Hybrid Carlab

Marktnaam / produktnaam
Automotive
Series hybrid demonstration platform
Hybrid Carlab
Advanced simulation and test
techniques. System integration
with extensive product knowledge.
The possibilities are embodied in
the Hybrid Carlab. How good can a
hybrid get?
In certain application areas,
hybrid vehicles offer an attractive
alternative to more conventional
offerings. Such as the flexible
configurations possible with a
series hybrid through the lack
of mechanical driveshafts. TNO
Science and Industry has integrated
its advanced powertrain capabilities
into a single project, encompassing
all major aspects of powertrain
design. From concept to vehicle
integration. Using this experience
and technology, TNO Science and
Industry can help you at virtually any
stage of the development process.
Where ever you may find a problem.
2006/08
It’s All About the Powertrain
TNO Science and Industry has invested in
the development of a complete series hybrid
powertrain. This powertrain provides a
kick-start for companies starting hybrid
development programmes, or who do not
consider hybrid to be a core product but
require the advantages of these systems.
The characteristic problems presented by
hybrids on reliability, control and safety have
been confronted, allowing TNO Science and
Industry to help you resolve development
problems quickly. The advanced techniques
used during the development of this
powertrain system can also help you reduce
the time and cost to market, while improving
product quality.
and the light and compact 40 kW generator
set based on a 1.2L diesel engine. Power
and thermal management are provided by a
central 32-bit MPC555-based microcontroller
with distributed I/O using CAN buses.
The powertrain itself is currently
implemented in a New Beetle. But due to the
flexibility of the concept, it can be scaled to
other applications as required. For example,
low-floor city buses. Automatically guided
vehicles. Distribution vehicles. Even low
signature military vehicles.
A Laboratory on Wheels
While the focus is on the powertrain, the
Hybrid Carlab doubles as a laboratory on
wheels to assist the research programmes
of our customers and our own internal
research. From testing the powertrain
concept and the effect of varying parameters
up to integration of advanced electrical
loads. Such issues as: what is the advantage
of using optimal control instead of a passive
workline? What is the effect of reducing the
battery size? How efficient is the system in
real-world use?
System Description
Traction is provided by a 150kW electric
motor driving the front axle. Electric power
for this motor comes from a combination
of the 256 cell Nickel Metal Hydride battery
pack, operating at partial state-of-charge,
Series hybrid demonstration platform
Hybrid Carlab
Automotive
Development Process
New development tools available on
the market require significant capital
investment, but their advantages for hybrid
powertrain development is not always
clear. In the process of creating the Hybrid
Carlab, TNO has evaluated and implemented
such tools and techniques to speed product
turnaround. Such as combining simulation
and automated testing to allow emissions
measurements long before the complete
powertrain is available in hardware.
Rapid control prototyping especially for
hybrid applications. And to assist a CAEfocused development path, a large series of
component simulation models have been
internally validated. These techniques are
not only applicable to series hybrid, but
also parallel and mild hybrid. Pure battery
electric and fuel cell powertrains can also
benefit from these techniques.
TNO Science and Industry
Powertrains Department
Schoemakerstraat 97
NL 2628 VK Delft
P.O. Box 6033
2600 JA Delft
The Netherlands
Further Information:
Salem Mourad
T: +31 15 269 48 04
F:+31 15 261 23 41
[email protected]
www.tno.nl
The Future
Further performance improvements,
integration and control of advanced
components will be investigated in the
future, to keep the services of TNO Science
and Industry on the cutting edge.
With the availability of such electrical
power levels on board and ease of control
prototyping, the Hybrid Carlab is also an
ideal platform to allow you to test the
impact of high-power electrical loads in
vehicle, investigate the impact of idle-stop
on components and improve your own
hybrid controls.
Configuration: Series Hybrid
Generator Set: 40 kW 3 cylinder diesel
engine with permanent magnet generator
Control: SOC based power management,
charge sustaining
Battery: 1kWh NiMH, 320V
Traction motor: Asynchronous 50 kW
continuous, 150 kW peak
mass: 1498 kg
ZEV range: 10 km
fuel consumption: 4.5 L/100km
emissions level: EURO4