Technical characteristics and prospects of power transmissions for commercial vehicles under the “Carbon-Peak and Carbon-Neutrality” target

doi:10.3969/j.issn.1674-8484.2023.04.001

Journal of Automotive Safety and Energy ›› 2023, Vol. 14 ›› Issue (4): 395-412.DOI: 10.3969/j.issn.1674-8484.2023.04.001

• Review, Progress and Prospects • Next Articles

Technical characteristics and prospects of power transmissions for commercial vehicles under the “Carbon-Peak and Carbon-Neutrality” target

XU Xiangyang(), ZHAO Junwei, DONG Peng^*(), WANG Shuhan, LIU Yanfang

School of Transportation Science and Technology, Beihang University, Beijing 100191, China

Received:2023-07-29 Revised:2023-08-14 Online:2023-08-31 Published:2023-08-31
Contact: *Dr. DONG Peng, Associate Professor, An associate Professor and doctoral superviso in the School of Transportation Science and Engineering, Beihang University. He presided over the National Natural Science Foundation of China General and Youth Projects, Sub-Projects of the National Key Research and Development Program as well as a number of provincial and ministerial key projects, etc. He has published more than 50 academic papers. He has won the Special Prize of China Machinery Industry Scientific and Technological Progress, the First Prize of China Society of Automotive Engineering Scientific and Technological Progress, and the First Prize of Jiangsu Province Scientific and Technological Progress. His research mainly focuses on the optimal design and control of vehicle powertrain systems.
About author:Dr. XU Xiangyang, Professor. A professor, doctoral supervisor and the director of the academic committee, School of Transportation Science and Engineering, Beihang University. He is also the deputy director of National Engineering Research Center for Passenger Car Automatic Transmission, a member and executive director of China Society of Automotive Engineers. He has made outstanding contributions to basic theoretical innovation, engineering technology development and industrial application in the field of vehicle transmission in China, and published more than 100 SCI/EI papers and authorized 85 innovation patents. He led the R&D of world first front-across application 8-speed automatic transmission (8AT) and its series of products, and awarded First Prize of National Scientific and Technological Progress in 2016, achieving a major breakthrough in the core transmission assembly technology in China, breaking the foreign monopoly, building and completing the independent controllability of the automatic transmission industry chain in China, and promoting independent technological breakthroughs in automatic transmissions, hybrid transmissions, electric transmission systems for vehicles such as passenger cars, commercial vehicles, construction machinery and military vehicles. In addition, he has successively presided over more than 30 projects at the national, provincial, and ministerial levels and school-enterprise cooperation, including National Science and Technology Support Program and Key Project of International Science and Technology Innovation Cooperation, and won the Special Prize of China Machinery Industry Science and Technology Progress Award and the First Prize of China Society of Automotive Engineering Scientific and Technological Award.

Abstract

Abstract:

Commercial vehicles are an important force in road transportation and a large carbon emitter. Realizing the green transformation and development of commercial vehicles is an important breakthrough in accelerating the achievement of the “Carbon-Peak and Carbon-Neutrality” target in the automotive industry. However, policy-driven and market demand have posed new challenges and requirements for the development of commercial vehicle technology, especially with the emergence of multiple technological routes for power transmissions. This paper focuses on the application scenarios of medium and heavy trucks, light and pickup trucks, and buses under different power sources such as traditional fuel, hybrid, pure electric, and hydrogen fuel cell, and analyzes the technical characteristics, product spectrum, applicability in different scenarios, and technological development trends of power transmission systems for commercial vehicles. A new prospect is put forward for the development of power transmission technologies for commercial vehicles to provide a reference for the technical path selection and technological innovation and development of commercial vehicle transmissions.

Key words: commercial vehicle, power transmissions, automatic transmission, electro-mechanical coupling transmissions, EV drive system, Carbon-Peak and Carbon-Neutrality

CLC Number:

U463.2

XU Xiangyang, ZHAO Junwei, DONG Peng, WANG Shuhan, LIU Yanfang. Technical characteristics and prospects of power transmissions for commercial vehicles under the “Carbon-Peak and Carbon-Neutrality” target[J]. Journal of Automotive Safety and Energy, 2023, 14(4): 395-412.

Figures/Tables 13

References 60

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产品谱系	传统燃油商用车	混合动力商用车	纯电动和氢燃料电池商用车
中重卡	MT、AMT AT、DCT	增程混动、并联混动	单电机多挡、双电机多挡，集中式电桥、分布式电桥（轮边电桥、轮毂电桥）
轻微卡和皮卡	MT、AMT AT、DCT	增程混动、并联混动、专用混联DHT（含串并联、功率分流）	单电机直驱、减驱、多挡
客车	MT、AMT、AT	增程混动、并联混动、专用混联DHT （含串并联、功率分流）	单电机直驱、减驱、多挡、双电机多挡、集中式电桥、分布式电桥（轮边电桥、轮毂电桥）

产品谱系	传统燃油商用车	混合动力商用车	纯电动和氢燃料电池商用车
中重卡	MT、AMT AT、DCT	增程混动、并联混动	单电机多挡、双电机多挡，集中式电桥、分布式电桥（轮边电桥、轮毂电桥）
轻微卡和皮卡	MT、AMT AT、DCT	增程混动、并联混动、专用混联DHT（含串并联、功率分流）	单电机直驱、减驱、多挡
客车	MT、AMT、AT	增程混动、并联混动、专用混联DHT （含串并联、功率分流）	单电机直驱、减驱、多挡、双电机多挡、集中式电桥、分布式电桥（轮边电桥、轮毂电桥）

产品类型	AMT	AT	DCT	MT
技术优势	1. 结构设计简单，换挡控制简单 2. 挡位数目多（6~16挡） 3. 速比范围广，最大速比大 4. 最大扭矩承载能力强	1. 挡位数目集中于6~9挡 2. 动力换挡，换挡品质高 3. 传动比范围较广 4. 大扭矩承载适应面较广	1. 挡位数目多为7挡、9挡 2. 动力换挡，换挡品质高 3. 传动效率较高	1. 结构设计简单 2. 成本较低 3. 手动控制
技术劣势	1. 换挡动力中断 2. 换挡冲击大，舒适性较差	1. 结构设计复杂 2. 传动效率相对较低 3. 换挡控制难度较大	1. 结构设计相对复杂 2. 对控制系统要求较高 3. 离合器工作对温度敏感 4. 传递扭矩受限	1. 驾驶操作强度高 2. 传动效率较低
代表企业	德国采埃孚、斯堪尼亚、伊顿、法士特、中国重汽、东风商用车、一汽解放	德国采埃孚、美国艾里逊、爱信、法士特、长城、盛瑞	伊顿、沃尔沃、博格华纳	德国采埃孚、法士特、上汽变速器、万里扬、重庆青山

产品类型	AMT	AT	DCT	MT
技术优势	1. 结构设计简单，换挡控制简单 2. 挡位数目多（6~16挡） 3. 速比范围广，最大速比大 4. 最大扭矩承载能力强	1. 挡位数目集中于6~9挡 2. 动力换挡，换挡品质高 3. 传动比范围较广 4. 大扭矩承载适应面较广	1. 挡位数目多为7挡、9挡 2. 动力换挡，换挡品质高 3. 传动效率较高	1. 结构设计简单 2. 成本较低 3. 手动控制
技术劣势	1. 换挡动力中断 2. 换挡冲击大，舒适性较差	1. 结构设计复杂 2. 传动效率相对较低 3. 换挡控制难度较大	1. 结构设计相对复杂 2. 对控制系统要求较高 3. 离合器工作对温度敏感 4. 传递扭矩受限	1. 驾驶操作强度高 2. 传动效率较低
代表企业	德国采埃孚、斯堪尼亚、伊顿、法士特、中国重汽、东风商用车、一汽解放	德国采埃孚、美国艾里逊、爱信、法士特、长城、盛瑞	伊顿、沃尔沃、博格华纳	德国采埃孚、法士特、上汽变速器、万里扬、重庆青山

产品谱系	AMT	AT	DCT
中重卡	8挡、12挡、14挡、16挡重卡扭矩需求可达3 kNm以上中卡扭矩范围在0.8~1.6 kNm 速比范围最高可达16~18	8挡、9挡扭矩范围可覆盖0.6~3.0 kNm	由于传递扭矩受限，DCT仅在需求扭矩较低的中卡场景探索应用
轻微卡和皮卡	6挡、8挡扭矩范围在0.4~1.8 kNm	由于结构复杂、成本较高AT在轻微卡应用场景有限，但在高性能皮卡应用前景看好	7挡适配于扭矩需求较小的轻微卡
客车	新能源客车渗透率逐渐增大，以驱动电机为动力源的自动变速器市场将占主导地位以燃油发动机为动力源的传统自动变速器在客车领域的应用占比将逐渐变小

Technical characteristics and prospects of power transmissions for commercial vehicles under the “Carbon-Peak and Carbon-Neutrality” target

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产品类型	并联混动系统	串联混动系统	专用混联式混动系统
技术优势	1. 结构布局简单，仅在传统自动变速器基础上进行电机位置的布局，以P2为主 2. 发动机和驱动电机均可直接参与驱动 3. 动力性、工况适应性较好	1. 结构设计简单，补能方便 2. 发动机与发电机形成增程器，与轮端解耦，能够使发动机保持在高效区工作 3. 驱动电机能够与变速器结合工作	1. 分为串并联式和功率分流式，具有多种工作模式，能量调节自由度高 2. 发动机、驱动电机和发电机均可参与驱动 3. 经济性、动力性、工况适应性可同时兼顾
技术劣势	1. 挡位与工作模式多，换挡换模平顺性 2. 轴向尺寸难以控制，利用空间较大 3. 单电机无法同时驱动和发电	1. 重载、高速亏电工况能量利用效率较低 2. 亏电状态下，动力性较差 3. 发动机无法直接参与驱动，能量调节自由度较低	1. 多挡结构设计复杂、构型寻优难度增大 2. 控制难度较大、平顺性和NVH难控制 3. 重载传递扭矩能力有限
代表企业	沃尔沃、奔驰、法士特、江淮、苏州绿控	江淮、凯博易控、吉利远程、比亚迪	艾里逊、宇通、江淮、上汽

产品谱系	并联混动系统	串联混动系统	专用混联式混动系统
中重卡	结合传统变速器的技术优势，应用于中等中、长运距场景	在纯电驱动系统基础上，为有效补充电池能力不足，增设增程器进行适时补能	由于传递扭矩有限，目前尚未在重卡场景应用
轻微卡和皮卡	由于并联混动系统成本较高，对于小载重轻微卡多采用纯电驱动系统	对于补能有需求的中长运距，串联混动系统在轻微卡场景下有应用潜力，尤其在生鲜冷链运输场景下很有应用潜力	有效解决中长运距里程焦虑，串并联混动系统具有很大的应用潜力，具有TCO优势
客车	并联混动系统早期应用于城市客车	对于给定固定路线的客车场景，多以纯电为主	对于非固定路线的小型客车有一定的应用潜力

产品类型	电驱动及传动总成	集中式电桥	分布式电桥
技术优势	1. 通过采用单电机、双电机和不同挡位进行组合，能够有效匹配不同载重商用车，包括单电机纯电直驱、减驱、多挡系统，双电机多挡传动系统，适用场景广 2. 结构设计简单、控制策略简单 3. 与驱动电机组合传动效率较高，能够实现制动能量回收	1. 在电驱动及传动总成基础上进一步集成，结构布置更紧凑 2. 重量相对减少，扭矩密度显著提升 3. 传动效率更高	1. 布置空间更灵活，未来可实现即插即用 2. 转矩密度、功率密度优势明显 3. 传动效率更直接 4. 减少不必要且复杂的传动部件、重量大幅减轻，轻量化优势明显
技术劣势	1. 对电池充放电能力要求较高 2. 重载、大扭矩运行条件下对电机能力要求高 3. 高速状态下NVH性能较差、对传动系统设计能力要求高	1. 成本较高 2. 造成簧下质量增加问题	1. 结构设计复杂、成本较高 2. 非簧载质量大 3. 三向协同控制难度较大
代表企业	采埃孚、艾里逊、博格华纳、凯博易控、法士特、特百佳、绿控、汇川、精进电动	艾里逊、特斯拉、东风德纳、比亚迪	奔驰、采埃孚、比亚迪、湖北泰特

产品谱系	电驱动及传动总成	集中式电桥	分布式电桥
中重卡	双电机多挡位传动系统能够适用于49T以上重卡车型单电机多挡位传动系统能够有效匹配中卡车型	双电机集中式电桥适用于载重与扭矩需求大的中重卡	分布式电桥的产业化应用将持续探索验证
轻微卡和皮卡	纯电减驱系统能够应用于3.5T以上轻卡车型微卡可直接使用纯电直驱系统	单电机集中式电桥适用于载重与扭矩需求小的轻微卡	分布式电桥的产业化应用将持续探索验证
客车	可有效匹配单电机直驱、减驱、多挡传动系统	根据载重与扭矩需求可匹配单/双电机集中式电桥	轮边电桥适用于低地板客车

共性技术1	创新动力传动系统拓扑构型，与目标整车及底盘协同设计
共性技术1	动力传动系统机械、液压、电控部件高效化设计
共性技术3	智能网联大数据技术赋能动力传动系统
共性技术4	动力传动系统开发、测试、验证工具链自主可控

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