17/2006
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Car motor disappears into the wheels: Siemens VDO eCorner
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click on pic for schematic
Canter Eco Hybrid goes into production
It's powered by a 3.0 liter four cylinder turbodiesel with 125 hp (92 kW)
and a slim 35 kW (48 hp) electric brushless motor in a parallel hybrid
configuration, with Li-Ion batteries (346 Volts, 5.5 Ah, 1.9 kWh, 96 cells),
and is now shipping in Japan. The Eco Hybrid can be driven by either
the diesel engine or the electric motor, or both in parallel and
using Mitubishi Fuso's Inomat automated manual transmission. The
integrated regenerative braking system produces an additional
fuel savings of as much as 20%. Last March Mitsubishi Fuso showed
a prototype at the MidAmerica Trucking Show to evaluate interest.
Owing to extremely densely populated areas, hybrid vehicles such as
the Canter ECO Hybrid play an important role in Japan.
What Van? review of Canter ECO Hybrid
7/6/2006
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Bosch and Getrag form hybrid alliance
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California's first diesel electric bus goes into service today
56 Clean Air Daimler Orion VII low floor buses are to roll
out in the fall. San Francisco Muni will own the third largest hybrid fleet
in the United States. The buses use the BAE Systems diesel-electric series
hybrid HybriDrive based on a 5.9 liter Cummins ULSD turbodiesel and electric
traction motor with 250 hp and 320 hp peak. Last fall New York City
Transit / MTA Bus ordered a large fleet, Transit Toronto already operates
them and in St. Louis the Missouri Metro is testing them.
www.dcbusna.com
SF Muni
6/1/2006
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Luk Electrical shift gearbox (ESG)
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GM, DaimlerChrysler, BMW release some details
The result, say the three collaborators, is ”trend-setting hybrid technology that provides superior fuel economy, performance and load carrying capability”. Key Advantages.
Traditional hybrid systems typically have only one torque-splitting arrangement and no fixed mechanical ratios. These systems are often called "one-mode" hybrids. Due to their less capable mechanical content, one-mode hybrids need to transmit a significant amount of power through an electrical path that is 20 percent less efficient than a mechanical path. This requires usually substantial compromise in vehicle capability or reliance on larger electrical motors, which can create cost, weight and packaging issues. General Motors, DaimlerChrysler and the BMW Group conceive a full hybrid system featuring four fixed mechanical ratios, within the two ECVT modes, to reduce power transmission through the less efficient electrical path. Consequently, the electric motors are more compact and less dependent on engine size. This combination of two ECVT modes and four fixed gear ratios eliminates the drawbacks of one-mode hybrid systems to allow for efficient operation throughout a vehicle's operating range, at low and high speeds. It also allows for application across a broader variety of vehicles. It is particularly beneficial in demanding applications that require larger engines, such as towing, hill climbing or carrying heavy loads.
Existing internal combustion engines can be used with relatively minimal alteration because the full hybrid system imposes no significant limitation on the size or type of engine. It enables the three automakers to package internal combustion engines with the full hybrid transmissions more cost-effectively and offer the fuel-saving technology across a wider range of vehicles.
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EPRI Journal: "The Plug-In Hybrid Vehicle"
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| NiMH full hybrid battery
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Smart Electronic Start/Stop System (SES) for micro hybrids
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PSA Peugeot Citroën unveiled diesel-electric hybrid prototype
PSA Peugeot Citroën unveiled two demonstrators featuring
a diesel-electric hybrid powertrain, the Peugeot 307 and the
Citroën C4 Hybride HDi. The performance of these cars represents
a major breakthrough in further improving fuel economy and
reducing CO2 emissions. They also provide increased driving
comfort under all conditions, especially in urban traffic.
The main features of the Peugeot 307 prototype are:
1.6 liter 66 kW HDi turbodiesel with EU 4 particulate filter
parallel hybrid drive configuration
synchronous permanent magnet electric motor rated at 16 kW continuous and up to 23 kW peak
new generation stop/start system
six speed automated manual gearbox
fuel consumption of 3.4 liters per 100 kilometers (NEDC, combined) - 90 g CO2 per kilometer - 69 MPG
240 NiMH battery cells with 288 Volt total
all electric driving with up to 50 km/h
PSA Peugeot Citroën diesel-electric hybrid
January 31, 2006
VW starts hybrid cooperation with Continental, ZF, SANYO
Volkwagen ordered a hybrid power control module
from Continental Automotive Systems. The EP220 hybrid controller
takes 100 kVA CW and 160 kVA peak for up to 60 seconds.
Continental also received a specific order for the hybrid drive modules.
ZF will supply the electric motor, the clutch and the dual-mass flywheel.
SANYO and Volkswagen agreed to codevelop next generation Nickel Metal Hydride
HEV battery systems.
January 31, 2006
The BMW Concept X3 EfficientDynamics
Rainer Rump the General Manager Hybrid Cooperation BMW talks us
through the innovations that make up the BMW Concept X3 EfficientDynamics.
Vodcast
January 17, 2006
Degussa expands production for lithium-ion electrodes
Degussa expands electrode production for large format lithium-ion
batteries at Li-Tech GmbH (SK Firmengruppe) in Kamenz near Dresden.
The Kamenz facility complements Degussa's production capacities in
China through the joint venture Degussa-ENAX (Anqiu) Power Lion Co. Ltd.,
Anqiu. The German site will target large-volume energy storage
applications - such as batteries for hybrid vehicles.
Jan 13, 2006
"The California HybridMercedes" = Mercedes + Prius
With the sticker the single occupant Prius can use car pool
lanes. The Toyota Prius can't be plugged into the grid like the
Sprinter PHEV. Folks are working on an upgrade kit.
CalCar's PHEV
Hybrid sales reach 200,000 in 2005
Hybrid vehicle sales increased to more than 200,000 in
2005 up from 9500 in 2000. In comparison 543,000 diesel vehicles
were sold last year in the USA, including E320 CDI, Jeep
Liberty, Sprinter van and Dodge RAM.
Dec 15, 2005
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Degussa tests Honda Civic IMA hybrid with SEPARION
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F600 Hygenius introduced in Tokyo
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NYC orders 500 Orion VII diesel electric hybrid buses
After testing diesel electric hybrid buses for several years, New York
City Transit, MTA Bus placed a large order with Daimler for 500
Orion VII low floor buses equipped with the diesel electric HybriDrive
using the 5.9 liter inline 6 Cummins turbodiesel, in a series hybrid
configuration, like the Mercedes diesel electric test bus shown in 1969.
BAE HybriDrive
Oct 11, 2005
JESMB Testdrives CLK 500 ISG M273
JESMB drove a CLK 500 ISG Hybrid prototype at the IAA. It has the new
M273 E 55 (5.5 liter V8 with 388 hp und 530 NM) V8 and the ISG integrated
starter generator hybrid. There is no engine running at the red light
but surprisingly the climate system keeps running. It takes only 0.3 seconds
to start. Overall the fuel economy is estimated to be around 9-10 liter per
100 km with the ISG saving around 6%. ZF built the 6 kW electric motor.
Sep 13, 2005
"DIRECT HYBRID" and "BLUETEC HYBRID" S-Class concept cars
Mercedes showed two concept cars at the IAA 2005 in Frankfurt.
The DIRECT HYBRID uses spray-guided direct gasoline injection and an 6 kW/8.2
hp electric motor and a DeNOx catalyst. Fuel consumption drops due
to a combination of spray-guided injection and the start/stop mild hybrid.
The BLUETEC HYBRID uses a 3.0 liter V6 turbodiesel, the same
electric motor and SCR to clean the exhaust.
The diesel engine can be run more efficiently with SCR/Adblue reducing
consumption in addition to the start/stop system.
This mild hybrid captures benefits
like start/stop, regenerative braking and torque assist at low
engine speeds with comparable low cost.
S350 DIRECT HYBRID 221 kW/300 hp 395 Nm 7.5 sec 0-100 consumption in l/100km: 8.3 instead of 10.2
S320 BLUETEC HYBRID 179 kW/243 hp 575 Nm 7.2 sec 0-100 consumption in l/100km: 7.7 instead of 8.4
Sep 13, 2005
DIESEL BEATS HYBRID: ML320CDI RX400h Coast-to-Coast-Marathon
Autobild tested diesel vs hybrids in a coast to coast marathon. Overall results:
ML320CDI driven 5229 kilometers
RX400h driven 5126 kilometers
ML320CDI 127.4 gallons fuel
RX400h 139.3 gallons fuel
ML320CDI consumption 9.2 liters/100km (25.5 MPG)
RX400h consumption 10.3 liters/100km (22.9 MPG)
diesel info page
8/7/2005
Dodge RAM Contractor Special
The RAM diesel HEV comes with a 5.9 liter Cummins
turbodiesel with 325 hp / 600 lb-ft, starter/generator, 20-30 kW
off-grid power generation capability with 110/220 AC outlets, regenerative
braking and better fuel economy. Small scale production started in
December 2004 and it's only available to fleet customers.
GMC Tahoe Two-Mode hybrid
This full hybrid employs two electric motors, one for stop and go
driving and another one (mode 2) runs at highway speed, improving
both city and highway fuel economy by about 25%. The technology is
developed with Daimler and should come to market in 2007.
2008 GMC Tahoe (estimated)
EPA CITY: 20 MPG instead of 16
HIGHWAY: 25 MPG instead of 20
4/11/2005
GMC Sierra and Chevrolet Silverado RWD hybrid
In this mild hybrid the Continental supplied integrated starter,
generator and damper (ISAD) installs between the engine and transmission,
thus reducing gas consumption up to 15%, depending on driving cycle.
First installed in the 2004 GMC Sierra. The ISAD system was first
developed to ease the transition to 42 Volt electrical systems.
The later did not become popular, however. Update: Overall 3000 were
produced before production ended in December 2006 as the
technology was not brought forward to the new platform.
EPA CITY: 18 MPG instead of 16
HIGHWAY: 20 MPG instead of 19
3/1/2005
Ford Escape Hybrid 4WD SUV
Comparing the standard version with 4 cylinder, 4WD and automatic with
the hybrid, the fuel economy improves quite a bit in the city and less so
on the highway. Conti Teves supplies the regenerative brake (and ESP) system.
EPA CITY: 33 MPG instead of 19
HIGHWAY: 29 MPG instead of 22
2/1/2005
E-class diesel with good highway fuel economy
MBUSA offers the E-class with gas or diesel. The E320 CDI
improves the highway and also the city fuel economy of the E320
by more than 30% each while also accelerating faster. Better
economy than a hybrid and it's built in Sindelfingen.
EPA CITY: 27 MPG instead of 20
HIGHWAY: 37 MPG instead of 28
Lexus RX400h introduced
It improves the 0-60 by half a second to 7.3 seconds while also
increasing the combined fuel econony by 33% to 28 MPG (30 MPG CITY,
26 MPG HWY) compared to the RX330 AWD.
It's quite complex with three separate electric motors:
the NG1 starter generator, the NG2 123 kW motor with permanent magnets
and the NGR 50 kW rear axle motor in addition to the 3.3 liter gasoline
V6 with 208 hp. Overall it's rated at 268 hp and can add up to 247 lb-ft.
at launch on the front axle and 96 lb-ft. on the rear axle. But most
owners claim the published numbers are too optimistic obtaining
only up to 25 MPG, even in city driving!
EPA CITY: 31 MPG instead of 18
HIGHWAY: 27 MPG instead of 24
2/1/2005
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Active M-class transmission
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S400 diesel-electric hybrid concept with 328 hp (241 kW)
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DaimlerChrysler and GM Join Forces to Develop Two-Mode Full Hybrid Propulsion System
The result is expected to be
"a series of strong hybrid propulsion
systems that will serve as a solution for our alternative powertrain needs."
MB will focus on high-tech hybrid propulsion systems in passenger cars in
the luxury segment. Volkswagen may also be interested in this technology.
The first products will be the Dodge Durango and GMC Yukon in 2007 and
furtheron this technology will be used in GM, Chrysler and Mercedes vehicles.
12/13/2004
Mercedes to develop gasoline electric hybrid
Mercedes-Benz will bring to market a gasoline
electric hybrid with rear wheel drive, designed particularly with the market
in Japan and the USA in mind, in areas with much stop-and-go traffic. "It
will take less than 5 years and will be a typical Mercedes-Benz premium
vehicle", said chief of development Dr. Thomas Weber. To save costs, Mercedes
is completely open to cooperate with suitable partners and suppliers.
Reuters
10/25/2004
SANYO may develop Mercedes-Benz hybrid batteries
SANYO Electric Co., Ltd. may develop batteries for Mercedes hybrid electric
vehicles. They also make battery systems for DaimlerChrysler's fuel
cell program and have similar battery contracts with Ford and Honda.
10/19/2004
Update on F500 Mind diesel-electric hybrid research car
Hybrid drive returns fuel savings of as much as 20 percent in NEDC cycle - but not real world
Practical research revealed both the benefits and drawbacks of the alternative drive technology. One of the plus points is the electronic load share apportionment between engine and electric motor: when driving in slow-moving stop-go traffic, pulling away or parking, the diesel engine is shut off and the F 500 Mind switches to purely electric drive. This allows fuel consumption to be cut by some 20 percent in the NEDC cycle. Just the ability to switch off the diesel engine when stopped at traffic lights and pull away again using the power from the electric motor represents a fuel saving of around ten percent. Automatic energy recovery during braking also comes into the equation, accounting for a further five to seven percent reduction.
However, researchers at Daimler detected a discrepancy between theory and practice, as the fuel consumption figures for the NEDC test cycle and for testing under practical operating conditions did not tally.
"The actual fuel consumption of the hybrid drive on longer
interurban or motorway journeys is actually higher than with the
standard Mercedes diesel model," says Dr Herbert Kohler, Powertrain
Research and Chief Environmental Officer for Daimler,
and continues: "We are looking to fine tune the hybrid drive and
deploy it in such a way that its benefits outweigh the tremendous
technical effort involved. As a result of the practical tests that
have been held so far, we now know that the diesel engine holds a
greater overall potential for reducing fuel consumption and levels
of CO2 emissions."
diesel engines
10/8/2004
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Sprinter Hybrid and Sprinter Plug-in Hybrid Drive
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S-Class Hybrid
A 28 module NiMH battery with 6 Ah, 200 Volts and 1.2 kWh was used. It weighs 99.3 lbs, was supplied by Varta and could supply 20 kW for 30 seconds. |
| electric hybrid drive system (S-Class, NAIAS 2004) | ||
| Output | V6 engine Electric motor 1 Electric motor 2 |
180 kW - 241 hp 25 kW - 34 hp 25 kW - 34 hp |
| Max. torque | V6 engine Electric motor 1 Electric motor 2 |
350 Nm - 258 lb-ft 150 Nm - 111 lb-ft 300 Nm - 221 lb-ft |
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Mercedes F500 and GST II Hybrids
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BMW Efficient Dynamics Makes More Power
The BMW Group introduced an X5 research project at the IAA which
enhances the torque of the combustion engine with an electric motor.
The two powerplants complement each other since the electric motor
starts with full torque from zero rpm, while the combustion engine
reaches the maximum around 4000 rpm. The combined total torque
of both electric motor and combustion engine exceeded 1000 Nm at
1000 rpm.
August 18, 2003
Continental's integrated starter alternator damper (ISAD) chosen by
General Motors
for GM's hybrid truck project. At the time the prevalent thinking was
that this project would signal the move towards 42Volt battery and
electrical systems.
MIT/Industry Consortium on Advanced Automotive Electrical/Electronic
Components and Systems
Jan 7, 2003
Maybach active integrated rectifier regulator
The active integrated rectifier regulator (AIRR) developed for
the Maybach increases the efficiency of rectifing the AC current
supplied by the generator to DC suitable for charging the battery
and supplying the onboard circuits, and foreshadows the move to
the integrated starter alternator over the next decade.
International Rectifier Announces Technology Breakthrough
Dec 18, 2002
Mercedes-Benz M-Class HyPer diesel-electric hybrid
In 2002 DaimlerChrysler Research has introduced the M-Class HYPER - a new hybrid vehicle that consumes up to 20 percent less fuel than a comparable production model. The powertrain of this sporty four-wheel drive vehicle is equipped with a special clutch and an electric motor that eliminate the need for a generator or starter. The result is not only a reduction in vehicle weight, but also reduced costs. Stuttgart. December 1, 2003. The English word "hybrid" derives from the Latin "hybrida", which means "half-breed". In the automotive industry, engineers use the term hybrid vehicle to designate an automobile that has two energy converters - combustion engine and an electric motor, let's say. Because it has two power sources, such a vehicle also requires two energy stores - a fuel tank and a high-voltage battery. But if you took a peek under the hood of one of the latest hybrid vehicles developed by Daimler Research - the M-Class HYPER - you would hardly believe that this sport-utility vehicle is a hybrid. Although the standard 2.7-liter CDI diesel engine would be impossible to overlook, you would notice that the M-Class HYPER doesn't appear to be equipped with a conventional electric motor and the associated battery. Head of Advanced Propulsion Systems, Prof. Karl E. Noreikat, holds the key to this mystery. "We have already achieved a high degree of integration of the two drive units," he explains. "The electric motor is being ever-more tightly integrated into the powertrain and now takes up almost no additional space. It is positioned directly on the clutch shaft, between the clutch and the transmission, with which it forms a connected unit." From the cylinder to the disc This integration was realized thanks to a new design for the electric motor. The motor doesn't have the elongated, cylinder-shaped rotor found in conventional electric motors, such as those in drills, for example. Instead, the new type of electric motor features a very narrow, ring-shaped rotor with a comparatively large diameter. Noreikat and his team refer to the contrasting designs as the "sausage" and the "disc" motors. With an output of 61 hp (45 kW), the high-torque disc motor has the advantage that it can be easily incorporated into existing drive trains. And its sophisticated electronic control system and state-of-the-art clutch offer even more benefits:
Prof. Herbert Kohler, head of the Body and Powertrain research unit, can point to still another advantage. "Although they consume less fuel, all of our hybrid vehicles offer considerably better driving dynamics than comparable conventional vehicles," Kohler reports. The reason is that electric motors immediately reach their maximum torque when a vehicle is started, which means that the car can accelerate very quickly from a standing start. The electric motor can also support the combustion engine with additional torque while a vehicle is being driven, which improves acceleration as well. As a result, the M-Class HYPER powered by a 163 hp (120-kW) five-cylinder in-line turbodiesel engine can match the acceleration of an M-Class equipped with a more powerful engine of the next highest rating. [The acceleration time for the more powerful ML400 CDI is 8.1 seconds, instead of 11.4 seconds for the ML270 CDI.] New combinations of proven parts Lower fuel consumption, fewer emissions, superior driving dynamics and easy integration into the powertrain - the advantages of the M-Class HYPER are the results of the work carried out by Noreikat's team in their search for a simple and compact solution. "Our aim was to develop effective new combinations of proven parts that would allow us to come up with reliable, cost-effective solutions," explains Noreikat. The engineers succeeded in making optimal use of the advantages of hybrid technology. Using a simple "parallel hybrid concept," they retained all of the comfort-enhancing and performance features of a conventional drive train - and even improved them. "One advantage here was that we didn't have to modify the transfer case of the permanent four-wheel drive in order to assemble the hybrid system," reports Christof Bunz, a member of Noreikat's team. Bunz and his colleagues made a considerable investment of time and effort in the development of the electronically controlled clutch unit, which controls the constantly changing interaction between the combustion engine, the electric motor and the automated 6-speed manual transmission. The clutch is remarkable because it can balance the different speeds and torques of the motor, the engine and the transmission so gently that the vehicle is guaranteed to run smoothly. And drivers will barely be aware of gear shifts during acceleration. A closer look at the different driving modes gives a clearer understanding of just how clever the clutch really is: When starting up, driving at low speeds in city traffic or when stuck in a traffic jam, the diesel engine is switched off altogether; only the electric motor propels the vehicle. Depending on driving conditions, the clutch ensures that the combustion engine is push-started once the vehicle reaches approximately 25 km/h. In normal driving mode, the combustion engine powers the car. "Here, the electric motor is only used to synchronize the transmission during gear shifts," says Bunz. During the acceleration process - while overtaking, for example - the electric motor is automatically activated, so that the torques of the motor and the engine are combined. This is what engineers call the "booster function." During extended application of the vehicle's brakes, the diesel engine switches off and the electric motor is used for regeneration. The motor is powered by the wheels via the transmission and functions as a generator, converting kinetic energy into electrical energy. This energy is then fed into the car's battery. The battery is also charged when the vehicle is being driven at a constant highway cruising speed, and the combustion engine is not required to operate at its maximum output. In this mode it is the engine, not the transmission, that turns the motor so that it functions as a generator and charges the battery. Water-cooled battery
The battery used in the hybrid vehicle is a water-cooled, nickel
metal-hydride battery with an output of 50 kW. It is installed together
with the electronic battery control in the spare wheel well at the rear
of the vehicle. And in addition to being a space-saver, this arrangement
also solves the mystery of that missing second energy-storage device.
You remember. The one that was nowhere to be found under the hood.
©1998-2004 DaimlerChrysler. All rights reserved. |
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ZF Sachs introduces DynaStart for commercial vehicles
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| MCC smart GmbH: smart HYPER
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| Mercedes A-Class Hyper
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L.A. Autoshow 2001: Dodge Powerbox CNG hybrid concept
Dodge showed a CNG gas electric TTR hybrid. The supercharged 2.7 liter
V6 with 250 hp (187 kW) running on compressed natural gas drives the rear
wheels while a Siemens Automotive electric motor with 70 hp (52 kW) drives
the front wheels. The two systems are not connected other than through
the road. Compared to a Durango the PowerBox
fuel economy improves to 25 MPG, or 60% and the range is 350 miles.
Chrysler's head of engineering Richard Schaum: "Introducing
a CNG-electric hybrid SUV, with patented 'through-the-road' (TTR) technology,
gives consumers the option of an environmentally-friendly vehicle without
sacrificing their wants and needs for both performance and utility." Lateron,
on May 17, 2002, the Detroit News reported the Durango hybrid was
discontinued due to low demand.
Siemens Automotive announces the Integrated Starter Generator (ISG)
"Siemens Integrated Starter Generator Stands Ready To Meet SUV Makers' Aggressive Fuel Economy Targets"
"Siemens Soft Hybrid Stands Ready to Meet SUV Makers' Aggressive Fuel Economy Targets"
Oct 16, 2000 and Mar 7, 2001
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Mercedes S-Class RWD Hybrid
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Diesel-electric drive system in the Cito midibus debuts in 1998
In 1998 Mercedes-Benz introduced the Cito urban midibus. The
innovative low-floor vehicle had a diesel-electric drive system.
An OM 904 LA diesel engine with an output of 130 kW (177 hp) served
to drive a generator. The generated electric power was fed into the
electric traction motor. The unit consisting of diesel engine,
generator and electric motor was installed in the rear of the
vehicle and called a power pack. Mercedes-Benz developed the
system together with Siemens. The Cito was built from 1999 to 2003.
In 2000 it won the distinction of "Bus of the Year 2001."
| Mercedes-Benz A-Class EV zero emission
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Integrated starter alternator damper (ISAD) wins the German
Business Innovation Award 1997
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Audi Duo A4 Avant diesel-electric plug-in hybrid and Toyota Prius debut in 1997
After showing concepts for several years starting around 1989,
Audi introduced the Audi Duo A4 Avant at the IAA in 1997. It was based
on the A4 wagon and had a 1.9 liter TDI direct injection turbodiesel
and Siemens electric motor, both
driving the front axle. 22 lead acid batteries in series with 10 kWh
capacity weighed 320 kg and were charged primarily by plugging them
into a regular 220 Volt outlet, and secondarily when driving.
The duo was substantially more expensive than the regular diesel model.
Only 60 were sold. Ten Audi Duos participated in the ELCIDIS program
to evaluate their performance over 30 months. 38% of the total
mileage covered in the test was in electric mode. The ELCIDIS report
concluded the Audi Duo uses more energy than the Audi A4 1.9 TDI
standard vehicle. In the following years the European car industry
focussed on diesels instead.
In the same year, 1997, Toyota introduced the Prius gas-electric hybrid
at the Tokyo motor show for the domestic market in Japan, albeit with
1.7 kWh NiMH battery weighing 57 kg and without plug-in capability nor
diesel engine.
European Commission: ELCIDIS Electric Vehicle City Distribution
Who'll Help Build Hayek's Dream? : Swatch for This Car
Nicolas Hayek has a vision for a hybrid SwatchMobile with a
range of 550 miles. This article appeared on January 15, 1994 in the International
Herald Tribune. In the concept Swatchmobile a small 2 cylinder
250 cc gasoline engine with 40 hp drives a generator (genset)
and charges a battery, which in turn power four individual
electric wheel mounted motors.
Mercedes-Benz C-class "Taxi Hybrid" in 1993
This was the first parallel hybrid from Mercedes-Benz.
It combined a 55 kW/75 hp inline four diesel with an
electric motor, with an output of 20 kW/28 hp and 130 Nm of torque,
and 120 Volt battery. In electric mode it can travel about 15 miles.
Two years later another C-Class model followed with serial hybrid
engine.
Hybrid with boxer engine in 1982
Some guys at DaimlerBenz Research unveiled the first mobile prototype
with hybrid technology in 1982. This vehicle, however, was fitted with
only a two-cylinder horizontally opposed boxer engine, enough to keep
the car on the road if the battery ran flat.
Mercedes introduced world's first hybrid bus in 1969
At the IAA in 1969 Mercedes-Benz presented a technological feat:
the Elektro-Versuchsbus, an electric hybrid bus for testing, designated
the OE302 ("E" standing for Electric) with 205 hp electric motors, plenty
for a bus at the time, 380 Volt Varta lead acid batteries and 65 hp diesel
engine, in a series hybrid configuration. It had a range of 55 kilometers
on electricity alone and could run all day in service when also using the
diesel. The top speed was around 70 km/h.
1898: The first electric automobile in the history of Daimler AG
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Invented for life |