Vehicle Powertrain Concepts
Vehicle Powertrain Concepts
Vehicle Powertrain Concepts
Over the past 100 years, vehicles have changed our lives; they have provided mobility
which we exploit in all out commercial activities around the globe and they have also provided
millions of us with new opportunities afforded by personal transportation. At the very heart of
vehicle design is the powertrain system; it is the engineering of the powertrain system which
The output from the power source – to date dominated by the internal combustion (IC)
engine – is controlled by a transmission system and driveline to deliver tractive effort to the
wheels. And all these components, collectively referred to as the powertrain system, are
controlled by the driver. Drivers, who are also viewed as discerning customers by the vehicle
manufacturers, have a range of performance criteria; acceleration, top speed, fuel economy,
gradeability, and towing capacity are some of the more obvious quantitative features. But
subjective judgements such as driveability, fun to drive, refinement and driving pleasure play a
huge part in the commercial success of vehicles. On the other hand, society imposes different
performance demands – with a huge recent emphasis on emissions and CO2 usage of vehicles.
And governments have gone as far as imposing overall emissions control targets on
In order to meet all these conflicting demands, engineers need to master the complete
powertrain system. If there is one underlying theme to this book, it is that in order to understand
vehicle mobility one must analyse the entire system together – driver, engine, transmission,
driving cycles etc. The aim of this chapter is to provide the background to this theme.
The key issue at the heart of this textbook is to adopt a systems approach to hybrid
electric vehicle powertrain design. In simple terms, this means collecting together all the
how they combine and interact. The ultimate aim is, of course, to predict the overall vehicle
First, the behaviours of the powertrain components are analysed – and then these
components are combined together as a complete system to capture the overall vehicle driveline
from the prime mover, through the transmission – clutch, gears, differential etc – to the final
drive at the wheels. The important theme is that it is only by taking a system level view of the
powertrain that the vehicle designer can achieve the desired goals of vehicle performance. In a
systems approach to any problem, it is important at the outset to define the system boundaries.
So, for example, if we wish to study the overall usage of energy in passenger car transportation,
the system would look like that shown in Figure 1.1 – in which the energy is tracked from its
original source through to its final usage in propelling a vehicle. This overview is important in
the context of powertrain system design, and is now commonly referred to as the Well-to-Wheels
Pipeline
Wheels
Driveline
Fuel tank
Engine
(b) Tank-to-Wheels
Figure 1.1 Overall energy conversion process in vehicle transportation – the Well-to-Wheels idea
incorporating a gearbox and final drive unit. A typical structure for a front-engined, rear wheel
drive (RWD) car is shown in Figure 1.2, with a notation of how the chapters in this book are
mapped on to the powertrain system. The most common layout for small passenger cars is front-
engined, front wheel drive (FWD) but the principles associated with powertrain analysis are
Vehicle performance
Driving force
Resistive forces
Clutch Gearbox Driveshaft Differential
Transmission Chapter 4
Figure 1.2 Overview of vehicle powertrain system and related book chapters
The world’s total population of cars and light trucks is estimated in 2009 at around 900
million, with a production of new cars and light trucks of about 61 million in the same year. The
vast majority of these – more than 99% - employ conventional powertrains as described above.
Hence, despite the enormous interest from 2000 onwards in alternative powertrains, described
under the general heading of Low Carbon Vehicles (LCVs), it is clear that the principles of
analysing and understanding conventional powertrain systems as described in this textbook will
Daimler, Benz, Peugeot and Panhard & Levassor in the 1890s and 1900s – people have quoted
performance Figures as a means of comparing vehicles. In the first instance, these were usually
top speed and range; then came other performance measures as more powerful engines were
based on very simple models using Newton’s Second Law. For example, in Kerr Thomas’ 1932
book (6), a chapter on the ‘Mechanics of a Moving Vehicle’ shows how to calculate speeds and
accelerations based on knowledge of the engine torque and speed characteristics, gearbox ratios
According to a review paper in 1936 by the pioneering automobile engineer, Olley (7), the
typical American car of that period weighed around 2 tons (2000 kg) and had an engine power of
around 100 horsepower (75 kW), resulting in a typical acceleration of about 10 ft/s2 (~3 m/s2), a
gradeability of about 11% and a top speed around 85 m.p.h. (38 m/s ~ 140 km/h). The accuracy
of these performance predictions gradually improved from the 1930s onwards as measurement
techniques for engine performance (8), tyre rolling resistance characteristics (9) and aerodynamic
drag effects (10) improved. An example to illustrate approximately where all the energy is used
in vehicle longitudinal performance is shown in Figure 4 for typical urban and highway
conditions.
100 %
19 %
-3% 13 %
Aerodynamic
- 17 %
100 % Standby
-6%
Fuel tank Driveline
13 % - 62 % 19 % 13 %
Engine
Driving -2%
Energy Accessory
-6%
Braking
-4%
Rolling
(a) Urban driving
100 %
25 %
- 11 % 20 %
Aerodynamic
-4%
100 % Standby
-5%
Fuel tank Driveline
20 % - 69 % 25 % 20 %
Engine
Driving -2%
Energy Accessory
-2%
Braking
-7%
Rolling (b) Highway driving
Figure 1.4 Example of typical energy flows during urban (a) and highway (b) driving
In the 1970s, there was a massive shift in interest in vehicle performance to focus on fuel
economy calculations. In the USA, this was prompted by the Corporate Average Fuel Economy
(CAFE) regulations first enacted by Congress in 1975; these were federal regulations intended to
improve the average fuel economy of cars and light trucks sold in the U.S. in the wake of the
1973 oil crisis. Basically, it was a sales-weighted average fuel economy of a manufacturer's
range of passenger cars or light trucks, manufactured for sale in the United States. This signalled
the start of a huge amount of interest around the world in both fuel economy and the linked topic
of emissions – and governments became very active in legislating for the measurement and
Over recent decades, the highly competitive commercial environment for selling cars has
meant that consumers require data and performance figures to compare different manufacturers’
abilities etc – are straightforward to measure and fairly non-controversial. In contrast, however,
comparative data on fuel economy, and hence emissions – has proved extremely controversial.
The established method of quantifying a vehicle’s fuel economy is to subject the vehicle,
mounted on an instrumented dynamometer, to a standard drive cycle. The drive cycle simply
consists of a set of data points which specify a speed vs distance travelled profile. Different drive
cycles have been developed to simulate different types of vehicle operation – for example, extra-
emerged in different countries and different regions of the world. Thus, global comparisons of
the fuel economy of vehicles are fraught with difficulties! Broadly speaking, the current range of
standard drive cycles has emerged from the world’s big 3 automotive markets – Europe, USA
and Asia – and the differences to some extent reflect different driving patterns in those regions.
An excellent overview of the comparative driving cycles is reported in (11). The situation is
further complicated by the fact that different countries or regions have developed different
targets for fuel economy and emissions – which of course, makes life difficult for global
Because of these regional differences, drive cycle testing has been a source of
considerable controversy in the industry. But it has also proved extremely controversial from the
consumer’s point of view, because in real world driving it has proved virtually impossible to
achieve the ideal figures obtained under the standard test conditions. To the engineering
community, this is an expected outcome – the tests and measurements are carried out in
laboratory conditions over a repeatable drive cycle which can only be ‘typical’ of millions of real
driving conditions. The key advantage is, of course, that vehicles are at least compared under fair
and repeatable conditions. Nevertheless, consumer organizations and popular car publications
continue to argue that the quoted figures – which now usually have to be displayed in the vehicle
In the European Union, the fuel economy of passenger vehicles are commonly tested
using two drive cycles, referred to as 'urban' and 'extra-urban'. The urban test cycle (ECE-15)
was introduced in 1999 and simulates a 4 km journey at an average speed of 18.7 km/h and
maximum speed of 50 km/h. The extra-urban cycle (EUDC) simulates a mixture of urban and
highway running; it lasts 400 seconds with an average speed of 62.6 km/h and a top speed of
120 km/h. In the USA, the testing procedures are administered by the Environmental Protection
Agency (EPA) and were updated in 2008 to include 5 separate tests – which are then weighted
together to give an EPA City and Highway figure that must be quoted in car sales information. It
is claimed – with some justification – that these figures are a better reflection of real world fuel
Just to add to the confusion, fuel economy continues to be quoted in different units
around the world. For example, both the US and the UK use miles per gallon (mpg) – although
even these are not comparable since the US gallon is 0.83 of an imperial gallon! In Europe and
Asia, fuel consumption is quoted in units of l/100km. Note that both lower (l) and upper case (L)
can be used for litres. This is effectively an inverse of the mpg approach and a large mpg is
comparable to a small l/100km – so for example 30 mpg = 9.4 l/100km and 50 mpg = 5.6
l/100km.
However, most vehicle analysts agree that overall, the drive cycles are all less aggressive
than typical real world driving; in practice, this means that they include lower values of
acceleration and deceleration than typically used in normal driving situations. With the upsurge
of interest in hybrid powertrains over the first two decades of 2000, there has inevitably been an
powertrains. This has generated an on-going debate about whether the drive cycles tend to favour
HEV powertrains over conventional ICE based powertrains. The underlying principle is that
HEVs offer the biggest scope for improvement under stop-start driving conditions in heavy city
traffic for example; hence, it is argued that since most drive cycles have their bias towards urban
operation and inclusion of idle periods, they can distort the potential benefits available from
‘tailpipe emissions’ for the rather obvious reason that they emerge from the exhaust pipe as
products of the combustion process. The first issue is the pollutant emissions – these include
Carbon Monoxide (CO), unburnt Hydro Carbons (HC) and oxides of nitrogen (NOx). In Europe,
engine emission standards were introduced in the early 1990s to reduce all these pollutants from
vehicles. It led to significant improvements in harmful emissions from passenger cars. Euro 5 is
due to come into effect for passenger cars in 2011 and a further tightening of the regulations,
Euro 6, is planned after that for both commercial vehicles and cars.
The second issue is the Carbon Dioxide (CO2) emission levels of vehicles. These have
assumed increasing attention during the early part of the 21st century due to global concerns
about the environment – and they form part of the Carbon Footprint calculations which have
become embedded in all aspects of life. In the UK from 2001, the vehicle tax was linked to the
CO2 emissions of new vehicle, so that vehicle emitting less than 100g/km were actually free of
road tax. And in 2008, an ambitious piece of legislation was passed which committed European
car manufacturers to cut average CO2 emissions from new cars to 130g/km by 2015.
opportunities for personal transportation provided by the motor car, there were three competing
technologies for the powerplant – steam, electric and petrol. Each of these had their own merits
and disadvantages, and it was not at all clear at the time which was likely to dominate in the
longer term. In fact, a 1900 census in the eastern US states (5) showed that each of these
technologies shared about a third each of the emerging market – however, horse drawn carriages
Steam had a longer history of development and there was no problem installing sufficient
power to give good performance. But fuel economy was poor, the boiler needed firing up prior to
a journey and both water storage and usage were problems. Electric vehicles looked extremely
promising – they were quiet, clean and remarkably easy to operate. Range was the major
problem limited by the available energy storage in the battery – a problem which remains to this
day! Gasoline cars in that period were less well developed and appeared extremely troublesome
– they were difficult to start and when running they were noisy, dirty and pretty unreliable. But
their fundamental advantage – which of course is obvious now – was the energy density of
gasoline which was about 300 times better than a lead-acid battery. This meant it was worthwhile
investing in the engineering refinement of the gasoline-based powertrain – and this approach of
Given these discussions at the time about the best way forward for the automobile
powerplant, it is not surprising that several forward-thinking engineers suggested combining two
powerplants in order to extract the benefits of each – and hence, the notion of a hybrid vehicle
was born around the turn of the 19th century. They were not called ‘hybrid’ at the time, but it is
nevertheless remarkable that, for example, the 1902 Woods gas-electric car (5) had realised the
potential of what we now know as a series-electric hybrid layout. The vehicle was driven by a
motor which doubled as a generator, it could run on battery power alone at low speeds, the
down-sized gasoline engine could be used to charge the battery and it featured regenerative
braking.
Although there are a substantial number of different powertrain architectures for hybrid
vehicles, at the time of writing this book in 2011 there are three of particular interest, all linked
to commercially available vehicle models. These three types are summarised in Figure 1.3 and
are:
Generator
External Engine
recharging source
Battery pack
Electrical power flow
Motor/
Generator
Motor/ Generator
Figure 1.3 Three types of typical hybrid/electric vehicle architectures available in 2011
This book contains a chapter which introduces highly topical subject of hybrid vehicle
subject of hybrid vehicle technology – there are many excellent references already written on this
topic and they are referenced at the end of Chapter 7. Rather, the chapter is intended to show
how the same principles of powertrain systems analysis which is the core of the textbook can be
applied to different technologies. The aim is to show how the systems approach to the analysis of
so-called conventional powertrain components can readily be applied to powertrains built up of
The components in the powertrain are described in detail in each of the following chapters
in the book – and references for further reading of the best books are also provided. Needless to
say, all these components are subject to relentless efforts to improve their performance –
efficiency, emissions control, refinement – as well as their overall cost effectiveness. The most
Engine
Transmission
the converter
Vehicle structure
Reducing vehicle weight by using materials such as aluminium, fiberglass, plastic, high-
strength steel and carbon fiber instead of mild steel and iron
Using lighter materials for moving parts such as pistons, crankshaft, gears and alloy
wheels
Systems operation
Augmenting a downsized engine with an electric drive system and battery (mild hybrid
vehicles)
Improved control of water-based cooling systems so that engines reach their efficient
Although the focus of this textbook is entirely on the vehicle and the engineering of its
powertrain system, it is important to recognise that whenever a vehicle is used on the road, the
complete system actually involves both the vehicle and its driver. The complete system is shown
in Figure 1.5, in which the driver effectively acts as a feedback controller – monitoring the
performance of the vehicle and feeding back this information to compare with his demand
signals to the accelerator, brake, gear selection etc. Thus, from a dynamics point of view, we are
in practice dealing with a control system. In designing the vehicle engineering system, therefore,
Fuel input
Distance travelled
Gear selection (Drive cycle)
Target Accelerator Acceleration
Driver Vehicle
Driving Cycle Brake Speed
Figure 1.5 Overview of the driver-vehicle system governing vehicle longitudinal performance
Responsive
Controllable
Repeatable
Stable
The study of drivers’ assessments of the longitudinal control of the vehicle is called ‘driveability’
and it is emerging as a crucial feature of vehicle refinement to assess the customer acceptance of
new powertrain components. For example, it has been used in the industry from 2000 onwards to
assess the smoothness of gear changes in new transmissions developments such as dual clutch
gearboxes and continuously variable transmissions (CVTs). Indeed, procedures for the
assessment of the highly subjective perception of the driver have been incorporated on
specialized vehicle software packages such as AVL-DRIVE (12). The idea is to generate an
objective measure which is based on subjective judgments made by drivers using a range of
vocabulary such as – jerk, tip-in, tip-out, kick, response delay, oscillations, ripple, backlash etc –
necessary to include a mathematical model of the driver in the complete system shown in Figure
driver model which attempts to follow the specified driving cycle by applying appropriate
signals to the accelerator and brake inputs. The approach used in this case is often a simple PID
(Proportional Integral Derivative) model. This is good for tracking the speed profile, but not
necessarily representative of actual driver behaviour which is likely, for example, to include
The whole ethos of this book is based on a modelling approach to analysing and
understanding powertrain system design. The underlying aim is to explain how components
function and then represent their behaviour through mathematical models based on the physics of
their operation. Then, the components can be combined together as a complete powertrain
system – and the resulting model should provide an important tool to contribute to vehicle
design. Thus, although an analytical approach is used in order to understand the fundamental
behaviour, the results are always aimed at being of practical value to vehicle engineers.
The models used throughout the text are relatively simple – and examples are provided in
which the models are expressed and solved in the MATLAB/SIMULINK environment. Thus, it
should be easy to follow the complete process from the derivation of the governing equations,
Since the book is based on fundamental issues, it is felt important that the reader – whether a
student or a practising engineer can follow this whole procedure and try it out for themselves.
In calculations of vehicle performance over a specified driving cycle, there are two
fundamentally different approaches – which are often not well understood by newcomers to the
subject area. The most common simulation is called a ‘backwards facing’ calculation. This
means that at each point on the speed vs distance profile, the current values of both the vehicle
speed and acceleration are known and using these it is possible to work backwards through the
powertrain to calculate the speeds, accelerations, torques and powers of all the components. This
process is simply repeated for all the points on the driving cycle and the results summed together
at the end. This is the simplest and most commonly used method of predicting vehicle
The other approach is called a ‘forward-facing’ simulation; this requires a driver model in
addition to the vehicle model. The drive cycle is a target trajectory which the driver tries to track
via inputs to the vehicle system. The simulation is performed a then as a conventional time
history simulation, involving integration of the dynamic equations. This approach is required
when developing control systems for the powertrain elements in order to simulate how the
For more detailed analyses of powertrain components and systems, there are several
commercial packages available. These are used extensively of vehicle design offices around the
world, and whilst they undoubtedly offer increased fidelity in their representation of the
engineering systems involved, they are less informative of the underlying mechanics. Examples
ADVISOR – (ADvanced VehIcle SimulatOR) was created by the U.S. Department of Energy's
National Renewable Energy Laboratory's (NREL) Center for Transportation Technologies and
Systems in 1994. It was a flexible modelling tool that rapidly assesses the performance and fuel
economy of conventional, electric, hybrid, and fuel cell vehicles. It was acquired by AVL in
2003 (12).
AVL CRUISE - Vehicle and driveline system analysis for conventional and future vehicle
concepts (12).
AVL-DRIVE – Assessment of driveability (12).
CarSim – Vehicle performance in response to braking, steering and accelerating inputs (13).
IPG CarMaker – Vehicle performance in response to braking, steering and accelerating inputs
(14).
Dymola – A multibody systems dynamics packages with automotive as well as other industrial
applications (15).
WAVE – 1D engine and gas dynamics simulation; also includes a drivetrain model to allow full
(17).
The overall aim of this book is to provide a comprehensive and integrated overview of the
particular:-
– Transmissions
– Driveline components
To describe the fundamentals of hybrid electric components and the architecture of their
The books listed as references (1) to (5) all provide excellent background information on
developments. They are all worth reading to set the scene for powertrain systems analysis.
1.7 References
3. Daniels, J. Driving Force: The Evolution of the Car Engine. Haynes Manuals, 2nd ed,
4. Gott, P.G. Changing gears; the development of the automatic transmission. SAE, ISBN 1-
56091-099-2, 1991
5. Fuhs, A.E. Hybrid vehicles and the future of personal transportation. CRC Press, ISBN
978-1-4200-7534-2, 2009
6. Kerr Thomas, H. Automobile Engineering Vol 1, Sir Isaac Pitman & Sons, 1932
7. Olley, M. National influences on American passenger car design. Proc Institution of
8. Plint, M.J. Engine Testing (Third Edition). SAE International, ISBN: 978-0-7680-1850-9,
2007
9. Clark, S.K. (ed) Mechanics of pneumatic tyres. DOT HS 805 952, U.S. Dept of
10. Hucho, W-H. (ed) Aerodynamics of road vehicles. 4th edition, SAE, ISBN 0-7680-0029-7,
1998
11. Samuel, S.; Austin, L.; Morrey, D. Automotive test drive cycles for emission measurement
564, 2002