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September 29, 2011

48-volt electric supercharger for micro-mild hybrids

Currently the most cost-effective solution for reducing CO2 emissions is modular ‘Micro-Mild’ (MM) hybrid technology, based on highly boosted and radically downsized gasoline and diesel powertrains. Modular ‘micro-mild’ hybrid technology offers a compelling cost-effective route to reducing CO2 emissions in family cars says Controlled Power Technologies. Incremental manufacturing cost is €50-60 for every 1 per cent reduction in CO2 emissions compared with the €200-500 per cent typical for full hybrids. Further value enhancements are possible if the automotive industry were to standardise around the proposed 48 volt power networks developing in Europe.

For a 15-25 per cent reduction in CO2 emissions using micro-mild hybrid technologies we have established an incremental cost to the manufacturer of between €750 and €1500,” says Morris. “This compares favourably with the 8-20 per cent typical of CO2 emissions benefit offered by mild hybrids, full hybrids and plug-in hybrids, at a much higher manufacturing on-cost of between €1,600 and €10,000.”




CPT’s Micro-Mild hybrid solution for significant CO2 reduction facilitates radical engine downsizing, but also avoids compromising vehicle performance and especially torque response. The combination of a highly responsive electric supercharger with the world’s most powerful 12 volt integrated starter-generator (ISG) and low cost energy recovery and storage, using advanced lead acid batteries, offers a competitive, cost-effective solution in the micro-mild hybrid segment.

Early target technologies costing less than €20 for every 1 per cent reduction in CO2 emissions have already been adopted by vehicle manufacturers. This includes low viscosity oil, longer gear ratios and starter motor based stop-start. Raising this technology spend towards €50 for every 1 per cent reduction in CO2 emissions buys greater, yet still affordable, efficiency benefits for both the customer and the vehicle manufacturer, who also avoids hefty EC fines. It can also significantly enhance the value of highly boosted and radically downsized engines, which underpin most European manufacturer CO2 reduction strategies. And it reduces the need for more complex and expensive mild hybrids, full hybrids and plug-in hybrids, which would otherwise be essential to meet brand average targets.

The demonstrator, developed in co-operation with the Advanced Lead Acid Battery Consortium (ALABC), will improve significantly on the energy efficiency of a gasoline engine variant of the VW Passat, a large family saloon which is already a class leader in CO2 emissions. With performance similar to that of the 1.8 TSI and 2.0 TDI models, but even lower CO2 emissions and fuel consumption than the current production 1.4l TSI BlueMotion model, the CPT/ALABC demonstrator will provide carmakers with real world confirmation of the potential for this new class of ‘Micro-Mild’ hybrid vehicle.

“The MM hybrid concept, which was first proposed at the AVL conference a year ago, combines CPT’s modular VTES electric supercharger and SpeedStart stop-start technologies in a state-of-the-art yet affordable family sized vehicle,” says Morris. “The LC Super Hybrid validates that concept and will demonstrate significantly reduced CO2 emissions combined with excellent performance at relatively low cost compared to full hybrid and range-extended or plug-in HEVs. ALABC carbon-enhanced lead-acid battery designs complement the low voltage technology helping to maximise energy recuperation during deceleration, fully realising the potential in our stop-start and engine boosting technologies by enabling high power generation and electrical energy recovery as well as outstanding torque response.”

A 2009 analysis describes the hope that micro and mild hybrids could be adopted far faster than regular hybrids (which has not happened yet)



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