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Spotlight on Cenex LCV2012 exhibitors: CPT and the LC Super Hybrid

CPT and the LC Super Hybrid at Cenex LCV2012

Controlled Power Technologies (CPT)
has developed affordable
hybrid technology using an electric supercharger , as demonstrated in its VW Passat-based LC Super Hybrid.

The LC Super Hybrid is an example of CPT bringing together expertise in powertrain, power electronics and control software required for developing and commercialising carbon-reducing technologies for vehicle manufacturers.

CPT acquired asset and technology from Visteon Corporation that covers a family of low carbon powertrain related products already at an advanced stage of development. These include an electronically-controlled supercharger, a stop-start system and an exhaust energy recovery system . All the products utilise switched reluctance electric motor technology delivering ‘micro-hybrid’ vehicle functionality – with the aim of making hybrids affordable.

Controlled Power Technologies and the Advanced Lead-Acid Battery Consortium (ALABC) conceived the LC Super Hybrid, based on a series production 1.4-litre turbocharged VW Passat TSI model, to show that significant CO 2 reduction can be achieved through electric hybridisation at low voltages (12-48 volts) using the latest lead-carbon batteries. The production-ready technology offers the potential of a mass market, petrol-powered, large family car with good drivability, impressive performance and excellent 5.6 litres/100km (51mpg) fuel economy achieved at substantially lower cost than an equivalent diesel model. The low voltage technology enables aggressive yet near-term down-sizing and down-speeding of existing engine families.

The LC Super Hybrid technology

The technologies in the LC Super Hybrid comprise an electric supercharger , next generation belt-integrated starter generator with an advanced belt tensioning system, carbon enhanced valve regulated lead–acid (VRLA) batteries which avoid the need for super-capacitors, and higher gear ratios to reduce engine speed. Recalibration of the engine increases power from 122 to 142PS and torque from 200 to 275Nm. This power and torque is more comparable with VW’s bigger 1.8-litre TSI gasoline engine, which delivers 160PS and 250Nm, and the engine output of the LC Super Hybrid is generally equivalent to vehicles in the 2-litre class. Despite the enhanced petrol engine performance the vehicle achieves near diesel levels of fuel economy, but with substantially lower production costs.

The impressive performance and excellent fuel economy are underscored by the acceleration figures and results measured on the standard European drive cycle. The LC Super Hybrid delivers CO
2
emissions of less than 130g/km compared with 140g/km for the baseline Passat 1.4-litre TSI, which is already best in class, and an even more significant reduction when compared with 160g/km for the 1.8-litre TSI model. This represents a
reduction in CO
2
emissions
of 8 and 23 per cent respectively. Similarly, the fuel economy of 5.6 litres/100km (51mpg) represents a significant 11 and 24 per cent improvement respectively when compared with 6.2 litres/100km (46mpg) for the 1.4-litre TSI and 6.9 litres/100km (41mpg) for the 1.8-litre TSI also measured over the standard European drive cycle.

The electric supercharger aims to boost the performance of downsized turbocharged engines and eliminates turbo lag. Electric supercharging provides the same swift acceleration and drivability of a much bigger naturally aspirated engine, which is a characteristic much preferred by drivers. It’s powered by the battery and unlike mechanical superchargers and exhaust-driven turbochargers is not driven by the engine. This vital disconnect means it can provide maximum boost even at very low engine speeds.

The additional cost to the vehicle manufacturer is estimated between €750 and €1,500. By comparison, a high voltage hybrid typically delivers between 15 and 20 per cent CO
2
reduction
, but incurs an additional manufacturing cost of between €3,000 and €5,000. And while a plug-in hybrid electric vehicle can deliver better than 20 per cent CO 2 reduction, the additional manufacturing cost increases significantly to between €6,000 and €10,000 – dominated by the high cost of Li-Ion and NiMH batteries – hence the need for government subsidies so these vehicles are affordable for early adopters of EV technology.

Controlled Power Technologies has a portfolio of technologies delivering CO2 reduction including:

Boosting

• Electric supercharger

• Downsizing

• Reduced turbo lag

• 12V, 70k rpm, 1.8kW, air cooled

• Diesel & gasoline

Hybrids

• 12V stop-start

• Rapid start time

• High power generation 2.7kW

• Fully integrated electronics

• Liquid Cooled

• Diesel & gasoline

• Superb “Driver Change of Mind”

Regeneration

• Recover exhaust gas energy

• >4kW electrical power output

• Liquid cooled

• 12V & 340V design

Find out more: Controlled Power Technologies will be exhibiting at the
Cenex LCV2012 event at Millbrook, 5 & 6 September 2012
.