FEV North America, Inc. is showcasing its most recent transmission design at the SAE World Congress in Detroit, Mich. The plug‐in hybrid transmission’s capabilities include a 2‐speed all-electric driving mode; use as an ICE range extender in parallel mode for efficient highway driving; and a highly flexible eCVT mode (power split) that features strong launch and creep performance without clutch slippage. The transmission does not use a torque converter and includes only one electric machine.
|FEV’s P-REX1 transmission. Click to enlarge.|
The transmission is targeting the needs of transmission developers who are being asked to provide higher levels of capability in a smaller package that can be used in a downsized engine compartment, while at the same time reducing mechanical complexity and increasing robustness. FEV used a clean sheet approach to develop a transmission with such capability.
FEV’s transmission design process was supported by advanced CAE methods. The TCU software was developed in‐house; the calibration was optimized via FEV’s proprietary TOPexpert tool chain.
Use of FEV’s systematic development process and CAE methods resulted in a transmission that is 10 percent lighter, shorter and less costly to manufacture than a similar dual‐clutch transmission. The transmission is package‐neutral and offers very low complexity and a high degree of robustness.
Testing included putting the transmission through FEV’s extreme dynamic “Nürburgring” test cycle for sports car performance.