A Modular Gasoline Engine Family for Hybrid Powertrains: Balancing Cost and Efficiency Optimization 2020-01-0839

The electrification of the powertrain is a prerequisite to meet future fuel consumption limits, while the internal combustion engine (ICE) will remain a key element of most production volume relevant powertrain concepts. High volume applications will be covered by electrified powertrains. The range will include parallel hybrids, 48V- or High voltage Mild- or Full hybrids, up to Serial hybrids. In the first configurations the ICE is the main propulsion, requiring the whole engine speed and load range including the transient operation. At serial hybrid applications the vehicle is generally electrically driven, the ICE provides power to drive the generator, either exclusively or supporting a battery charging concept. As the ICE is not mechanically coupled to the drive train, a reduction of the operating range and thus a partial simplification of the ICE is achievable. The paper shows the advances on a modular powertrain technology approach with different combinations of ICE, electrification and transmission variants, based on an engine family architecture with common parts, machining and assembly concepts, as well as the feasibility to integrate different technology packages, such as variabilities on the cranktrain and valve train, advanced, electrically assisted boosting technologies, high pressure injection or water injection. The focus of the modular approach is on a balanced overall complexity of the powertrain with increasing electrical power in regard of cost and CO₂-reduction.