AVL is the world's largest independent company for the development, simulation and testing of powertrain systems, their integration into the vehicle as well as new fields like ADAS/AD and Data Intelligence.
AVL Powertrain Engineering is an expert partner to the global automotive and mobility industry for the development of innovative powertrain systems. From diesel engines to electric drives, from alternative fuels to control software, from transmissions to batteries, we have been working in partnership with companies all over the world for more than 60 years. Unique synergies with AVL Instrumentation and Test Systems and AVL Advanced Simulation Technologies enable the development of highly creative, mature and application-specific solutions to enable our customers to meet their future market challenges.
The need for CO₂ reduction, the increasing complexity of new powertrain systems, and a requirement to achieve the highest possible level of process efficiency - along with the need to quickly launch new models - are some of the key challenges facing the automotive industry now and for the foreseeable future.
Controls are a key characteristic to differentiate the behavior of the powertrain in regards to vehicle performance, emissions, robustness of diagnostic and brand style (Brand DNA). AVL can deliver independent and modular powertrain software control solutions from prototype through to production to meet individual customer demands.
AVL designs and develops e-drive solutions which are tailored to your specific applications, including hybrids, e-vehicles or auxiliaries. We have over 15 years of experience under our belts in hybrid and e-vehicle development and have a profound knowledge of e-drive and actuators. Challenges: To reach a zero-emission mobility the electrification of vehicle powertrains will be necessary. This fact leads to new challenges for car makers and suppliers: How to make powertrain component more efficient to extend the range & reduce the charging time? How to combine compact and lightweight construction of high-power electronics under considering of passenger security? How to fit new technologies like SiC for e-Drive applications to extend functionality and maximize the performance? How to ensure safe operation in every environmental condition and for all areas of application? How to achieve a faster market entrance by efficient development? AVL offers a range of services for e-drives: Concepts – from the simulation of electric systems to the prototype Series development – design, simulation, integration, testing and verification Component development - motors, generators, power electronics and actuators E-Drive Software development for electronics EMC design and simulation Testing and validation of performance, functionality and EMC Electrification of auxiliary systems and accessories Solutions We develop single e-components but also integrated e-Drives for electric powertrains on every application of use. The AVL Abilities Methodologies & Engineering Know-How of the powertrain system integration to increase the system efficiency Enhancing the development of products and technologies through the interaction of computer-aided engineering tools to exploit feasibility Improvement loop of technical hardware innovations including the combination of hardware and software to perform high efficiency in power electronics System validation and durability tests performed by AVL’s high tech test benches Proprietary development & validation as well as cooperation with leading suppliers Your Benefits AVL designs, develops, integrates and tests your specific e-drive solution and can take it all the way to series development. Key features include: Optimal technology for your requirements: PMSM, ASM, SRM, BLDC, linear drives Electromagnetic compatibility (EMC) of all components Frontloading with innovative simulation technologies
To handle the increasing complexity in combustion engine development and avoid costly recalls, OEMs need advanced tools and smart testing methods that consider the manufacturing and assembling process. At AVL, we have the skills, experience and know-how to meet these challenges head on. Our deep understanding of the test mechanism and our leading system experience is second to none. AVL’s test systems and cutting-edge solutions for all sectors, such as light-duty, mid-duty and heavy-duty engines complete the portfolio. Our end-of-line solutions feature container systems that can be easily integrated into any existing production environment. At AVL, we take pride in being a reliable partner that delivers testing technologies for production, that combine a high degree of flexibility with precision and quality at the highest level. Examples for supported standard solutions include: End-of-Line Loaded Hot Test Systems Quality Audit (QA) / Conformity of Production (COP) Systems Qualified Hot Test Systems End-of-Line Engine Cold Test In-Process Verification Test System (IPV) AVL Guarantees Turnkey systems that suit each application and customer requirement Huge experience thanks to numerous turnkey projects globally Consistency between AVL test systems with our Integrated and Open Development Platform. High-precision measurements with reproducible results
The development of modern vehicles with extremely complex powertrain concepts puts high requirements on new development and validation methods with the associated tools. In order to save costs and reduce development times, road tests are increasingly being transferred to vehicle testbeds and replaced by simulation. Transferability and a balance between the individual test environments (off-line simulation, hardware-in-the-loop, component testbed, vehicle testbed, road, etc.) must be guaranteed.
As part of the Keytech4EV project, a consortium headed by AVL has developed a hybrid fuel cell/battery drive system for a demonstration vehicle. Particular attention was given to energy efficiency and cost reduction. Supported by the Austrian Climate and Energy Fund, the flagship project has now been successfully concluded after three years of intensive research activities.
As its name suggests, the Keytech 4EV project is all about key technologies for electric vehicles, and has the overall objective of creating a highly efficient, costoptimized and zero-carbon drive concept based on hydrogen fuel cell and battery technologies.
Innovative combination of two technologies
The current state of technology is represented by vehicles with either large fuel cell systems and very small buffer batteries, or with pure battery-electric systems. The innovative approach taken by the Keytech4EV project is to combine both technologies into a single, hybridized, overall system that utilizes all synergies. Pre-studies have shown that, compared to both pure fuel cell systems and pure battery solutions, this type of fuel cell/battery hybrid is able to reduce drive system costs significantly, and is also much better suited to fulfil all the requirements (efficiency, drivability, etc.). In addition, the fuel cell/battery hybrid has the benefit of delivering long range and short refueling times. This means that the drawbacks of pure battery electric vehicles, such as limited range and lengthy battery charging times, are avoided altogether.
Tightly integrated project, and parallel research activities
Following a horizontally and vertically tightly integrated organization structure, Keytech4EV was headed by an industrial powertrain-engineering provider (AVL) in cooperation with component and subsystem manufacturers (Hoerbiger, Magna, ElringKlinger), research institutions (TU Graz, TU Wien, HyCentA) and IESTA (SME). Starting with a common concept, the project involved parallel research efforts, leading to the development of central core technologies to be employed in the drive system.
Hoerbiger developed the hydrogen injection valve and, in collaboration with HyCentA, worked out the passive hydrogen recirculation system. Magna designed a hydrogen storage vessel for the center tunnel, and supplied the vehicle’s hydrogen storage vessel system. HyCentA was responsible for the calculation and simulation of refueling processes. ElringKlinger refined its fuel cell platform in order to achieve a fuel cell output of 70 kW. TU Graz assisted with durability testing. AVL developed the entire fuel cell system including its control unit and, in cooperation with IESTA, the fuel cell cooling system. TU Vienna took charge of model development for fuel cell state monitoring during operation.
Finally, all core technologies were integrated and validated at system and vehicle level by AVL.
The final project goal was the development of a hybridized fuel cell/battery demonstration vehicle. The full-featured, medium-sized vehicle serves to demonstrate the following goals:
Another central motivation for this project was to contribute to the creation of a national/European value added chain for fuel cell technology. The participation of five major global passenger car manufacturers as associated project partners underscores the project’s innovative nature and market-oriented goals.
About AVL List GmbH
AVL is the world’s largest independent company for the development, simulation and testing of powertrain systems (hybrid, combustion engine, transmission, electric drive, batteries, fuel cell and control technology) for passenger cars, commercial vehicles, stationary engines, large engines and their integration into the vehicle. AVL has more than 10,400 employees all over the world. In 2018, sales revenues reached EUR 1.75 billion.
About the Austrian Climate and Energy Fund’s energy research and innovation programs
The energy research and innovation programs offered by the Climate and Energy Fund (Klima- und Energiefonds) are central tools for the implementation of the Austrian Federal Government’s National Energy and Climate Plan, thereby contributing significantly to Austria’s long-term economic success. Since 2007, the Climate and Energy Fund, in cooperation with the Ministry of Infrastructure, has invested around 400 million euros in more than 800 energy and mobilityrelated research projects. The strategy is specifically geared to technologies with high growth potential, both nationally and internationally. As a one-stop shop, the Climate and Energy Fund provides research and environment funding instruments throughout the entire innovation process, from research to demonstration.
Information: www.energieforschung.at and www.vorzeigeregion-energie.at
Dipl.-Ing. Michael Ksela
AVL Company Spokesperson
Cell phone: +43 664 132 81 78
Mag. Katja Hoyer
Climate and Energy Fund Press Spokesperson
Cell phone: +43 664 886 13 766
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Federal Minister Leonore Gewessler
“It is my aspiration that we must make the transition to zero-emission mobility. Only then will we be able to reach our energy and climate objectives. This means that concentrated research efforts are needed to address the issue. The project team has proved that innovations made in Austria can make an important contribution to meeting this challenge. I would like to express my sincere thanks to the entire team for their commitment and innovative power, and to the Climate and Energy Fund in its role as competent partner to the bmvit (Federal Ministry of Climate Action, Environment, Energy, Mobility, Innovation and Technology).”
Prof. Helmut List, CEO AVL
“The electrification of the automotive drive system is absolutely crucial to achieving carbon neutrality in future transportation. Fuel cell systems serving as efficient and clean energy converters from hydrogen to electricity in electric passenger cars and trucks will gain greatly in significance, because hydrogen fuel cell vehicles enable CO2-free mobility, long ranges and short refueling times. By employing a novel combination of fuel cell and a deliberately larger battery to create a fuel cell/battery hybrid – Austria’s very first fuel cell vehicle – the project team has made a huge step forward toward high efficiency, attractive drivability and good cost effectiveness.”
Theresia Vogel, Climate and Energy Fund
“For us to remain competitive in the global market, it is paramount for Austria’s automotive industry to put innovative technologies 'made in Austria' swiftly on the market. When it comes to emission-free mobility, green hydrogen will matter at an international level too – so it’s all about achieving efficiency and range. Projects like this one, which we support with our energy research program, secure Austria’s position as industry location, and help us reach the European climate goals.”
The flagship project Keytech4EV demonstrates innovative key technologies for hydrogen fuel cell electric vehicles with a special focus on energy efficiency and costs.
This project (FFG number 855237) is funded by the "Climate and Energy Fund” and carried out as part of the “Energy Research Program 2015”. The program is managed by the Austrian Research Promotion Agency (Österreichische Forschungsförderungsgesellschaft, FFG).
February 2017 to January 2020
HyCentA Research GmbH
Total cost of project:
5.81 million euros
Funding by Climate and Energy Fund:
3.59 million euros
The heart of the Keytech4EV drive system is a 70-kW fuel cell, with which the vehicle achieves maximum speed and gradeability. Together with a battery with ~10 kWh of capacity, the system delivers maximum efficiency, outstanding acceleration and good drivability.
Further features of the C-Class demonstration vehicle:
100 kW e-motor
~4 kg hydrogen for a range of 500 km
~3 minutes hydrogen refueling time
0.8 kg/100 km hydrogen consumption
At AVL we understand the importance of the availability and usability of equipment and devices throughout the product lifecycle. The delays caused by operational downtime can be extremely costly. We aim to reduce the total cost of ownership and increase the availability and accuracy of test equipment. In this way AVL Customer Services for Testing Solutions helps to avoid the unplanned costs and reduces test repetitions caused by inaccurate equipment. How we do it: Worldwide, the AVL support infrastructure consists of more than 700 service employees working in more than 50 locations. 14 Hotlines guarantee access to AVL expert help and the AVL CARE™ Service Solution manages services for more than 1400 testbeds. In addition: AVL operates more than 240 of its own testbeds at 17 different locations AVL resident teams maintain, support and operate more than 1500 testbeds at customer sites AVL assistance offers application support that can reduce testing time by more than 70% by using the right calibration methodology and infrastructure. A tailored service concept can boost utilization rates to more than 80% and technical availability to more than 97% Find out more about AVL Service Modules and AVL Managed Service Contracts.