6. Hybrid vehicle ICE fueled with HVO and electrical axle

Lead partner: Ford Otosan

Objectives:

  1. 10% energy saving (based on reference vehicle) in a representative drive cycle by hybridisation of the truck with smart (predictive, connected) control algorithms;
  2. Engine robustness and capability assessment and testing with bio-fuel usage such as HVO E.g. The use case will evaluate Engine robustness and capability assessment and testing with bio-fuel usage with reduction of CO2; by 50-90% (well to wheel; depending on the HVO feedstock);
  3. Zero emission and low noise capability provided by pure electric drive with at least 10 km range.


1. Concept selection and fuel economy road map [FORD РApr 2020]
Heavy-duty vehicles are widely used in the transport sector in Europe. Heavy-duty vehicles transport 75% of freight over land in Europe. Because of their load capacity and annual mileage, heavy-duty vehicles are also a significant source of greenhouse gas (GHG) emissions in Europe. Therefore, any reduction in the emissions of these vehicles will aid in overall reduction of GHG. Ford Otosan proposed the hybridization of the long haul tractors as a solution to support the efforts to reduce GHG emissions of heavy-duty vehicles. -> Public Summary

2. Layout design report [FEV – Aug 2020]
Report on the transmission’s initial layout design. Description of the transmission concept and results of initial layout calculations (gears, shafts, bearings). Screenshots incl. description of initial 3D package model.

3. Detailed Design Report [FEV – Jul 2021]
Report on the transmission’s detailed design. Results of the detailed system model calculations (gears, shafts bearings) and FE analysis. Screenshots incl. description of the final 3D model, including torque transfer, lubrication and actuation system.

4. E-axle Prototype [FORD – Aug 2021]
This deliverable is the assembly of the first e-axle system designed in this project. The first physical prototype will be assembled. A report associated with this progress will be shared.

5. Comparative engine dyno test results HVO vs Diesel [FORD – Dec 2021]
A 13 lt Ecotorq Euro6 engine will be installed to engine dyno and a back to back test will be run with HVO fuel and conventional diesel fuel. The activity will be the pre-assessment of the vehicle testing with HVO usage. A report which will summarize the effect of usage HVO in Ecotorq engine will be shared.

6. Documentation of control system test results [FORD – Apr 2022]
Documentation of control system test results will be a report containing the test results of the algorithms for hybrid control strategy, vehicle control (torque path), electrical system (charge control / thermal management) and e-axle transmission control. The report will inform about the latest status of the algorithms in the reporting day. The tests will be executed at least in one of the MIL, HIL, rig, vehicle environments depending on the algorithm and prototype maturity.

7. Vehicle test results [FORD – Jun 2023]
As a result of the vehicle level design activities, the prototype vehicle will be assembled and tested in proving ground. Vehicle test results will be a report giving information about the prototype vehicle and showing test results of vehicle running in hybrid mode and zero emission mode successfully and gear shifting can be executed in the e-axle. As a back to back testing with the reference vehicle will be executed together with IDIADA and reported out separately, this deliverable will be focusing only to the functional capability of the prototype vehicle rather than targeted energy saving.

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