Design & Development of Advanced 48 V Electrified Powertrain for Meeting Future CO ₂ Emission Requirements

Environmental Protection Agency (EPA) study indicates that a typical passenger vehicle emits about 4.6 metric tons of carbon dioxide per year. ICCT (International Council on Clean Transportation) establishing fleet-average emissions targets of 95 g & 175 g CO2 per kilometer for passenger cars & light commercial vehicles respectively. In view of the same, extensive work has been executed for implementation of 48 V electrified drivetrain technology, which plays an important role to meet stringent CO2 emission norms. A 3-phase permeant magnet Electric Motor and associated inverter, including the Packaging of the battery, for a P3 hybrid rear drive vehicle was developed. The requirements, relating to design of 48 V drivetrain technology, power and duty cycle has been extensively addressed in the paper. The Objective of paper to propose low cost, lightweight & compact solution to Global Automotive industry, which will play an important role to mitigate stringent CO2 emission norms defined by EPA agency. The permanent magnet compact size Electric motor having rated capacity of 28 kW & torque of 74 Nm supplied by a 48 V link by dc-ac convertor has been proposed for hatchback segment of passenger cars. The major focus of the work presented in this paper is complete mechanical design to transfer power from Electric motor to secondary shaft of transmission with minimum frictional losses by belt drive mechanism. The final test results in the lab after implementation of 48 V electrified drivetrain technology to meet fuel economy targets presented in this paper.