FEV showcasing 48V technology at 2016 SAE World Congress

FEV will showcase some of its 48-Volt technology capabilities at the 2016 SAE World Congress next week in Detroit. FEV says it believes that 48V technology will be the next evolution in in-vehicle power.

The proliferation of components and systems that require electrical power in today’s vehicle are pushing the standard 12-Volt battery to its limits. Under idle conditions and especially under low-temperature conditions, current 12V electrical systems can account for the entire power output of a conventional alternator, FEV notes.

Increasing the vehicle’s power network (or portions thereof) to a higher voltage reduces losses in the vehicles distribution system. At higher voltages (over about 60V) safety regulations make this a much more challenging effort.

Industry OEM’s are also facing significant challenges in terms of meeting fleet consumption thresholds in nearly all of their production vehicle segments. Vehicle electrification will play a significant role in finding a solution path.

However, the plug-in hybrid that offers so much benefit in this regard also necessitates massive intervention into the design of the transmission which generates additional cost. These costs then need to be amortized over what, at least for the moment, are relatively small production volumes.

FEV engineers are working on a mild hybrid approach that has promise, in this regard, since accommodating a 48-Volt architecture does not require a complete redevelopment of the entire powertrain.

FEV engineers used the AMG45 as a technology carrier to demonstrate how a production-compatible solution might look by advantageously integrating an additional 48V E-Charger.

The AMG A45—the smallest AMG with a 2-liter, 4-cylinder turbocharged engine—features a specific performance of 133 kW/l (181 HP). FEV engineers installed an additional E-Charger. The electronically operated unit supports the twin-scroll turbocharger, optimized for maximum performance at low speed and highly dynamic load changes. The maximum torque of 450 N·m becomes available early in the speed range at 1,750 rpm—500 rpm earlier than in the series version.

Torque curves with and without the E-Charger. Source: FEV. Click to enlarge.

The result is that the elasticity and the responsiveness of the AMG A45 considerably increase and the number of gear changes can be minimized.

The E-Charger, incorporated into the AMG technology demonstration vehicle, was a way for FEV to showcase its capabilities to support this upcoming technology. The E-Charger combined with a high power vehicle electrical system supports downsized engines with high specific power by improving transient response and low-end torque.

A 48-Volt system also enables new vehicle features with high power demand such as active damping, electric power steering, and off-engine climatization. In combination with a 48-Volt battery and 12-Volt DC/DC converter, mild hybridization is also possible.

The system’s capabilities can be used to obtain a reduction in fuel consumption of up to 15% via down-speeding or, alternatively, used to increase performance and provide even better responsiveness.

FEV engineers performed the mechanical integration of e-Booster hardware and modified the charging system, integrated the 48V electric system, and performed all the Rapid Control Prototyping (RCP), functional development and calibration for the e-Booster operating strategy. Also contributing to its environmental advantage is the fact that raw engine emissions can be reduced by supplying transient boost more rapidly.

FEV displays Ford 1.0L EcoBoost engine at SAE World Congress; provided early development support

FEV, Inc., is showing the 1.0L I3 Ford EcoBoost at the SAE 2012 World Congress. (Earlier post.) FEV provided early development stage support for the engine in the area of design and CAE, combustion development, and engine build for 36 engines. We have been very fortunate to have supported Ford Motor Company in the development of this breakthrough powertrain. This is a prime example of FEV’s business model, which is designed to integrate its expertise into the development process for customer propulsion systems on an as-needed basis. The EcoBoost engine represents one of the recent trends in the automotive industry, a move towards downsized and highly boosted engines that deliver higher power and better fuel economy than the larger engines they replace. And these engines are capable of doing that with very low exhaust emissions levels. —Gary Rogers, president and CEO of FEV The three-cylinder engine is designed for Ford vehicles such as the Focus, the B-MAX and the C-MAX. The engine will initially be offered with power ratings of 73.5 and 92kW (98 and 123HP, respectively), providing the power of the 1.6L four-cylinder, naturally aspirated engine in the Ford Focus. Both versions will deliver 170 nm (125 lb-ft) of torque between 1,300 and 4,500 rpm, which is an improvement over the 1.6L engine. The smaller power plant also provides an overall weight reduction of approximately 20 lbs. According to Ford, the Focus with the 73.5 kW engine achieves CO 2 emissions of 109 g/km. Source: Green Car Congress

FEV to show compressed natural gas light-duty concept engine with ATAC combustion system at 2011 SAE World Congress

FEV Inc., (FEV) a leading developer of advanced powertrain and vehicle technologies, will exhibit a lean burn engine concept at the SAE 2011 World Congress that has been modified to run on Compressed Natural Gas (CNG). The engine is designed for use in light-duty vehicles, and demonstrates the potential of modifying passenger vehicle engines to achieve diesel-like fuel efficiency and power using CNG as an alternative fuel.

The Advanced Turbulence Assisted Combustion (ATAC) system was implemented via modifications to the cylinder head, combustion chamber, pistons and intake system to create high turbulence through an increase in the intake swirl from the baseline diesel engine. FEV developed ATAC more than a decade ago, targeting large-bore engines in stationary and heavy-duty applications.

The lean burn combustion process also offers significant improvements in fuel consumption and CO₂ emissions in comparison with more conventional CNG technology as a result of dethrottling and better combustion efficiency.

The effects of our dependency on a petroleum-based infrastructure have recently been demonstrated on the global stage as we see fuel prices rise and automotive market capitalization decline. t is a wake-up call that we must develop the technology that can run on alternative fuel sources that are available both cost effectively and domestically. This engine demonstrates a potential near-term solution.

—Gary Rogers, FEV, Inc. president and CEO

Natural gas offers significant benefits in comparison with conventional fossil fuels, due to inherently better lean burn combustion properties and reduced knocking tendency, as well as better mixture preparation characteristics. A diesel engine has been selected as the baseline for the development to enable the benefits of combustion at high peak pressures.

In developing the demonstrator, FEV implemented a number of alterations to a Volkswagen 2L TDI base engine design, including creating a custom intake manifold, requiring the modification of the direct injection system, creating a multi-point injection system similar to port injection. FEV also optimized the velocity of the charge entering the combustion chamber, the piston geometry, the type of spark plug (whether for stoichiometric or lean burn), and made necessary adjustments to the turbocharger.

The compression ratio is adjusted so that it falls between a diesel and a gasoline engine compression ratio, resulting in higher combustion efficiencies.

In addition to the design of new components, FEV considered the increased strain on various components, such as valves and valve seats. Due to the operating conditions characteristic for CNG combustion, parts were designed to be more robust to mitigate excessive wear.

Source: Green Car Congress

Vienna Motor Symposium Shows Off FEV LiiON Vehicle With Wankel Range Extender

The FEV Li Ion Drive Plug-in Hybrid

FEV Motorentechnik GmbH (FEV) featured its LiiOn Drive with Wankel Range Extender Vehicle at this year’s Vienna Motor Symposium, 29-30 April, where it was one of the most popular Ride & Drive vehicles. Earlier, at the SAE 2009 World Congress, FEV had displayed a 295 cc Wankel genset for extended range electric vehicles.

The FEV LiiON Drive is based on a Fiat 500, equipped with a 12 kWh battery pack mounted under the floor and a permanent magnet synchronous motor with 60 kW peak power. The vehicle can accelerate to 60 km/h (37 mph) in less than 6 seconds, and top speed is higher than 120 km/h (75 mph). Urban use of the vehicle results in an almost emission-free operation with a range of 50 miles. The 20 kW Wankel Range Extender provides up to 190 miles (306 km) of extended range, with 80 g/mile of CO₂ emissions.

Powertrain elements. Click to enlarge.		Power electronics. Click to enlarge.

While the vehicle shown in Vienna is a concept, the electric vehicle LiiON Drive with Wankel Range Extender is licensed for public road traffic.

FEV developed the Wankel Range Extender in cooperation with the Wankel engine production supplier AIXRO. The basic powertrain has been comprehensively revised for automotive use. Modern engine management with electronic throttle, inlet pipe injection and three-way catalyst ensure that the exhaust gas emission limits will be met. The heating and temperature preservation strategy of the catalyst has been specifically adapted.

An FEV assessment of the properties of different range extender modules. Click to enlarge.

The partially encapsulated Wankel Range Extender was mounted in the position of the fuel tank, which had been reduced to a capacity of 12L. The engine, which is inertia force-free by design, together with careful tuning of the thermodynamics, yields an excellent, previously unparalleled NVH behavior. All test drivers acknowledged this feature specifically.

The positive response to the FEV concept, which was chosen for the first E-Car Tech Award in 2009, provides further validation among the international powertrain community of the vehicle’s potential, FEV says.

We definitely want one of these great commuters!

Source: Green Car Congress

FEV Showcases its Internal Advanced Hybrid Development Projects at SAE World Congress

FEV Converted Diesel Electric Extended Range Vehicle





FEV has the right idea and if only a major auto manufacturer would follow their lead, we would have something. Even the gas hog Hummer H3 can be tamed with this technology, which is saying alot.

From Green Car Congress:

At SAE 2009 World Congress, FEV showcased two advanced hybrid development projects it undertook with partners—the range-extended electric vehicle (ReEV) HUMMER H3 done in cooperation with Raser and a heavy-duty series hydraulic hybrid yard hostler done in partnership with EPA—as well as two internal hybrid development projects: a Dodge Caliber-based range-extended electric vehicle, and a small Wankel-based 18 kWe APU that could, for example, also be used as the genset in the Caliber.

FEV, a powertrain and engineering company, works closely with OEMs on a variety of projects—many of which it has to keep confidential. That can make it a bit tough to drum up new business, said David Gian, FEV Chief Engineer, Vehicle Integration “when your prospective customer asks ‘What have you done?’ and you have to say ‘I can’t tell you.’” With its ongoing push to be fully capable in transmission and driveline design, development, and testing, FEV decided to produce a couple of demonstrations of capability (the Caliber and the Wankel APU) that prospects could see and drive.

HUMMER H3 ReEV. The HUMMER H3 was commissioned by Raser (earlier post) as part of its lead role in the Plug-in Hybrid Development Consortium, formed in 2005. (Earlier post.) FEV performed the full vehicle integration of the concept.

Raser’s intention is to commercialize the ReEV drivetrain and vehicles, said David West, Vice President of Marketing for Raser. Pcific Gas & Electric will buy two this year (earlier post), and West said that they have some 12,000 soft orders from utilities for a truck version of the H3 ReEV drivetrain (e.g., HUMMER HUT or Chevy Silverado), and expects to have 2,000 units in utility fleets by the end of next year. (Earlier post.)

Propulsion comes from a 200 kW Raser Symetron traction motor mated to a 4–speed automatic transmission. A 100 kW Rase Symetron generator, driven by a GM Ecotec 2.0L SIDI turbocharged engine provides electrical power.

A liquid-cooled, 41 kWh lithium-ion battery pack operates at 700V and provides the energy storage. The pack in the demonstration vehicle comes from Electrovaya. For the upcoming production versions, Raser is considering other pack suppliers, including A123Systems which is a member of the coalition, as well as others, West said.

The Raser Technologies scalable plug-in series hybrid design in the Hummer H3 provides 40+ miles all-electric range. Acceleration from 0-60 mph takes less than 9 seconds.

FEV’s responsibilities in the project included:

• Supported performance simulation
• Powertrain and electrical packaging
• Component, system and controller integration
• System architecture development and integration
• Hybrid controller development
• Vehicle build
• Supported battery development
• Developmental vehicle testing and validation

Caliber ReEV. FEV’s internal development project converting a Dodge Caliber to a full ReEV was designed to demonstrate its full spectrum of capabilities in hybrid engineering.

The ReEV propulsion system was developed entirely by FEV, including:

• Performance modeling and simulations
• Component selection and procurement
• Design, analysis and packaging
• High Voltage system architecture, development and integration
• Hybrid controls and powertrain development and testing
• Complete vehicle integration
• Vehicle exhaust and evaporative emission calibration
• Overall vehicle calibration, testing and validation
• NVH optimization

The Caliber ReEV propulsion system employs a 1.0L, 3-cylinder, 4 valve engine that is mated to a UQM PP75 generator that provides 41 kW of continuous power in extended-range mode, with a peak power of 75kW. The energy storage system consists of a 20 kWh liquid-cooled lithium-ion battery pack that operates at 346V, with a Delphi DC/DC converter. A UQM PP125EX traction motor powers the wheels.

The Caliber ReEv accelerates from 0-60 mph in 8.3 seconds and has a tope speed of 84 mph.

Wankel-based APU for range-extended electric vehicle. To illustrate another possible approach to a ReEV, FEV designed the small Wankel-based APU. The 295cc Wankel genset, fueled by gasoline or LPG, delivers 18 kW of electric power output. The APU could be dropped into the Caliber ReEV, Gian said, albeit with a change in battery and genset operating strategy.

The project allowed FEV to highlight a number of capabilities:

• Benchmarking and target setting
• Concept layout and development
• Simulation of system
• Development and optimization of operational strategies (i.e., to account for the smaller genset)
• Genset testing in hybrid powertrain testcells
• Vehicle integration and validation

Hydraulic Hybrid. In addition to the ReEV and related projects, FEV had on display the heavy-duty hybrid hydraulic yard hostler it is developing in partnership with the US Environmental Protection Agency (EPA), APM Terminals, Parker-Hannifin, Kalmar Industries, R.H. Sheppard, Inc., Webasto, Port Authority of New York & New Jersey, and New Jersey Department of Environmental Protection. (Earlier post.)

Specific benefits of the hydraulic hybrid system include an improvement in fuel efficiency of 50 - 60% with a concomitant reduction in CO₂ and reduced maintenance costs on engine, starter and brakes.

FEV integrated the hydraulic hybrid system capable of hauling two loaded twenty-foot containers at maximum speed of 25 mph. FEV performed the following:

• Design, analysis, simulation and fabrication of hydraulic drive unit (frame mounted end-to-end unit) from a clean sheet of paper
• Vehicle integration and build of hydraulic systems

This hydraulic hybrid technology can be applied to light-duty trucks, SUVs and heavy-duty urban vehicles such as city transit buses and refuse trucks.

A Dodge Caliber Range Extended Electric Vehicle from FEV

A quite cool concept from FEV that converts a Dodge Caliber into a Volt-like PHEV. Let's hope this particular vehicle becomes a reality.



From FEV.com:

FEV, Inc., (FEV) a leading developer of advanced powertrain and vehicle technologies, announced today that it will show a range-extended electric vehicle (ReEV) with plug-in capability based on the Dodge Caliber platform at the 2009 SAE World Congress. FEV's internal development project is designed to demonstrate the company's full spectrum of capabilities in hybrid engineering. The announcement was made by Dr. Joachim Wolschendorf, CTO and vice president of the Vehicle and Drivetrain Engineering Division of FEV, Inc.

“FEV believes that to provide the most value to our customers, we must continue to develop innovative technologies and capabilities within our own walls, conceiving and developing projects that our customers will need now and in the future,” said Wolschendorf. “This ReEV concept vehicle has been developed as an internal R&D project, and gives us an opportunity to show our capabilities. We are also using this vehicle to evaluate different options for the engine/generator unit, and the associated calibration strategies.”

The Caliber ReEV concept is one of several new hybrid vehicle technologies that are being developed in FEV's recently completed Hybrid and Electric Vehicle Development Center in Auburn Hills, Michigan.

The ReEV propulsion system was developed entirely by FEV, including:

• Performance modeling and simulations
• Component selection and procurement
• Design, analysis and packaging
• High Voltage system architecture, development and integration
• Hybrid controls and powertrain development and testing
• Complete vehicle integration
• Vehicle exhaust and evaporative emission calibration
• Overall vehicle calibration, testing and validation
• NVH optimization

The ReEV propulsion system employs a 1.0L, 3-cylinder, 4 valve engine that is mated to a UQM PP75 generator that provides 41kW of continuous power in extended-range mode, with a peak power of 75kW. The energy storage system consists of a 20 kW-h liquid-cooled Lithium Ion battery pack that operates at 346V, with a Delphi DC/DC converter. A UQM PP125EX traction motor powers the wheels.

Performance statistics for the demonstrator vehicle include:
• All-Electric Range – 40 miles
• 0 - 60 mph time – 8.3 seconds
• Top Speed – 84 mph

About FEV

FEV is an internationally recognized powertrain and vehicle engineering company that supplies the global transportation industry. FEV offers a complete range of engineering services, providing support across the globe to customers in the design, analysis, prototyping, powertain and transmission development, as well as vehicle integration, calibration and homologation for advanced internal combustion gasoline-, diesel-, and alternative-fueled powertrains. FEV also designs, develops and prototypes advanced vehicle / powertrain electronic control systems and hybrid-electric engine concepts that address future emission and fuel economy standards. FEV Test Systems, Inc. is a global supplier of advanced test cell, instrumentation and test equipment. FEV employs a staff of over 1,400 highly skilled specialists at advanced technical centers on three continents.