European Competitiveness in Commercial Hybrid and Automotive Powertrains (ECOCHAMPS): Effective Passenger Car Hybridization via a 48V DCT

Abstract

The ECOCHAMPS project has addressed the topic GV-04-2014 Hybrid Light and Heavy Duty Vehicles of the
Green Vehicles work program under Horizon 2020. This project realized, in a single, coordinated action, all the
aspects of this call through the activities of a twenty-five member consortium representing of the European
Automotive Industry. The overall objectives of the ECCHAMPS project are to achieve efficient, compact, low
weight, robust and cost effective hybrid powertrains for both passenger cars and commercial vehicles, with
increased functionality, improved performance, comfort, safety and emissions levels below Euro 6 or VI. In
particular, to achieve 20% powertrain efficiency improvements and weight plus volume reductions with respect to
the best in class vehicles on the market at the time of proposal (2013), whilst having a maximum of a 10% cost
premium. At the time of the TRA in Vienna, the ECOCHAMPS project will just have been completed after three
years of activity.
In Work Package 4 of the ECOCHAMPS project a 48V hybrid passenger car demonstrator is being developed. In
this vehicle, the powertrain is fitted with an electrical machine directly coupled to a double clutch transmission
(DCT). As such, the powertrain configuration gives the possibility to achieve hybrid vehicle functionality, e.g.
regenerative braking, acceleration assistance and limited EV operations, whilst not detracting from the vehicle
packaging and being a lower cost solution appropriate for rapid market uptake. Initially the powertrain has been
developed with a state of the art electrical machine, rated at up to 15kW when running at 48V. However, an
advanced electrical machine and power electronics have been developed, which demonstrate up to a 25 kW rating
within the same practical package.
Results from the overall development and testing of the demonstrator vehicle and advanced electrical system will
be presented in this paper. It will be seen that such a hybrid powertrain configuration offers an appropriate step for
cost effective improved vehicle efficiency when compared to vehicles currently available. As a consequential
impact of the ECOCHAMPS project, the uptake of hybrid vehicle technology in the European passenger car market
is expected to be increased.