Continental Eco Drive 48 Volt Electric axial drive car

Innovative electric drives

Among the innovative solutions for driving on clean electric traction, it is worth noting the electric module of the power plant with a high degree of integration. It finds use in compact-class, executive-class cars. as well as in a large number of middle-class cars. The high-voltage power unit for electric vehicles or hybrid cars with recharging from the power grid is compact (the electric motor, gearbox and other electronics form one unit) - it is not only lighter, but also more powerful than its counterparts. In addition, it greatly enhances driving pleasure, which is an important factor in public acceptance of electric mobility. A reasonable cost should be added to this, since a high degree of integration allows you to abandon cables and plug connectors. With a power of 150 kW and a weight of 75 kg, the drive has a very high power density. Continental offers automakers a complete electric axial drive in the form of a module with a power class of up to 320 kW and with an initial torque of up to 6,400 N·m, depending on the gear ratio. Thus, Continental has significantly improved the compactness and power of its drive system, which was put into mass production a few years ago. The new electric drive will first hit the market in 2019 in China.

Potential Hybridization - 48 Volt Eco Drive

48 volt technology allows the implementation of "intelligent" hybrid applied strategies that are suitable for passenger cars with both gasoline and diesel engines. Continental technology allows you to achieve a confirmed fuel economy of 21% in the context of real urban transport. Current examples of revolutionary electrification solutions brought to serial readiness include the French model with a 48 Volt hybrid diesel engine (Renault Scénic/Grand Scénic), the already high engine efficiency of which was further increased thanks to the Continental electric drive. The next start of mass production is scheduled for autumn 2017.

First Production Solution

On August 3, 2017, it was announced that the world's first 48-volt drive system, built on the basis of the Continental module, would be installed on Renault cars (Renault Scenic Hybrid Assist model). The first production solution combines an economical water-cooled induction motor with a built-in inverter. The electric motor transmits the force using a drive belt directly to the crankshaft of the internal combustion engine - a solution called by experts "configuration P0." In the near future, production is planned to be delivered to the stream based on a modular system for a 48-volt drive.

Such technology is considered the technology of the future, since low voltage provides significant fuel savings compared to conventional hybrid cars and thereby compensates for the moderate additional cost. According to Continental experts, such a technology will quickly gain popularity in the market and by 2020 four million low-voltage hybrid drives will be produced in the world. By 2030, experts predict an increase in the share of such cars in the global market to 25 million units. In the process of developing the modular system, Continental engineers focused on maximum efficiency, easy adaptation to the power plants of existing cars and on automated economical production.

The efficiency of the 48V system directly depends on the number of trips and recovery periods during continuous operation. As a result, Continental has chosen a water-cooled inductive electric motor that can be directly connected to the engine's cooling system. All this allows you to create a design that, depending on the version, can constantly develop 6 kW of power and 60 N·m of torque, and which can be installed in place of the usual starter-generator. The use of a drive belt allows up to 150 N·m of torque to be transmitted to the crankshaft. Within a modular system, only the shaft diameter of the electric motor changes power. An inverter based on a MOSFET channel transistor is built into the case cover to save space. Continental's modular system also includes a DC converter that allows you to connect the 48-volt system to the on-board power system. This makes it possible to use the energy stored in the lithium battery to stabilize the internal power supply system.

A key advantage of the P0 concept provided by Continental's development is the simple adaptation to the existing propulsion system design. It allows you to change the point of application of the load of the internal combustion engine. Test cars show fuel economy at 13% in the new European test cycle. In real conditions, especially in cities, this figure will be even higher (up to 21%) due to the fact that energy recovery will account for most of the trip. For example, an internal combustion engine can be turned off when approaching traffic lights when the speed drops below 20 km/h. With a 48-volt drive system, the internal combustion engine starts in just 0.2 seconds - a regular starter takes about twice as long. The combination of a 48-volt drive with a diesel engine, as implemented in the first car launched into production, provides an additional effect, which is that the nitrogen oxide emissions generated during acceleration are reduced by 10%, since part of the required torque is generated by an electric engine.

For cost-effective production of the system in large quantities, Continental developed new processes for the production of electric motors. For example, the winding copper wire for the stator is not wound, but supplied as separate segments. Combined with innovative connection technology, this solution not only improves the automation process, but also increases the density of the material, which allows for higher results in the same installation area.