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Euroforum Deutschland GmbH
Editor

CTI SYMPOSIUM 2019

18th International Congress and Expo 9–12
December 2019, Berlin, Germany
Editor
Euroforum Deutschland GmbH
Düsseldorf, Germany

ISSN 2198-7432 ISSN 2198-7440 (electronic)

Proceedings
ISBN 978-3-662-61514-0 ISBN 978-3-662-61515-7 (eBook)
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Preface

Dear reader,
The transformation to the age of electromobility and automation demands
enormous investments. The goal is clear, but the timeline is still uncertain – and
above all, region-specific. While China sets higher quotas each year for electric
vehicles, in the US electromobility still takes a back seat. In Europe, stricter CO2
limits – 81 g/km from 2025 and 59 g/km from 2030 – will further boost electrified
drives and accelerate the transition to sustainable mobility. As a result, in a few
years’ time nobody will be making drives without an e-motor – starting with the
companies producing premium vehicles.
Commercial vehicle manufacturers are also required to electrify their drives, not
just for the “last mile”. In this sector, recurring urban usage scenarios offer totally
new opportunities for electromobility – for example by adapting batteries and
charging infrastructures to range requirements. For heavy commercial vehicles and
buses, entirely different concepts, such as overhead power lines, are also being
discussed and tested.
So drive and transmission developers must prepare for multiple scenarios, with
factors such as automation and vehicle connectivity creating high levels of diversity
and complexity. Currently, variants range from conventional drives through
12 + 12 V or 12 + 48 V mild hybridization up to high-voltage 800 V electric
drives. With electromobility and automation transforming the markets, no manu-
facturer wants to be left behind. In a race that may not be wholly justified at a time
when consumers are hesitant about EVs, we are seeing rivalry among manufactu-
rers in electric drive concepts.
The primary goal for automotive suppliers and manufacturers is to safeguard
their future by offering more attractive products.
For this, they need to understand customer expectations and their impact on new
drive concepts. Many companies, and particularly small and medium enterprises,
could apply their skills here to add value for their customers – either by extending
the functionality of existing products, or by using existing facilities to build com-
pletely new ones. Conversely, automotive manufacturers need to hear what existing
or potential new opportunities the products suppliers can offer them. Never before

v
vi Preface

has communication at all levels been so important between automotive companies

and suppliers as well as sub-suppliers.
This year’s symposium addressed these issues in numerous contributions and
statements:
• Development of markets and regulations and their influence on drives.
• New hybrid and electric drives for passenger cars, commercial vehicles and
buses, networked and automated.
• 48 V mild hybridization for various drives and markets.
• New AT, DCT, CVT and MT concepts with enhanced comfort and efficiency,
plus their modular hybridization.
• Diverse DHTs for new hybrid drives.
• Single and multi-speed transmissions for EV drives, high-rpm concepts.
• Conventional and electrified four-wheel drives, torque vectoring.
• Semiconductors, electric motors and batteries as key technologies in electrified
drives.
• New generation of oils and lubricants for electrified drivetrains.
• Virtual, customer-focused development using AI to determine efficiency, dri-
veability and durability.
• Electro-mechanical actuators, sensors
• Compact, efficient launch and shift elements, jaw clutches, parking locks
• Production: quality assurance, lightweight battery housings, fuel cell stacks, ring
gear manufacturing, laser welding in EM production, surface treatment of
friction linings.
To address the broad range of topics outlined above, the extensive programme
included around 100 specialist lectures in plenary and in 16 parallel sessions. In
the panel discussion, the question “Do we have the technology to meet customer
expectations while meeting legal requirements?” was discussed by vehicle,
mobility and drive experts. All this was accompanied by CTI SYMPOSIUM
EXPO, our “hands-on technology market for innovative products” with 120
exhibitors.
The 18th CTI Symposium in Berlin was an excellent forum for international
drive and transmission specialists to exchange opinions and experiences, get
valuable updates on the industry status quo, and gain a clearer view of the chal-
lenges and solutions that lie ahead.
Thank you for your participation. I hope you had plenty of useful dialogue and
inspiration.
Yours sincerely,
Prof. Dr. Ferit Küçükay
Chairman of the CTI Symposium
Contents

48 V Hybrid Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Konstantin Baron, Matthias Werra, Arno Ringleb, and F. Küçükay
Torque Sensors for High Volume Production Applications . . . . . . . . . . 17
Julius Beck
Quick Start with AI for Diagnostics and Calibration . . . . . . . . . . . . . . . 25
Ulrich Bodenhausen
Thermal Management System for High Performance Battery
Based on an Innovative Dielectric Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 33
Nicolas Champagne
PUNCH Powerglide’s Dedicated Hybrid Transmission (DHT) . . . . . . . . 43
Philippe Ramet and Wolfgang de Loth
Development and Prototyping of Lithium-Ion Cells
for Demonstrator Drivetrains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Jan Diekmann and Sebastian Kraas
Spring Loaded Rotor Shafts as New Flexible Shaft Hub
Joint for E-Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Benjamin Dönges, Maximilian Rolfes, and Stefan Buchkremer
BEV Range Increase by Optimal Combination of 800 V E-Machine
and Multispeed Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Boris Dotz, Camelia Jivan, Sebastian Waider, and Norberto Termenon
A Comprehensive Approach of the Lubrication for the Electric
Powertrain Based on an Innovative Multi-purpose Fluid . . . . . . . . . . . . 80
Hakim El Bahi

vii
viii Contents

Assessing the Relative Endurance Capacity of Hybrid Drivetrain

Components in an Early Development Stage with an Indicator Based
on Preceding Drivetrain Generations . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Jannick Fischer, Simon Rapp, Katharina Bause, and Albert Albers
Drivemode – High Speed Electric Drivetrain . . . . . . . . . . . . . . . . . . . . . 103
Mattias Flink, Michael Burghardt, and Roland Bittner
Advances in Drivetrain Lubricating Fluid Technology for Hybrid
Electric Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Michael Gahagan
AVL High Performance 48 V Integrated Electric Axle . . . . . . . . . . . . . 133
Inigo Garcia de Madinabeitia Merino, Christian Schmidt, Julian Pohn,
Mohamed Essam Ahmed, and Klaus Kronfeldner
48 V High Power: Electric Drive for Excellent CO2 Emissions
and Electric Driving Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Friedrich Graf, Martin Beiderbeck, Thomas Knorr, Dietmar Ellmer,
and Mattia Perugini
Efficient CFD Simulation Method for Calculation of Drag Torque
in Wet Multi-plate Clutches in Comparison to Test Rig Results . . . . . . 164
Daniel Groetsch, Rudi Niedenthal, Katharina Voelkel, Hermann Pflaum,
and Karsten Stahl
Significant Drag Torque Reduction and Improved Clutch Dynamics
by Innovative, Very Compact Separating Springs for Wet Clutches . . . 177
Hüseyin Gürbüz, Jörgen Schulz, Ferit Kücükay, Fatim Scheikh Elard,
and Sascha Ott
48 V AWD Demonstrator with P0 + P4 Close to Wheel Concept . . . . . . 191
Matthias Werra, Matthias Ristau, Arno Ringleb, Sven Oliver Hartmann,
Julian Kumle, and Daniele Rosato
Industry 4.0 Applications for Improved Efficiency in EOL Testing . . . . 203
Ralph Heckmann
Triple Wet Clutch e-Module for P2 Hybridization: Architecture
and Technical Description of a Triple Wet Clutch Unit and the
Related Active and Passive Clutch and Shift Actuation System . . . . . . . 208
Olivier Simon and Wilhelm Heubner
Method for Thermal Modeling of Electric Traction Machines
for Hybrid Vehicle-Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Holger Hinrich
System Cost Reduction by Electric Powertrain Design Optimization . . . 226
Martin Hofstetter, Dominik Lechleitner, and Mario Hirz
Contents ix

The Ideal Future Hybrid Powertrain: How to Conduct a

Comprehensive Simulation and Design Analysis, Identifying Ideal
Hybrid Powertrain Architectures and Operating Strategies . . . . . . . . . . 236
Y. Jokmin, F. Holldorf, E. Montefrancesco, K. Loock, and N. Moeller
E-FDU: An Innovative Double Motor, Disconnectable Front Electric
Drive Unit for Ferrari Sport Car Application . . . . . . . . . . . . . . . . . . . . 249
Fabio Irato, Carlo Cavallino, Gianluca Quattromani, Giulio Lapini,
and Giuseppe Manici
Effective Battery Design and Integration of Cylindrical Cells
for High Power Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Helmut Kastler and Kilian Menzl
Compact E-drive for Trucks—Efficient Utilisation of the E-motor
Through Multi-speed Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
John W. Kimes
Representative AWD System Evaluation by High-Function
Dyno—New Simulation Model of Sand Road . . . . . . . . . . . . . . . . . . . . . 302
Wataru Kobayashi and Satoru Okubo
Environmental Benefits of Used Batteries from E-Vehicles as
Stationary Energy Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Juergen Koelch
Finite Element Modeling (FEM) and Fatigue Analysis of Hypoid
Gears and Laser Welding Joints Installed in a Power
Take-off Unit (PTU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Kibok Lee, Myeongeui, and Jongho Seo
Highly Efficient Drivetrains for the Mobility of the Future . . . . . . . . . . 330
Andreas Mair
The 8G-DCT Plug-in Hybrid Transmission for the Mercedes-Benz
Compact Car Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Matthias Maisch, Martin Hörz, and Daniel Jesser
Solutions for Increased Power Density at Shifting Clutches . . . . . . . . . . 346
Harald Merkel
A Brief Evaluation of Freewheeling Motor at P4 Position: Retrofit
Approach to Electrification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Jérôme Mortal and Ashwin Charles
Laser Joining of Copper-Copper and Copper-Aluminum Application
in the E-Mobility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Stefan Mücke
x Contents

ELIKA Automotive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

Danilo Persici and Michelangelo Musiani
Park by Wire System for Current Electric Drive Units . . . . . . . . . . . . . 398
Jan Nowack, Gereon Hellenbroich, Arnab Ghosh, Valerij Shapovalov,
and Ralph Fleuren
Innovative and Highly Efficient Clutch System for Multispeed BEV
with Highspeed Powertrains: Tackling the Efficiency and Drag Loss
Challenges Through a Novel Latching and Actuation System . . . . . . . . 407
Sascha Ott, Hüseyin Gürbüz, Falk Nickel, and Andreas Genesius
Multipurpose Oil Filter Systems for Innovative Drivetrains
and e-Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Marius Panzer, Claudia Wagner, Anna-Lena Winkler, Alexander Wöll,
and Richard Bernewitz
The Propulsion, Energy Storage and Charging System
of the New Opel Corsa-e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Peter Ramminger and Hans-Georg Schade
Fast and Accurate Road Interference Compensation for Objective
Drivetrain Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Johann Rutz, Thomas Ebner, and Ferit Küçükay
BEV AWD EDU Gear Ratio Selection for Efficiency . . . . . . . . . . . . . . . 448
Yogesh Mehta, Cong Liao, and Michael Schulte
An Efficient and Automated Design Strategy for Multiphysics
E-Motor Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Torben Schulze, Jean-Baptiste Mouillet, Thomas Lehmann,
and Lars Fredriksson
How to Ensure Safety of EV or FCV Without Reliable, Helpful Saving
Functions Made by ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Takashi Shibayama
P2i, a Family of Modular, Scalable, and Integrated Hybrid
Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
Heiko Jausel and Wolfgang Wenzel
Innovative Sensor Technology Revolutionizes Lubrication System
Analysis in Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
Mario Theissl, Hannes Hick, and Peter Neger-Loibner
Proposal of Application of Magnetostrictive Torque Sensor
in EV—Seamless 2-Speed Shifting with Torque Feedback Control . . . . 509
Seigo Urakami, Kota Fukuda, Junji Ono, Tomoyuki Miyazaki,
and Shinji Okada
Contents xi

Compact Pushbelt Variator Module to Improve Energy Economy

in Electrified Powertrains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
Gert-Jan van Spijk, Ingmar Hupkes, Mattijs Tweehuysen, Arno Klaassen,
Jordi Meegdes, and Rokus van Iperen
Supply Chain Implications of Increasingly Integrated EV Drivelines . . . 536
Claudio Vittori, Wen Gao, and Graham Evans
Fuel-Saving Potential of Hybrid Electric Vehicles Using Surroundings
Sensor System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
Dominic Waldenmayer, Johannes Buyer, Katharina Bause,
Nikolas Andriessen, and Hermann Koch-Gröber
Quality Assurance of Composite Materials for Powertrain
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
Andrew Willett
The Rolling Bearing in the Electrified Power Train—Requirements
and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
Thomas M. Wolf

Author Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585