Evaluation of future trends in conceptual design of belt tensioners for hybrid applications

Recently the automotive marked is showing a trend towards increased adoption of hybrid vehicles to reduce emissions and increase vehicle efficiency. Fleet average targets for CO₂ are compelling car manufacturers to reach very challenging fuel economy targets. The development of mild-hybrid vehicles has gained traction in this scenario. Another key driver has been the rapid evolution of electrical systems in new vehicles, ranging from advanced safety systems, driver assistance, and infotainment. This greater demand on electrical load has also contributed to the adoption of mild hybrid powertrains that work alongside traditional combustion engines and existing 12-volt systems. Many leading OEMs and suppliers are developing 48-volt architecture on the basis that it can achieve large efficiency gains at lower costs in the medium term than full electrification. Some of those new architectures based on belt driven system, which include the development of new types of pulleys and belt tensioners. The aim of this research is to review the evolution of belt tensioner design and its trend towards the adoption of 48-volt architecture using a systematic approach to engineering design that evolves from the definition of the global function and development of the functional structure through the identification of solution principles. This proposition could promote the development of novel design concepts and evaluation of existing ones for feasibility prioritization. Furthermore, conclusions of the research indicate how current designs could evolve to meet future trends in performance and reliability of new Front-End Accessory Drive systems configurations.