Development of light truck hybrid transmission (code name EVTR450P)
I. Project Background
With the continuous implementation of new energy policies, the traditional fuel-powered light truck market is accelerating its transition towards new energy. Although pure electric logistics vehicles with new energy have advantages such as convenient access to cities, they still have significant shortcomings in heavy loads, long range, and mountainous areas. Hybrid technology has become the optimal solution that balances environmental protection policies and practical performance.
A domestic commercial vehicle enterprise has taken the lead in entering the market of hybrid light trucks. Nantong Ruidong Technology Co., Ltd., leveraging its profound technical accumulation in the commercial vehicle power system field, has reached a strategic partnership with it and jointly developed the EVTR450P transverse power-split hybrid transmission project.
II. Product Technical Solution
2.1 Product Definition
EVTR450P is a longitudinal power-split electric drive transmission. It adopts a dual-motor coaxial hybrid connection architecture (as shown in the figure)
kernel module | function declaration |
PCU Three-in-One Electronic Control Module | Integrated MCU motor driver controller, GCU generator controller, and TCU transmission controller |
PG Power Distribution Planetary Gear Mechanism | Implement intelligent power distribution between the generator and the output shaft for the engine |
e-AMT multi-stage shifting mechanism | Provide multiple power level options to optimize overall vehicle performance and fuel efficiency. |
Hydraulic Control System | A dual-pump collaborative cooling and lubrication system combining mechanical pumps with electronic pumps |
2.2 Key Technical Parameters
Parameter Item | desired value |
Layout Type | Vertical |
structural style | Two-stage PS power division |
Maximum input torque | 450Nm |
Maximum system output torque | 2050Nm |
Maximum system efficiency | ≥91% |
Dust and water resistance rating | IP6K9K |
designed life | 10 years/600,000 kilometers |
Match Engine | 2.2L high-efficiency diesel engine |
Maximum input speed | 3500rpm |
Maximum system output speed | 4102rpm |
axial length | ≤900mm |
Net weight (including oil) | ≤155kg |
Lubricating oil quantity | ≤7L |
operating temperature range | -40°C to +105°C (125°C for 15 minutes) |
Storage temperature range | -30°C~+85°C |
Applicable altitude range | -100 to 5000 m (normal operation below 3500 m) |
Generator – Structure/Method | Flat wire/oil-cooled |
Generator-Type | Permanent Magnet Synchronous Motor |
Generator – Continuous/Peak Torque | ≥80/150 N·m |
Generator-Continuous/Peak Power | ≥60/100 kW |
Generator-Peak Speed | ≥11000 r/min |
Drive Motor-Type | Permanent Magnet Synchronous Motor |
Driving Motor – Continuous/Peak Torque | ≥175/350 N·m |
Driving Motor – Continuous/Peak Power | ≥88/135 kW |
Driving Motor – Peak Speed | ≥15000 r/min |
Controller – Rated operating voltage | 350 V |
NVH function | No-load noise ≤ 80 dB(A) |
Based on the characteristics of the EVT power splitting configuration and the demands for plug-in and heavy-duty applications in commercial trucks, DHT has the following features:
1. The power splitting feature has the capability to intervene in driving at zero speed and can achieve full-speed coverage.
2. To meet the requirements of low speed and heavy load, two additional gears have been added to the drive motor end. Combined with the motor's ability to generate large torque at low speeds, this enables a greater torque output capability. It can achieve simultaneous driving with the engine at low gears, thus providing a greater low-speed driving capacity.
3. The system employs both engine and TM as driving forces, and uses GM as the generator. The system can optimally combine these several powers according to various driving conditions.
4. The system adopts oil-cooled flat-wound motors, which have a high slot occupancy rate, high efficiency, and can output greater power in a smaller volume and weight, effectively reducing the weight and size of the system.
5. The system adopts a mechanical-electronic pump oil supply scheme. The motor, bearings, and key gears all use active lubrication. The internal and external integrated heat exchange control of the DHT transmission ensures normal operation in various scenarios.
6. The DHT transmission adopts a platform-based design concept. With minimal modifications, by matching the speed ratios on the motor side, it can cover applications for pickup trucks, vans, and light trucks.
2.4 Fuel Efficiency Advantage
In the commercial vehicle sector, fuel economy is one of the key indicators that users pay attention to. The power splitting technology adopted by EVTR450P optimizes the engine operating point and energy recovery, enabling it to maintain excellent fuel economy across all operating conditions.
The table below presents the comparison of fuel consumption under different technical routes for 4.5-ton light trucks:
Technology Type | Fuel consumption under operating conditions (L/100km) | prime cost |
Traditional diesel fuel | 12 | low |
Range Extension | 10+ | Middle |
P13 | 9.5 | High |
RuiDong EVT Power Shunting | 7.8 | Middle |
III. RuiDong Commercial Vehicle Power System Development Capability
3.1 System Architecture Design Capability
RuiDong is responsible for completing the overall system architecture design of EVTR450P, including:
1. Overall concept design of the entire machine and system matching analysis
2. Dynamic and economic simulation optimization
3. Motor performance definition and speed ratio matching
4. Cooling Lubrication System Design and Simulation
5. Gear shaft system layout and macro-micro design simulation
3.2 Key Component Development Capability
The key components that RuiDong is responsible for developing for this project include:
1. Power distribution planetary gear mechanism: Newly developed
2. Vehicle Controller Unit： Based on the mature VC16P platform of Rui Dong, it enables rapid matching and development.
3. PCU Dual-Motor Controller: Newly developed, integrating MCU/GCU/TCU into a single integrated control system.
3.3 Software and Calibration Development Capabilities
Ruitong possesses a complete set of software development capabilities for commercial vehicle control systems:
1. VCU software: Based on the AUTOSAR architecture, it realizes functions such as vehicle energy management, torque control, and thermal management.
2. PCU software: Comprises three algorithm modules: TCU, MCU, and GCU, as well as basic services such as diagnosis, safety monitoring, UDS, and OTA.
3. Calibration development: Completed two rounds of winter calibration (Mohe) and summer calibration (Turpan/Gergumen)
3.4 Test Verification Capability
RuiDong has established a complete test verification system for commercial vehicle powertrain:
1. Shelf testing: Overall functional and performance tests, lubrication shelf, high-speed and overspeed shelf, NVH shelf, pure electric durability test, and overall machine durability test.
2. Vehicle testing: Winter standard test, summer high-temperature test, mountain road test, power and economy test, vehicle thermal management test
3. Component testing: DV verification (electrical load, EMC, environmental load, mechanical load)
4. Simulation verification: Structural simulation, thermal simulation, flow resistance simulation, modal simulation
3.5 Industrialization Capacity
1. RuiDong has completed the construction of a 4,000-square-meter electric drive and control production base in the NanCheng Transportation Innovation Park:
2. VCU/PCU production line: The pilot line has been completed, with a production capacity of 10,000 units per shift for single shift operation and 20,000 units for double shift operation;the planned annual production capacity is 50,000 automatic lines.
3. Planetary Production Line: The pilot line has been completed, with a production capacity of 15,000 units per shift for single-shift operation and 30,000 units for double-shift operation;the planned annual production capacity is 50,000 automatic lines.
4. Production environment: 100,000-level clean workshop, equipped with MES traceability system
5. Capacity planning: 50,000 units per year for a 5-year period (comprehensive capacity)
IV. Summary
The EVTR450P hybrid transmission project fully demonstrated Ruidong's full-stack development capabilities in the commercial vehicle power system field.From the system architecture design, key component development, software calibration to industrialization implementation, Ruidong successfully created a high-quality hybrid power system that meets the demanding usage environment of commercial vehicles with its professional technical strength.
This project is a typical example of Ruodong's development capabilities in commercial vehicle power systems, laying a solid foundation for the subsequent expansion of more commercial vehicle customers.
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