Our customers profit from our proven expertise in delivering industry-leading powertrain solutions containing Li-Ion batteries, range extenders and vehicle control systems for passenger vehicles, trucks and buses. The scope of our services supports your organization in taking advantage of the opportunities provided by novel propulsion technology and by optimized vehicle thermal management systems.
A key core know-how of OBRIST Powertrain lies in the design and development of application-oriented HV and LV Li-ion battery systems. It has developed its own highly efficient and cost-optimized solution for use in a serial hybrid vehicle. In general, OBRIST relies on cylindrical 18650 cells. The main advantages of this cell technology are the continuously falling costs (high sales market, for example, in construction machinery and entertainment electronics), the interchangeability (due to continuous development over higher capacities and discharging rates) and manufacturer independence. In addition to battery variants with 18650 cells, concepts with pouch and prismatic cells were also developed through internal and customer projects. OBRIST, as a thermal management expert, also develops cooling concepts at the cell, module and battery level and integrates these into the overall vehicle thermal management concept.
- Development of HV und LV Li-ion Battery Systems
- Simple and Cost-optimized Solutions (for serial production)
- Development of Cooling Concepts (cell, module and battery)
- Integration into Vehicle Thermal Management
- Flexible Capacity
- Flexible Voltage Level
- Flexible Procurement
- Flexible Cell Chemistry
A key strength of OBRIST Powertrain is the development of demonstration vehicles such as the HyperHybrid concept vehicle based on a Geely Emgrand EC7. Drivetrain components (such as internal combustion engines, automatic transmissions, and suspension structures) were removed from the original Geely Emgrand EC7 vehicle and replaced by the HyperHybrid system components. System integration was carried out at CAD and various packaging variants were presented and examined. For the Li-ion battery, the installation location in the luggage compartment was selected directly behind the rear seat. A ZV generator and electric drive with converters were placed in the engine compartment for structural reasons.
Corresponding mounting structures were designed with CAD and tested and secured by FEM. After purchasing the components, support structures, auxiliary units and components of the thermal management system, these were installed in the vehicle, electrified and integrated into the bus system. The hybrid controller was then implemented in hardware and software, and the vehicle was commissioned, tested and tuned in the laboratory. The optimum coordination between drivability / performance values and system consumption was then determined by means of test drives.
- Concept and Feasibility Studies
- Prototyping of Components
- Component Measurement and Optimization
- System Measurement and Optimization
- Vehicle Erection and Conversion (electrification, hybridisation)
Construction of Concept Vehicles
- Basic Vehicles of All Kinds (pure petrol, diesel, electric and hybrid vehicles (parallel and serial hybrids))
- Test / Measurement of Selected Drivetrain Components and Auxiliary Units (at OBRIST's own component test stands)
- Mechanical Integration of Drivetrain Components and Auxiliary Units
- Adapt Existing and Interpret New Structures
- Packaging Examinations via CAD
- Strength Analysis with FEM
- Electrical Integration of Drivetrain Components and Auxiliary Units
- Interface Analysis Vehicle Drivetrain Components / Auyiliary Units
- Hardware and Software Integration
- Integration of Online Parameter Recording and Analysis Functions
- Hybrid Control and Operational Strategy Development
- Vehicle Tests (to optomize consumption and performance)
- Planning / Support for Surveying on Roller Test Stand (or in the wind tunnel as well as for NVH measurements (with external support))
Simulation / Testing
During the development of the hybrid system "HyperHybrid" a component test stand was erected. This was used for the initial commissioning of the main system components (ZV Generator HICE, HV battery and drive system) and to ensure the performance and efficiency values for the simulation. It consists of 3 separate cabins for the drive (electric motor), HV battery and CC Generator which can be operated individually or in a system network.
The test stands are indispensable for measuring and optimizing existing and developing new or improved components.
For the simulation, a system simulation tool was developed in Matlab / Simulink. With the aid of this tool, the components (ZV Generator, Li-Ion battery and traction motor) can be combined with the HyperHybrid control strategy with various variants (e.g. front, rear and four-wheel drive), with different control strategies (e.g. C-rate- Speed-based or purely electric), in various vehicles (e.g. Geely Emgrand EC7) and under different load profiles (e.g. driving cycles such as NEDC, WLTP or customer-specific driving profiles).
In principle, any vehicle with HyperHybrid components can be equipped and simulated to make the advantages / strengths of the developed concept visible. In addition, the tool forms the basis for the continuous further development and optimization of the system, the components and the control algorithm regarding fuel consumption and driving performance. The modular structure allows each component to be arbitrarily initialized and new components defined via tables or functions. For example, BEV A-segment vehicles can be equipped and simulated with the appropriate system components via the full-size SUV for long-haul routes, buses and trucks. The hybrid controller module allows the variation of the essential operating parameters, e.g. The charging strategy by the ZV generator, as well as the battery charge and discharge limit states.
After the simulation, numerous evaluation and analysis diagrams for internal system data (SOC curve, driving resistance characteristic etc.), system values (such as fuel consumption, CO2 emission, electrical range etc.) and performance parameters (such as required driving power, regenerative brake energy, battery currents etc.) to disposal. Thus, the operating strategy can be set optimally for each vehicle to achieve the respective simulation goal.
Simulation Testing area
- BEV and Serial Hybrid Vehicles (of all classes: economy, luxury class, sports vehicles)
- Misc. Vehicle Types (small cars, luxury sedans, SUVs, buses, trucks)
- Misc. Drive Modes (FWD, RWD, AWD
- All components Freely Parameterizable (from tire to battery - use of data sheet and measurement data)
- Acceleration Tests (constant driving, downhill runs, standard driving cycles and also real driving with speed and height profile)
- Component Tests (Battery, E-Drive and REX)
- Operation of the Components (in the system network)
- Actual State Analysis
- Determination of Potential for Improvement
- Implementation / Re-testing of Improvements
Presentation of certain HyperHybrid system advantages
- Customer Request via Simulation Requirement Sheet
- Detection of Real Vehicle Characteristics
- Detection of the Components (to be replaced / added)
- Installation and Mass Focal Point Investigation
- Design HyperHybrid Vehicle
- Supply of the Components
- First Simulation Shot
- Adjustment of the Components (according to the simulation goal)
- Subsequent Simulation Loops
- Documentation of the Results
- Presentation Creation
- Presentation and Discussion (with customers)
Extensive Test Possibilities
- HV Battery Tests (battery discharges up to 96kW, 2x3.5kW chargers, water-glycol battery low temperature cooling circuit available)
- REX Tests (fuel system, intake and exhaust air system available, feed possibility up to 100kW, water-glycol high temperature cooling circuit available)
- E-Drive Tests (DC bus, low temperature cooling circuit available)
Powertrain Thermal Management
In addition to the development of components for hybrid drive systems and the consumption optimization of internal combustion engines, OBRIST Powertrain and OBRIST Engineering together have many years of experience in design and efficiency optimization of the thermal management of complete vehicle systems (for example, the development of Fisker Karma series) and the equipment of vehicles with these systems. In the meantime, more than 50 vehicles have been equipped for the most diverse OEMs and suppliers. OBRIST also has a comprehensive network of partners which ensures the development and delivery of the required components. The wide range of know-how and acquired years of experience in automotive thermal management enables OBRIST to develop and implement holistic concepts for air conditioning of the interior, drive train components (electric motor, inverter) and HV battery as well as Range Extender high temperature circuits.
- Years of Experience
- Comprehensive Network of Partners
- Holistic Climate Control Concepts (can be implemented)
Thermo-management: Vehicle and Powertrain
- Cooling (cell, cell module, battery)
- Drive Motor Inverter Cooling (low temperature cooling circuits)
- REX Cooling (high temperature cooling circuit)
- Interior Cooling
CO2 Emission: 33g/km
NEDC - ECE101 Fuel Consumption
NEDC Fuel Consumption Results (Sustain Battery Charge): 4,75l/100km
NEDC ECE101 Battery Range: 58km
Vehicle: Geely Emgrand EC7 - Powertrain: HyperHybrid
>150 Internationally Active Patents
Intellectual Property: OBRIST Group
These patents include vehicle concepts for a new car generation.
More than 20 patents granted regarding the combustion engine and the battery.
Real-Life Test Drive: 2.93L/100km
Plus 6.6 kWh Power
Hamburg - Independent Test: Autobild Nr. 14 - 7.4.2017
Road Course: 150km Highway, City, Country
Consumption Values after 1 Full Round Course
Research and Development
Projects with the FFG: The Austrian Research Promotion Agency
Realization of industrial research and development projects regarding the mobility of the future.