Hybrid Powertrain Pulse Control for Low-Emission Heavy Trucks
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Solution Overview
Problem
The global heavy-truck industry faces significant challenges in developing a high performance-to-price ratio and production-ready powertrain technology that meets stringent CO2 and NOx emission regulations by 2027 and 2030, respectively, while maintaining vehicle power performance and reducing RDE fuel consumption and emissions.
Innovation Solution
A software-defined mixed hybrid powertrain (SDPt) with pulse modulation control (PMC) decouples software and hardware, enabling independent control of engine, motor, and battery pack operations to optimize fuel consumption and emissions across various driving conditions, allowing retrofitting of existing diesel trucks into automated-connected-electrified (ACE) trucks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If traditional diesel powertrain is used, then vehicle power performance is maintained, but CO2 and NOx emissions exceed regulatory standards
Solution Approach 1:
The powertrain is segmented into multiple independent power sources (diesel engine, electric motor, battery pack) that can operate independently or in combination. This allows the system to optimize emissions by using electric motor assistance during transient operations and maintaining diesel engine operation within optimal emission zones, while still meeting power demands and regulatory standards.
Solution Approach 2:
The powertrain control system dynamically adjusts the operating points of the diesel engine and electric motor based on real-time vehicle conditions, road gradient, speed, and power demand. This dynamic optimization ensures the diesel engine operates primarily in high-efficiency, low-emission zones while the electric motor handles transient peaks, achieving both emission compliance and power performance.
2Use of energy by moving object
If hybrid powertrain components are added to reduce emissions, then fuel consumption and emissions decrease, but hardware cost and system complexity increase
Solution Approach 1:
The electric motor is designed to perform multiple functions: providing torque assistance during acceleration, enabling regenerative braking, and serving as a standalone power source for low-speed urban operations. This multi-functionality reduces the need for additional specialized components, thereby limiting system complexity while achieving fuel savings and emission reductions across diverse driving conditions.
Solution Approach 2:
The system utilizes parameter changes in the diesel engine's operating characteristics by controlling it to operate primarily within a restricted high-efficiency zone. Combined with electric motor assistance for transient power demands, this parameter optimization achieves fuel consumption reduction without requiring complex hybrid system architecture.
3Use of energy by moving object
If diesel engine operates in high-efficiency zone only, then fuel consumption decreases, but vehicle power performance and responsiveness deteriorate
Solution Approach 1:
The electric motor acts as an intermediary between the diesel engine and the drivetrain, absorbing transient power demands during acceleration and hill climbing. This allows the diesel engine to remain in its high-efficiency operating zone while the electric motor provides the additional power needed for responsive vehicle performance, effectively decoupling the conflicting requirements of fuel efficiency and power output.
4Use of energy by moving object
If regenerative braking is implemented to recover energy, then fuel consumption reduces, but system complexity and manufacturing cost increase
Solution Approach 1:
The regenerative braking function is merged with the existing electric motor and battery pack components already required for hybrid operation. The same electric motor that provides torque assistance also serves as the generator during regenerative braking, eliminating the need for separate regenerative braking hardware and reducing manufacturing complexity while achieving energy recovery.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The SDPt technology achieves a 20-30% reduction in RDE fuel consumption and ensures stable compliance with EPA-2010 NOx emissions, meeting advanced regulatory standards ahead of schedule, with no additional hardware cost and leveraging software updates for optimal performance.
Implementation Method 1
at least one battery pack electrically connected with the motor controller
Implementation Method 2
at least one motor mechanically connected with the driving axle of the vehicle... converting the electric energy into mechanical energy for driving the vehicle, or converting the mechanical energy of the vehicle into electric energy
Data Source
AI summary
A dual-motor mixed-hybrid powertrain system, by performing pulse modulation control, i.e., series-hybrid intelligent start-stop control or parallel-hybrid intelligent power switching control, on the instantaneous power time-varying functions of an engine and a battery pack, can convert the surface working condition of an analog electric control engine into a simpler line working condition of a digital pulse control (DPC) engine, either a pre-determined high-state line working condition in the high-efficiency combustion area or a pre-determined non-combustion low-state line working condition with zero fuel consumption and zero pollutant emissions multiplexed in time. The traditional fixed one-to-one bidirectional mapping between an engine working condition and a vehicle working condition is converted into a dynamically adjustable many-to-many bidirectional mapping to achieve the full coverage of any overall vehicle working condition, achieving decoupling between a DPC engine working condition and the overall vehicle working condition and decoupling between software and hardware of a hybrid powertrain.