The progressive electrification of the power train for passenger cars currently brings a massive cost increase of the overall system itself.The additional cost result primarily due to the additional systems and components, such as battery, generator, electric motor, power electronics and the like causes, but is also increased due to the extended complexity in the control of these systems and their integration into the vehicle.Even in case of economies of scale in mass production for electric components maintaining well known powertrain technologies still remain substantial additional cost compared with non-electrified power trains. AVL's approach to cost reduction for comparable performance and fuel consumption target values with current production solutions is a radical and continuous integration of functions.The concept of functional integration critically scrutinizes and redefines existing interfaces, based on the established manufacturing and assembly sequences in mass production.This functional integration considers not only the singular main elements of the drive train, such as engine, gearbox and electric motor, but it also presents innovative solutions that logically bring these key elements together, in terms of overall power train function. Despite the high functional integration, it was possible to realize a modular drive train family, consisting of a conventional drive train, mild hybrid, plug-in hybrid up to a range extender and a pure electric drive line. The compactness and the wide spread of performance range of the modular AVL e-. Fusion family allows an universal application for A, B, and C segment passenger cars, whereas the 2 cylinder TGDI engine is capable to also cover the entry-/volume-power class in the C segment. The 3 cylinder TGDI is also able to cover higher vehicle segments. Center of attention was also paid on the NVH behavior of engines with lower number of cylinders. The unit cost reductions for the entire drive train achieved, depending on the application, is between 10 and 40% in comparison with known solutions. This presentation shows besides the overall system design the highly integrated transmission solutions for the AVL CEPT and explains in detail the operating- and control strategies for the different applications.
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