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The powertrain electrification is currently not only taking place in public road mobility vehicles, but is also making its way to the racetrack, where it’s driving innovation for developments that will later be used in series production vehicles. The current development focus for electric vehicles is the balance between driving power, range and weight, which is given even greater weighting in racing. To redefine the current limits, IAV developed a complete e-powertrain for a racing MX motorcycle and integrated it into a real drivable demonstrator bike. The unique selling point is the innovative direct phase-change cooling (PCC) of the three-phase e-motor and its power electronics, which enables significantly increased continuous power (Pe = 40 kW from 7,000 rpm to 9,000 rpm) without thermal power reduction. The drive unit is powered by a replaceable Lithium-Ion round cell battery (Ubat,max = 370V) with an energy storage capacity of Ebat = 5 kWh.

High pressure EGR provides NOx emission reduction even at low exhaust temperatures. To maintain a safe EGR system operation over a required lifetime, the EGR cooler fouling must not exceed an allowable level, even if the engine is operated under worst-case conditions. A reliable fouling simulation model represents a valuable tool in the engine development process, which validates operating and calibration strategies regarding fouling tendency, helping to avoid fouling issues in a late development phase close to series production. Long-chained hydrocarbons in the exhaust gas essentially impact the fouling layer formation. Therefore, a simulation model requires reliable input data especially regarding mass flow of long-chained hydrocarbons transported into the cooler. There is a huge number of different hydrocarbon species in the exhaust gas, but their individual concentration typically is very low, close to the detection limit of standard in-situ measurement equipment like GC-MS.

The paper presents a new 7-speed dual-clutch transmission (DCT) for transverse applications and a torque capacity of 200 Nm with an option for 300 Nm engine torque. Advantageously the system is designed for supplier parts of dual-clutch system, gear and clutch actuation, differential as well as bearings, synchronizers and additional standardized parts. The actuation could be also realized by an already developed hydraulic module which can be used and produced locally with supplier parts of valves, sensors and so on. Furthermore, the gear set is a state-of-the-art system which can be supplied by manual transmission manufacturer. Beside the cost focus. the DCT has a favorable gear set in terms of robustness and compactness. The design with a total length of 350 mm is realized through a common gear on the main shaft for each gear pair on the countershafts and multiple use of gears in the first speed.

The contribution presents a new structurally optimized 7-speed hybrid DCT for transverse applications. Advantageously the seven forward speeds can be provided with only two shafts. The space of the usually third shaft can be used for the electric motor or the mechanical reverse speed. This modular integration can be realized by using mostly identical parts for the components of the gear set and the transmission housing. The direct connection of the electric motor to the differential helps to avoid additional gear set loads and efficiency losses. Such modular transmissions will help in future to reduce development and production costs.