DSD’s extensive experience with hybrid and electric vehicles means we can support clients throughout their strategic planning and architecture definition across mechanical and control system design.
Once targets are defined, we can provide engineering concepts to satisfy those targets. We understand the background environment in which these decisions are taken. For example, 48v architecture is re-emerging as a potentially convenient hybrid solution, free from the safety issues of high voltage systems.
At a detail level, our expertise as systems integrators includes practical experience of such issues as thermal management of the motor and electronics cooling pack and clutch control development, such as kiss point adaptation.
Hybrid Electric Vehicles are challenging and expensive to produce compared to the base vehicle. DSD helps OEMs develop optimum strategies to migrate Hybrid Electric Vehicles (HEVs) from low to high volume manufacture using a scalable architecture shared across multiple platforms.
The objective is to maintain profitability in the end product.
DSD provides clients with the data to evaluate alternative architectures based on trade-offs between cost and functionality, identifying any compromises or brand inconsistencies. In particular, we investigate key limitations, such as motor or clutch performance, and how these impact vehicle targets for cost, weight, NVH, efficiency and CO2 emissions.
A fundamental decision is often choosing between one motor or two and requiring multi or single speed transmissions. DSD’s experience with powershifting AMTs means we can help clients establish the potential for the most cost-effective overall powertrain architecture consistent with vehicle targets.
DSD has extensive experience managing the mechanical, electrical and control systems in Hybrid Electrical Vehicles to deliver an effective solution. While system boundaries are useful for enabling many engineers to work in parallel, DSD can break down system boundaries to arrive at an optimum result.
Successful integration is achieved by managing the interfaces between the systems and configuring key elements, such as clutches, motors, controllers, in the best locations.
The importance of the mechanical aspects of Hybrid Electric Vehicles system integration, such as packaging, thermal management and NVH, are self-evident. Still, the control strategy is an equally key aspect.
DSD has particular experience controlling K0 clutches for engine start and disconnect: a vital part of successful Hybrid Electric Vehicle operation.
Our clutch characterisation rig allows the detailed study of clutch and actuator dynamics and friction characteristics. In addition, the data generated is used to populate unknowns in the control model, leading to better understanding and a more optimal result.