comparison of energy consumption and power losses of a conventionally controlled cvt with a...
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Comparison of energy consumption and power losses of a conventionally controlled CVT with a Servo-Hydraulic Controlled CVT and with a belt and chain as the Torque Transmitting Element
Siddharth Shastri, Andrew A FrankUC Davis HEV Center
04CVT55
Conventional CVT Control
Conventional CVT
Engine driven hydraulic controller Mechanically and electrically
complex High pressure bleed off – energy
intensive Control Vs Efficiency Idle stop systems?
Servo Hydraulic Control
Servo Hydraulic Control
Electro hydraulic system Pressure on demand Power consumption Idle Stop 42-300V Hybrid Applications
UC Davis SHC CVT Setup
INPUT
OUTPUT
M
CLAMPINGB40A8
M
RATIOB40A8
PRI
SEC
FORWARDCLUTCH
REVCLUTCH
M
TORQCONVERTERDC MOTOR
TORQUE CONVERTER
M
LUBE
P
P
P P
P
S
S
T
T
ClutchPressure
RatioPressure
ClampingPressure
TorqueConverterPressure
Sump
LubePressure
Servopump
Testing
Loaded and unloaded tests Characterize each system Energy and Efficiency mapping
Test Setup
DYNO PAD
CVTSYSTEM
DYNOABSORBER /
BRAKE
TORQUETRANSDUCER
ELECTRICMOTOR
TORQUE LOADCELL
Unloaded Tests
Ratio 2.3 1.5 1 0.7 0.4
Speed (RPM) 1000 2000 3000 4000
Pressure (psi) 100 200 300 400
Optimal operating region
Stock - Torque Vs Speed @ 300psi
0
5
10
15
20
25
30
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Speed (RPM)
To
rqu
e (N
m)
Ratio 2.3 Ratio 1.5 Ratio 1.0 Ratio 0.7
Belt SHC - Torque Vs RPM @ 300psi
0
2
4
6
8
10
12
14
16
18
20
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Speed (RPM)
To
rqu
e (N
m)
Ratio 2.3 Ratio 1.5 Ratio 1.0 Ratio 0.7
Stock & SHC Belt - Torque Vs Ratio @ 2000 RPM
0
5
10
15
20
25
30
35
40
45
00.511.522.5
Ratio
To
rqu
e (N
m)
Stock 200psi Stock 400psi SHC Belt 200psi SHC Belt 400psi
Belt Design
Clamping Pressure
Stock - Torque Vs Clamping Pressure @ 2000 RPM
0
5
10
15
20
25
30
35
40
45
0 50 100 150 200 250 300 350 400 450
Clamping Pressure (psi)
To
rqu
e (N
m)
Ratio 2.3 Ratio 1.5 Ratio 1.0 Ratio 0.7 Ratio 0.4
Belt SHC - Torque Vs Clamping Pressure @ 2000RPM
0
2
4
6
8
10
12
14
16
18
20
0 50 100 150 200 250 300 350 400 450
Clamping Pressure (psi)
To
rqu
e (N
m)
Ratio 2.3 Ratio 1.5 Ratio 1.0 Ratio 0.7
Power Consumption
Servo Hydraulic Control System Versus Stock CVT (Ratio 2.3)
0
2000
4000
6000
8000
10000
12000
1000 2000 3000 4000
Rpm
Po
wer
(W
atts
)
100psi SHC 400psi SHC 100psi Stock 400psi Stock
SHC 100 psi
SHC 400 psi
Stock 400 psi
Stock 100 psi
Test has been done on UC
Davis FacilitiesServo Hydraulic Control System Versus Stock CVT (Ratio 1)
0
2000
4000
6000
8000
10000
12000
1000 2000 3000 4000
Rpm
Po
wer
(W
atts
)
100 psi SHC 400 psi SHC 100 psi Stock 400 psi Stock
Testing has been done on UC
Davis Facilities
SHC 100 psi
SHC 400 psi
Stock 100 psi
Stock 400 psi
Power Flow and Losses
CVT
AC150
Losses
Electrical
Mechanical
42V
12V
Clamp RatioTorque
Converter
Controls
Sensors
Friction Belt
Power Input
Power Output
Data
Flow Diagram
Power Consumption of SHC Vs Stock
0
500
1000
1500
2000
2500
2.3 1.5 1 0.7
Ratio
Po
we
r (W
atts
)
Stock Pump Power 42V
Power consumption of SHC Vs Stock 3000RPM and 100psi
Loaded Tests
Torque input (Nm)
(psi) 10 50 100 150 200
Ratio
2.326 22 110 220 330 440
1.5 15 75 150 224 299
1 11 54 107 161 214
0.7 9 46 92 137 183
0.434 8 39 78 117 156
Efficiency
Stock 100Nm Efficiency Vs Speed at different Ratios
77
78
79
80
81
82
83
84
85
86
87
0 500 1000 1500 2000 2500 3000 3500 4000 4500
RPM
Eff
icie
ncy
Stock 100Nm - 2.3 Stock 100Nm - 1.5 Stock 100Nm - 1.0 Stock 100Nm - 0.7 Stock 100Nm - 0.4
Belt SHC - 100Nm Efficiency Vs Speed at different Ratios
74
76
78
80
82
84
86
88
90
0 500 1000 1500 2000 2500 3000 3500 4000 4500
RPM
Eff
icie
ncy
Belt 100Nm - 2.3 Belt 100Nm - 1.5 Belt 100Nm - 1.0 Belt 100Nm - 0.7 Belt 100Nm - 0.4
Chain Vs Belt - Unloaded
SHC - Chain & Belt - Torque Vs Speed
0
2
4
6
8
10
12
14
16
18
20
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Speed (RPM)
To
rqu
e (N
m)
Chain 1.5 Chain 1.0 Chain 0.7 Belt 1.5 Belt 1.0 Belt 0.7 Stock 1.5 Stock 1.0 Stock 0.7
Chain SHC - Torque Vs RPM @ 200psi
0
2
4
6
8
10
12
14
0 500 1000 1500 2000 2500 3000 3500 4000 4500
RPM
To
rqu
e (N
m)
Ratio 2.3 Ratio 1.5 Ratio 1.0 Ratio 0.7 Ratio 0.4
Chain, Belt & Stock - Torque Vs Ratio @ 2000RPM
0
5
10
15
20
25
00.511.522.5
Ratio
To
rqu
e (N
m)
Chain 200psi Belt 200psi Stock 200psi
Chain Design
Loaded Tests
SHC Chain - Efficiency Vs Speed
75
76
77
78
79
80
81
82
83
84
85
86
0 500 1000 1500 2000 2500 3000 3500 4000 4500
RPM
Eff
icie
ncy
50Nm - 2.3 50Nm - 1.5 50Nm - 1.0 50Nm - 0.7 50Nm - 0.4
Chain SHC - 100Nm - Efficiency Vs Speed
76
78
80
82
84
86
88
90
92
0 500 1000 1500 2000 2500 3000 3500 4000 4500
RPM
Eff
icie
ncy
100Nm - 2.3 100Nm - 1.5 100Nm - 1.0 100Nm - 0.7 100Nm - 0.4
Chain SHC - 200Nm - Efficiency Vs Speed
86
87
88
89
90
91
92
93
94
95
96
0 500 1000 1500 2000 2500 3000 3500 4000 4500
RPM
Eff
icie
ncy
200Nm - 2.3 200Nm - 1.5 200Nm - 1.0 200Nm - 0.7 200Nm - 0.4
Chain Vs Belt Vs Stock at 100Nm - Efficiency Vs Speed
76
78
80
82
84
86
88
90
92
0 500 1000 1500 2000 2500 3000 3500 4000 4500
RPM
Eff
icie
ncy
Chain 100Nm - 1.5 Chain 100Nm - 1.0 Chain 100Nm - 0.7 Belt 100Nm - 1.5 Belt 100Nm - 1.0
Belt 100Nm - 0.7 Stock 100Nm - 1.5 Stock 100Nm - 1.0 Stock 100Nm - 0.7
SHC - Chain Vs Belt - Efficiency Vs Load @ Ratio 1.0
78
80
82
84
86
88
90
92
94
96
0 50 100 150 200 250
Load (Nm)
Eff
icie
ncy
1.0 - 1000 1.0 - 2000 1.0 - 3000 1.0 - 4000 1.0 - 1000 - Belt
1.0 - 2000 Belt 1.0 - 1000 Stock 1.0 - 2000 Stock
Conclusions Stock CVT 89.5% efficient SHC system is 50% more efficient The VDT Belt
Optimum at Ratio 1.0 2000 – 3000 RPM Energy intensive below Ratio 1.0
GCI Chain Ratio 1.5 3000 RPM Linear with respect ratio change Exhibits about ½ the internal losses of the belt at 1:1 -
lesser at overdrive
SHC CVT with GCI Chain 94.97% 3% more than SHC CVT with Belt 5.56% more than Stock CVT