Investigation on the Dynamic Behaviour of a Torque Transmission Chain for an Innovative Hybrid Power Unit Architecture 2020-37-0013

In this contribution, the mechanical torque transmission between the Electric Motor (EM) and the Internal Combustion Engine (ICE) of a P0 architecture hybrid power unit is analysed.

In particular, the system is made up of a brand new, single-cylinder 480cc engine developed on the basis of the Ducati 959 Panigale V90 2-cylinders engine. The thermal engine is assisted by a custom electric motor (30 kW), powered by a Li-Ion battery pack. The Ducati 959 Panigale engine is chosen because of its high power-to-weight ratio, and for taking advantage of its V90 2-cylinders layout. In fact, the proposed hybridization process considers to remove the vertical engine head and to replace it by the electric motor directly engaged to the crankshaft using the original valvetrain transmission chain, thus achieving a very compact package. This solution could be suitable for many V-type engines and it aims to obtain a small hybrid power unit for possible motorcycle/small vehicle applications.

The original timing chain object of this study is a silent chain, which is commonly employed as a transmission component in hybrid power units because it can operate at high speeds transmitting high loads and ensuring noise reduction. For this reason, the aim of this study is to assess the possibility of using the original chain to couple the EM and the ICE. This investigation allows the replacing of the minimum number of components during the hybridization process leading to a real plug&go solution.

Therefore, the mechanical behaviour of the chain is investigated performing a dynamic analysis of the whole crank mechanism. In particular, the original twin cylinders model considering the original valvetrain system is compared with the single cylinder model engaged with the EM. The dynamic analysis provides the maximum load on the single chain link in both configurations, allowing the evaluation of a relative fatigue safety factor.