Hyundai Blue Drive for the future


Posted on December 30, 2008 12:00 AM

Hyundai aims to be the most fuel-efficient automaker in the world in less than 10 years and the way it will achieve that position is through its Blue Drive strategy. The core element in the strategy is a hybrid drive which will enable Hyundai’s fleet average fuel consumption to be 35 USmpg (18.9 kms/litre) by 2015 - 5 years earlier than the US National Highway Traffic Safety Administration’s (NHTSA) deadline. The goal will also benefit Hyundai customers in other countries since the Blue Drive strategy is a global one.

A new hybrid architecture has been developed by Hyundai with a proprietary parallel hybrid drive system which mates the already fuel-efficient 2.4-litre Theta II engine to a 6-speed automatic transmission and a 30 kW/205 Nm electric motor for maximum fuel economy.

The Hybrid Blue Drive has an all-electric mode and a parallel drive mode. This means the wheels are turned by power coming directly from the petrol engine, or the electric motor, or both together, as conditions demand. This parallel hybrid drive architecture will serve as the foundation for future hybrid drive vehicles to be developed by Hyundai.

To maximize fuel economy, all of the Theta II major driveline and cooling system components have been optimized to reduce friction, while the crankcase has been filled with low friction oil. Engine management software automatically shuts off the engine when the vehicle comes to a halt, cutting emissions to zero. When pressure is reapplied to the accelerator pedal, the Integrated Starter Generator (ISG) automatically restarts the engine.

The Theta II’s engine management software governing injection pressure, engine cycle timing and exhaust retreatment rates has been revised to further reduce fuel consumption. This control strategy assures that maximum efficiency is achieved during gentle acceleration and greater power is immediately available during full acceleration. During deceleration, braking regeneration comes into play.

In addition, the top three gear ratios in the transmission have been extended to ensure the engine runs at lower RPMs, the latest electric motor-assisted steering system reduces power drain and low-resistance tyres further optimize fuel economy.

Hyundai’s hybrid system stores its electrical charge in a 270V lithium polymer rechargeable battery (5.3 Ah/270 V) that surpasses existing nickel-metal hydride and pending lithium-ion applications. Lithium polymer batteries are more durable and space-efficient than other hybrid batteries and by using them, Hyundai expects to leapfrog other carmaker’s initiatives which use the other two battery types.
 
Compared with nickel-metal hydride batteries, lithium polymer batteries deliver the same power with 30% less weight, 50% less volume and 10% greater efficiency over the nickel-metal hydride batteries found in all of today’s hybrids. Lithium polymer batteries also offer more than twice the energy density of nickel-metal hydride batteries, and 175% greater volumetric energy density. This means reduced demands on space and weight for the battery pack. Lithium polymer batteries also hold their charge 20 times longer, are more resistant to changes in temperature (which improves cycle life) and their self-discharge rate is less than a third of a nickel-metal hydride battery.

When compared to lithium-ion batteries, lithium polymer batteries have higher energy density and lower manufacturing costs. Lithium polymer is more resistant to physical damage and can handle more charge-discharge cycles before storage capacity begins to degrade. Lithium polymer technology also offers significant advantages in thermal robustness and safety compared with typical lithium-ion batteries.

A key difference between traditional lithium ion batteries and Hyundai’s lithium polymer battery solution is the overall packaging of the cell – the anode, the cathode, the electrolyte, and the encasement material. Traditional lithium-ion batteries, like those found in laptops, use what’s known as the '18650 cell’ format. In this format, each mass-produced cell is 18 mm in diameter and 65 mm tall, which is a bit larger than an AA battery. Each of these small metal cylinders is filled with a liquid electrolyte which facilitates the movement of lithium ions across anode and cathode, creating the battery current.

Traditional lithium-ion batteries are easy to handle, can withstand mild internal pressures, and have been around in various forms since 1991. That means a manufacturing infrastructure is in place, and scale economies are reasonably high. However, they do have several disadvantages. For example, their cylindrical shape reduces packaging efficiency and they are surprisingly complicated to manufacture since they have so many small parts. These small parts make them robust to thermal fluctuations and add significant cost and weight to the overall battery system. Cell-to-cell consistency also is extremely critical in a vehicle battery package, since the pack is only as robust as its weakest cell. Traditional lithium-ion batteries have considerable cell-to-cell variation, while Hyundai’s lithium polymer batteries are claimed to deliver outstanding cell-to-cell consistency.

Hyundai has spent hundreds of hours testing Hybrid Blue Drive’s lithium polymer battery system with its battery supplier, LG Chem. This testing has proven that Hyundai’s lithium polymer technology has greater thermal and mechanical stability than existing systems, meaning better safety.

Another key engineering challenge for Hybrid Blue Drive has been assuring maintenance-free battery operation over the vehicle’s life – at least 10 years, and 150,000 miles (240,000 kms) – in all weather conditions. Heat is the enemy of battery cycle life. Hyundai’s thermal imaging testing shows how much cooler a lithium polymer battery is compared to today’s nickel-metal hydride battery or a conventional lithium-ion battery. Consumers will notice these advantages in improved useful life and lower maintenance costs.

Turbocharged GDI engine is one of the aspects of Blue Drive

Another aspect of the Blue Drive will be in turbocharged petrol Direct Injection technology. This was already displayed in the HED-5 concept which had an advanced 2.0-litre Theta turbocharged petrol direct injection (GDI) 4-cylinder engine capable of developing as much as 286 bhp, and delivering more than 12.7 kms/litre in highway driving. This engine will appear in various Hyundai models in the future.

By injecting the fuel directly inside the cylinder in a small, precise amount, combustion is improved, resulting in higher fuel efficiency and lower exhaust emissions. The performance and response of the engine also improves, thanks to intake charge cooling. When direct injection is combined with turbocharging, customers should enjoy even better performance and fewer trips to the station. 4-cylinder turbocharged GDI engines can be 15 – 20% more fuel-efficient than V6 engines without compromising performance.

Next year, Hyundai will introduce high mileage “Blue” editions of its Accent and Elantra models in the US market. The company claims these models will deliver outstanding fuel economy without adding thousands of dollars to the price. In fact, “Blue” models will even be priced lower than other models, assuring they will be both efficient and economical.

North American market Elantra will have high mileage 'Blue' edition in 2009

The ultimate expression of Hyundai Blue Drive is the hydrogen-powered Fuel Cell Electric Vehicle, the most promising technology for future transportation. Hyundai is participating in fuel cell verification programs around the world. In the USA, the company has been a member of the California Fuel Cell Partnership (CaFCP) since 2000. The CaFCP is a collaboration of 33 member organizations, including auto manufacturers, energy providers, government agencies and fuel cell technology companies, that work together to promote the commercialization of hydrogen fuel cell vehicles.

Hyundai is making good progress toward meeting its goal of putting a Hyundai Blue Drive Hydrogen Fuel Cell Electric Vehicle in series production as early as 2012. before then, it will offer a petrol-electric full hybrid edition of the next-generation Sonata for the North American market in 2010.


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