Hybrid System Development

IAV – The Partner for Electrification

Contents

A Partner for the Paradigm Shift 4

System Architecture Definition 6

Powertrain Systems Design 8

Electrical System Engineering 10

Hybrid and Electric Drive Control and Calibration 12

Integration Engineering 14

About IAV 16
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 high-

tech 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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5
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 the 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 lithium-
ion cells, prototype inverters and DC-DC converters.

Topics covered:

u High-voltage battery
u Battery management systems
u Power electronic design
u High-voltage wiring
u 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
u Battery management systems
u Regenerative braking
u Enhanced stability systems
u Electric machine control
u Engine management
u Engine start/stop
u Driveline management
u Functional safety IAV designs and calibrates the energy management system to exceed
u 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 services
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
P1f
of the hybrid electric sub-systems, to the electro-mechanical P12
P1r
calibrations and OBD required for saleable production.
P2 P1fP2

IAV engineers have extensive hybrid electric cross-platform

P3 P1fP3
experience spanning light-duty front-wheel drive passenger
cars, to rear-wheel drive premium sports cars, to light- and P4 P1fP4
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 Berlin
Chemnitz
Europe, Asia and the Americas. Founded in 1998 as the Gifhorn
Friedrichshafen
North American subsidary of IAV GmbH, IAV Automotive Lenting
Ludwigsburg
Engineering Inc. develops breakthrough concepts and Munich
Neckarsulm
technologies — from powertrain design and development to London Regensburg
Ruesselsheim Shanghai
controls and electronics — for future vehicle generations. Detroit Weissach Seoul

Kaluga
Clients include leading automotive manufacturers and Paris
component suppliers, all of whom rely on the knowledge of
IAV’s engineers to help them design and develop some of Tokyo
São Paulo
the industry’s most advanced engines and powertrains. The
Pune
IAV Technical Center North America is now open in
Northville, MI. The technical center includes four state-of-
the-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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Subject to change without notice, effective: D 03/2010
IAV Automotive Engineering Inc. · 15620 Technology Drive · Northville, MI 48168 · USA · Tel. +1 734 233-3300 · Fax +1 734 233-3320 · · www.iav.com

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