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Group 5: The Wolf Pack
 Anthony Tawaf S3194049
 Abdul Alidin s3313307
 Nicholas Reisis S3336270
 Samuel Sainty S3345524

Auto 1027 – Automotive Project 1

 To minimise Mercedes Benz E-Class CO2 Emissions
2016 target = 137 g/km to ensure adherence to
Euro-6 legislative standards.

 To upgrade the Mercedes Benz E-Class Powertrain
system utilising current technologies implementing a
Hybrid system.

 The design must comply with Mercedes Benz E-Class
“Einspritzmotor”, core values.

 The design must comply with Mercedes Benz E-Class
customer values.

Samuel Sainty – S3345524 14nd of May, 2012 2

◦ Top Speed ≈ 250 km/hr
◦ Acceleration (from 0-100 km/hr) ≈ 6.3s
◦ Driving Range ≈ 500km
◦ Maintain the signature E-Class “look”;
◦ High level of safety, reliability, build and ride quality;
◦ Maintain rear wheel drive; and,
◦ Minimise NVH.


 Series Architecture
◦ Zero emission driving range
◦ Engine operates @ maximum operating efficiency
◦ Packaging versatility


◦ x2 Electric Motors = AWD
Electric Motor Performance

350
200

300

250 150
Torque (Nm)

Power (kW)
200

100
150

100
50

50

Power to Accelerate Power for Top Speed
0 0
0 2000 4000 6000 8000 10000 12000 14000

Engine RPM
Torque Power Power to Accelerate Power for Top Speed


Ach Nein…
Thank God
it’s AWD!


 Gear Reduction = 5.91
Total Wheel Torque
4000
Maximum Wheel Torque = 3570 Nm
3500

→ Acceleration = 6 m/s2
3000
Wheel Torque (Nm)

2500

2000

1500

1000

500

0
0 500 1000 1500 2000 2500

Wheel RPM

1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear 7th Gear Electric Powertrain


 Based off Mahle Range Extender ICE /
Generator Package
◦ Fuel Consumption = 280 g/kWh
◦ 40 kW @ 4000rpm
◦ Inline Triple
◦ 1000 cc
◦ 95 Octane Fuel


 Li-Ion Battery chosen is from SAFT VL 34 P.
 The VL 34 P Li-Ion Battery offers advantages in
terms of charging/discharge times. This enables
the E-class to achieve 0-100km in 6s and a top
speed of 250km/h.

Nicholas Reisis– S3336270 14nd of May, 2012 10

 To achieve the requirement of the electric motors
the batteries are arranged in a way to achieve
voltage and current requirements.

 The generator regulated output is 400V and 60A
therefore there are 2 batteries in parallel and 8
units in series to supply power to the motors.


 It is required to buck/boost the voltage for the
battery and the electric motor. The converter has
the ability to buck/boost 300V to 500V.

 The Mercedes E-class control system will control
the direction of converter depending on the SOC.


OPTIONAL

GENERATOR

REGENERATIVE
BRAKING CONTROL
CIRCUIT ALREADY
INCLUDED
Figure 1: AC Propulsion electrical system / components[4]

13
Abdul Qaiyum– S3313307 14nd of May, 2012

Figure 2: Control Flowchart Engine On–Off or Thermostat Control Strategy
Table 2: Generator Performances
Table 1: Generator Operating Voltage
Operating Voltage
Performance Nominal
Peak power 100 hp 75 kW battery input 270 to 336 VDC
Continuous power 60 hp 45 kW range
Peak torque 176 lbf·ft 240 N·m Operating
Continuous torque 110 lbf·ft 150 N·m voltage input 250 to 400 VDC
Maximum speed 8000 RPM range
Maximum efficiency 94% Minimum 180 VDC (with derated
Power density (based on 75 kW) 1.11 hp/lb 1.83 kW/kg voltage limit power output)
Input current
limitation RMIT University©2011 A
400 14

1000
European Drive Cycle @ 26.53%
Regen
Without Regen
800
With Regen
Energy (Whr)

600

NEDC No Regen = 996.88 Wh

400
NEDC With Regen = 732.25 Wh

200

0
0.0
23.3
53.3
86.7
120.0
133.3
160.0
206.7
236.7
263.3
303.3
330.0
350.0
383.3
423.3
460.0
470.0
526.7
540.0
566.7
596.7
636.7
666.7
700.0
733.3
746.7
773.3
820.0
920.0
1046.7
1130.0
Time (s)

Anthony Tawaf– S3194049 14nd of May, 2012 15

State Of Charge for 55 NEDC.
20000 90%
18000
33.3 km 168 km
16000
Charge Discharge
Battery Power KWhr

14000

12000

10000

8000

6000

4000
20%
2000

0
Range Max = 605 km
0 100 200 300 400 500 600
Km

Worst Case @ 40% Reduction = 363 km
Approx. Ave = 484 km

Original Mass = 1689 kg


Hybrid Mass = 1990 kg
differences of 299 kg


Original HYBRID
Cost € Mass (kg) Cost € Mass (kg)

ICE 21000 165 ICE + Gen 3500 77

Trans 7000 80 Electric Motor x 2 4200 130

Tail shaft 1400 20 Diff x 2 3000 80

Driveshaft's x 2 2800 40 Driveshaft's x 4 4000 80

Diff 2100 40 Exhaust 1500 50

Exhaust 3500 60 DC/DC Convertors x 2 150 20

Fuel + 70lt 2100 80 Fuel + 18lt 1000 25

Wiring 1400 25 Invertor 0 39

Reduction 20650 510 Battery Pack include Packaging 30240 270

Total 66000 1540 Wiring 5000 50

Power train Bare 45350 1030 Total 52590 821

Percent 31% New Hybrid Cost 97940 1851


Design Aim Value Accomplished
Emissions 54.4 CO2g/km

Fuel Consumption 2.45 L/100km

Top Speed > 250 km/hr

Acceleration (0 - 100 km/hr) < 6.3 s

Driving Range 484 km

Vehicle Mass 1854 kg

- Einspritzmotor
- Safety
Maintain Customer Values
- Reliability
- NVH

Packaging More Room

Vehicle Life > 15 years







- Einspritzmotor
- Safety
- Reliability
- NVH

Packaging More Room


◦ http://www.hybridcarblog.com/2009/11/nimh-hybrids-long-way-from-dead.html
◦ http://about-auto-and-trucks.blogspot.com.au/2011/04/electric-car-batteries-how-well-do-
they.html
◦ http://www.ecofriend.com/entry/eco-tech-li-ion-batteries-to-get-safe-and-cheap-with-a-
change-in-their-chemistry/
◦ http://astrobotic.net/2010/12/01/new-dcdc-converters-for-the-red-rover-successfully-
integrated/
◦ http://www.evassemble.com/index.php?main_page=product_info&cPath=17_18&products_id=1
30
◦ Wikipedia, “File: Hybrid Peak.png”, http://en.wikipedia.org/wiki/File:Hybridpeak.png, March
2012
◦ Koopmans, L. “AUTO1027 – Automotive Project: Lecture Slides, Weeks 1-5”, RMIT University
◦ http://www.ecofriend.com/mercedes-unveils-electric-drivetrain-sls-amg-cell.html
◦ http://www.sim-drive.com/english/technology/index.html
◦ Lino Guzzela, Antonio Sciarretta, “Vehicle Propulsion Systems, Introduction to modelling and
optimization”, Springer, Verlag Berlin Heidelberg Germany, ISBN-13 978-3-540-25195-8,
2005
◦ http://www.google.com.au/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&ved=0CCYQFjAA&u
rl=http%3A%2F%2Fwww.midmichigansae.org%2Fdocuments%2FDrGoverPresentationSAEApril20.p
df&ei=Uw14T6CJF4ePiAfp4Y2FBQ&usg=AFQjCNFpo5iowEyRZqa_fjTZ6K5NhUD9Dg


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