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[Due to the increasing size of the archives, each topic page now contains only the prior 365 days of content. Access to older stories is now solely through the Monthly Archive pages or the site search function.]

GM details 2016 Chevrolet Malibu Hybrid powertrain design and operation

April 18, 2016

The 2016 Chevrolet Malibu Hybrid (earlier post) is EPA-rated at 46 mpg (5.11 l/100 km) combined, 47 mpg city and 46 mpg highway; the powertrain shares the transmission architecture with the 2016 Chevrolet Volt extended range electric vehicle (EREV), but includes changes to optimize the system for engine-driven charge-sustaining operation in the range of conditions represented by the US EPA 5 cycle fuel economy tests.

At the 2016 SAE World Congress, GM engineers presented a paper describing the development of the new hybrid powertrain for the popular mid-size sedan. Development was guided by four main objectives:

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New Renesas 32-Bit MCUs for improved fuel efficiency in vehicle powertrain control applications

April 05, 2016

Renesas Electronics Corporation announced the 32-bit RH850/E1M-S2 microcontrollers (MCUs) for automotive powertrain control applications. The new MCUs provide high performance and advanced functionality to enable improved fuel efficiency. The RH850/E1M-S2 MCUs include four product versions, including the high-end R7F701216EABA (BGA304, 320MHz).

To help meet increasingly stringent fuel efficiency and CO2targets, engine control systems must optimize the ignition and fuel injection timing to match a variety of conditions, such as current combustion and driving status. Transmission control systems, for their part, must instantly select the optimal gear ratio to match the driving conditions, which change moment by moment, in order to minimize power loss in the transmission.

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BASF 2016 science competition seeks synthetic lubricant solutions for future high-efficiency vehicles

March 31, 2016

BASF has kicked off its second annual North American Science Competition. This year’s competition focuses on chemistries that can be used to develop a synthetic fluid to meet the needs of future high-performance, high-efficiency engines and transmissions.

With more advanced machinery, lubricating and functional fluids represent a steadily growing industry projected to reach $11 billion by 2020. Synthetic fluids, which are more expensive than petroleum-derived materials, address increasing market demands for higher quality and purity, increased performance and more stringent environmental standards. By developing high performing synthetic fluids with better thermal stability, BASF aims to extend the life cycle of these materials, reduce waste and support the development of more fuel-efficient vehicles.

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Volkswagen Commercial Vehicles introduces CNG Caddy van with dual-clutch gearbox

February 24, 2016

Volkswagen Commercial Vehicles will present the Caddy TGI—the first vehicle in its segment to be equipped with a CNG drive system and a DSG dual-clutch gearbox—at the Geneva Motor Show. The Caddy TGI BlueMotion is a family/city delivery van that runs on either CNG or bio-natural gas. Both the panel van and passenger car variant of the Caddy can also be ordered with a short wheelbase or in the Caddy Maxi version.

With combined natural-gas consumption of 4.1 kg and 4.3 kg per 100 kilometers (short wheelbase and Caddy Maxi, respectively), Caddy drivers can achieve a range of approximately 630 km (391 miles), or 860 km (534 miles), in the pure gas mode. The CO2 emissions of the Caddy TGI amount to 112 g/km in the short-wheelbase version and 116 g/km in the Caddy Maxi version in combination with the six-speed manual gearbox, and 123 g/km and 126 g/km, respectively, with DSG (provisional data).

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GM’s new RWD PHEV system for Cadillac CT6 designed for fun-to-drive high performance as well as efficiency; Volt on steroids

February 19, 2016

In a preview of three detailed papers to be presented at the SAE World Congress in April, Tim Grewe, GM’s General Director of electrification, and Pete Savagian, GM General Director of electric drives and systems engineering, provided a technical overview of the new rear-wheel drive PHEV propulsion system for the Cadillac CT6 (earlier post) at the recent SAE 2016 Hybrid and Electric Vehicle Technologies Symposium in Anaheim.

The efficient and very fun-to-drive system, with 335 kW (449 hp) combined system power, propels the CT6 from 0-100 km in 5.6 seconds; delivers an all-electric range of more than 60 km (37 miles) and an all-electric top speed of 125 km/h (78 mph); and features combined fuel consumption of less than 2.0 L/100 km (117.7 mpg US).

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Continental and Fallbrook to collaborate on new CVTs for urban mobility incorporating Fallbrook NuVinci technology

November 20, 2015

Continental has entered into licensing and engineering services agreements with Fallbrook Technologies Inc. (Fallbrook). The central focus of the collaboration is Fallbrook’s NuVinci transmission technology. (Earlier post.)

This innovative continuously variable planetary (CVP) is a new class of continuously variable transmission (CVT) utilizing rotating balls that allow the transmission ratio to change continuously.

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Schaeffler introduces new high-voltage P2 hybrid module; up to 800 N·m; first production application in China in 2017

September 29, 2015

Schaeffler has developed a new P2 (parallel, two-clutch) high-voltage hybrid module—arranged between the internal combustion engine and transmission—that can transmit engine torques of up to 800 N·m (590 lb-ft) to the transmission without having to incorporate a commensurately expensive clutch.The new generation P2 hybrid module can be used in both medium- and very high-performance transmission concepts—e.g., from mild to plug-in hybrids.

The high-torque module distributes the flow of forces in an innovative way; the pathway of torque conveyance depends on its direction. Torques are transmitted to the crankshaft via a 300 N·m disconnect clutch, while traction torques from the internal combustion engine are transmitted to the transmission via a one-way clutch. The clutch can therefore have a compact design, even at high torques, with the corresponding advantages in terms of space utilization and cost. Schaeffler showcased the unit at the International Motor Show (IAA) in Frankfurt.

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GKN Driveline develops two new eAxles for Concept_e BEV

September 09, 2015

GKN Driveline has developed new electric drive technologies as part of its role in the Concept_e project, a £16-million (US$25-million) UK Government-backed initiative to develop advanced hybrid and electric powertrain systems.

The two-year collaborative research and development project has designed and developed three research technology demonstrators to showcase next-generation technology for a mild hybrid electric vehicle (MHEV); a plug-in hybrid (PHEV); and a full battery electric vehicle (BEV). The technologies were unveiled by Jaguar Land Rover and the project partners at the LCV2015 low carbon vehicle show on Wednesday.

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Evolute Drives test results show 18% reduction in energy consumption with 3-speed MSYS EV transmission compared to single speed

August 20, 2015

Evolute Drives, incorporated as a separate entity by its sister company Drive System Design (DSD) (earlier post), will present practical test results for its high efficiency 3-speed MSYS electric vehicle transmission (earlier post) at the upcoming CTI Symposium in Shanghai (16-18 Sept).

In independent tests, a B-class demonstrator vehicle fitted with the transmission achieved a reduction in energy consumption of up to 18% over the NEDC test cycle, compared to the single-speed base vehicle.

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BRUSA offering new high-efficiency motor/gearbox combination for electric commercial vehicles

July 27, 2015

BRUSA Elektronik AG is offering its Planetary Traction Drive DTSP1—a fully integrated electric vehicle drivetrain combining motor and gearbox—with its higher power HSM1-10.18.22 Hybrid Synchronous Motor, offering 220 kW (295 hp) maximum power (145 kW/194 hp continuous) and up to 460 N·m (339 b-ft) peak torque (270 N·m/199 lb-ft continuous). With this configuration, BRUSA is targeting light commercial vehicles, vans or sports cars.

The compact design of the transmission in combination with the powerful motor results in a highly efficient power set. The DTSP1 unit can be used as an axle or four-wheel drivetrain set. By using the differential on the axles, powerful yet weight-optimized drives can be realized. With the adjustment of the axle differential every application can be achieved with the right ratio.

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Magna to acquire Getrag for approximately €1.75B

July 16, 2015

Magna International Inc. signed an agreement to acquire the Getrag Group of Companies for approximately €1.75 billion (US$1.9 billion). This represents an enterprise value of approximately €2.45 billion (US$2.7 billion) less proportionate net debt and proportionate pension liabilities, which together are estimated to be approximately €700 million (US$762 million) at closing.

Getrag is the world’s largest (by volume) OEM-independent supplier of automotive transmissions, offering a range of transmission systems which include manual, automated-manual, dual-clutch, hybrid and other advanced systems.

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Audi launches next-gen A4 with new Millerized TFSI engine; g-tron model w/ Audi e-gas

June 29, 2015

Audi has unveiled the new-generation Audi A4 and A4 Avant, developed with a high priority on the reduction of CO2 emissions. Among other developments, the new A4 is the launch vehicle for the new high-efficiency 2.0L TFSI based on Miller cycle, introduced by Audi earlier this year at the Vienna Motor Symposium. (Earlier post.) The A4 Sedan and the A4 Avant will be launched in the market this fall.

The new models deliver CO2 emissions as low as 95 grams per kilometer (152.9 grams per mile) for the A4 Sedan 2.0 TDI ultra with 110 kW (150 hp). The new A4 Sedan has the best drag coefficient in its class at 0.23, while Avant has cd 0.26. Further, although compared with the previous model the car’s dimensions have grown, its weight has been reduced by up to 120 kilograms (265 lbs), depending on the engine. The body of the new Audi models is one of the lightest in its class due to an intelligent material mix and lightweight construction.

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Evolute Drives seeking investors for MSYS multi-speed transmission for hybrids and EVs

June 09, 2015

Evolute Drives, incorporated as a separate entity by its sister company Drive System Design (DSD) (earlier post), is seeking investors to help commercialize its high efficiency MSYS multi-speed transmission system for hybrids and electric vehicles. (Earlier post.)

The MSYS transmission was originally developed under a 3-year Technology Strategy Board (now InnovateUK) grant awarded in 2011, and in 2013 DSD was named as a key member of a £16-million (US$24.4-million) UK government-supported consortium known as the Evoque_E development program. Evoque_E took a pragmatic look at how new transmission and motor technologies could be implemented to increase the range, performance and refinement of electric vehicles. Almost completed, the project has investigated a number of evolving powertrain options, including multi-speed transmissions and the potential for doubling electric vehicle motor speeds.

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