01 Hybrid Development

TAILOR-MADE POWERTRAINS FROM MICRO-HYBRID TO ELECTRIC VEHICLES

HYBRID SYSTEM DEVELOPMENT SUPPORT

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WHY HYBRIDIZATION?


Aside from the CO2-regulations, the increasing electric energy demand within a vehicle poses special challenges that favor electrification and hybridization. Recovery of brake energy and its re-use within electrical machines to avoid suboptimal areas in the operating map of a conventional powertrain is a good possibility to face the emission limitation. But additional comfort features as well as driver assist systems and connectivity require higher degrees of electrification.

The level of electrification depends on several parameters such as

  • vehicle segment
  • market demand
  • established powertrain technology
  • component cost
  • brand strategy




FEV YOUR EXPERIENCED PARTNER


FEV has a long track record in the development of hybrid technologies and powertrains as well as vehicle integration. Since 2010, FEV has operated its own fleet of electric vehicles – including battery vehicles. Vehicles exist both with and without Range Extender and fuel cell solutions. In addition, FEV has recently completed a number of customer projects that involved the development of batteries for various applications from high performance to highly modular hybridization.







FEV´S SCOPE OF CAPABILITIES


Hybrid Strategy development from Concept to Calibration

FEV offers a comprehensive and standardized process for the development of the hybrid operating strategy. This includes dedicated analysis of the system requirements and advanced validated simulation platforms. Functional development and final calibration are performed in dedicated environments: from Model-In-the-Loop, to Software-In-the-Loop and ultimately up to vehicle integration – assuring functional safety according to ISO26262 safety standards.

Battery development, management and integration

At FEV, multi-disciplinary teams for Lithium ion battery development offer profound knowledge gained through years of expertise in the development of battery systems for multiple purposes. Our services not only include the physical battery, but since we understand powertrain development as a holistic discipline, FEV also offers knowledge and products for battery management and integration.

Hybrid engine and transmission development

Close to market experience with all types of electrification enables FEV to support it’s customers with the right concept for every hybrid powertrain implementation. Package optimized transmissions as well as powerful yet small sized e-motors are key factors in achieving economical, future hybrid concepts.

Software development: FEV PERSIST

FEV is able to conserve functional excellence and software best practices in a modular architecture approach. The software modules are defined on the basis of consistent guidelines with structured and automated continuous verification and validation. The resulting software library is sustainable and modular.

48 Volt technology

48 V architectures offer mild hybridization and fuel economy potential without a complete redesign of the entire powertrain. FEV’s 48 V systems enable for advanced functionalities like engine-off sailing, early stop and electric super-charging.

Highlights at a glance

  • Simulation supported system layout
  • Battery cell data base
  • Modular battery packaging
  • Hybrid powertrain and component test benches around the globe
  • ISO 26262
  • Modular software architecture approach (PERSIST)




PROVEN RESULTS


FEV’s efforts in the performance of various customer projects has led to impressive results such as the development of a liquid-cooled high performance battery for plug-in hybrid vehicles which was developed for a manufacturer of high performance cars.

  • Nominal energy of 10 kWh
  • Power output of up to 200 kW
  • Battery weight <150 kg

The BMW i8 represents a further indication of FEV’s plug-in-hybrid experience. FEV was responsible for:

  • Hybrid function development
  • Hybrid calibration and OBD
  • Calibration & validation of eDrive system
  • Functional safety for powertrain
  • Software development for the battery management system
  • Durability testing hybrid powertrain



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Technical Papers

Request your copy of our technical papers, which show our expertise and success in the hybridization of powertrains.





Jürgen Ogrzewalla

Dipl-Ing. Jürgen Ogrzewalla

Director Hybrid Development

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