The secret of hardcore hybrid: Interpretation of Blue Whale iDD electric drive transmission technology

On July 11, Wang Yin, project development manager of Changan Automobile's Blue Whale iDD hybrid system, and David, chief engineer of transmission system at Changan Automobile's UK R&D center, had a live video conference to explain the technical support behind the Blue Whale iDD hybrid system and the four core technologies of the Blue Whale electric drive transmission.

The Blue Whale iDD hybrid system is an advanced multi-mode electric drive system designed entirely independently by Changan Automobile. It consists of four major components: a hybrid-dedicated engine, a Blue Whale electric drive transmission, a large-capacity battery and an intelligent control system. It has more than 400 independent components that jointly guarantee a "full-speed, full-field, full-temperature and full-time" driving experience.

At the live broadcast, David, chief engineer of transmission system at Changan Automobile UK R&D Center, shared his views on the Blue Whale iDD hybrid system via video link. "The Blue Whale iDD has many key attributes. The hydraulic control unit is its heart, the mechanical gear system is its bones, the motor is its muscle, and the control software and electronic control unit are its brain."

David emphasized that the hydraulic control unit is specially designed to meet the requirements of the Blue Whale iDD system. It can operate at both high and low pressures and is powered by an electronically controlled oil pump, enabling the hydraulic system to provide perfectly controlled hydraulic oil, thereby achieving high controllability and high efficiency. Combined with advanced sensing technology, it provides an intelligent dual drive with a perfect heart.

As the "bones" of the Blue Whale iDD, the mechanical gear system is designed to provide a wide range of gear ratio coverage, enabling dynamic driving capabilities and long-range driving. Its 6-speed ratios are perfectly matched to provide performance and excellent shifting capabilities, operating through a three-clutch mechanism to ensure that the driven wheels receive maximum torque in all driving scenarios.

In line with the hydraulic control unit and mechanical gear system, the "muscle" of the Blue Whale iDD, the drive motor, is also committed to meeting challenging performance standards, capable of providing 125Kw of peak power and 330Nm of peak torque. At the same time, through careful design, torque fluctuations are minimized to achieve a smooth and efficient driving experience.

A strong "body" also requires a smart enough brain. The core of the Blue Whale iDD electronic control unit adopts a high-performance multi-core microprocessor, which allows the precise allocation of control tasks through performance and economic cores, enabling the control system to optimize performance according to system requirements and achieve efficient and economical computing power.

During the live broadcast of the Blue Whale iDD Technology Laboratory, Wang Yin, Project Development Manager of Changan Automobile's Blue Whale iDD Hybrid System, focused on introducing the important component of the Blue Whale iDD hybrid system - the Blue Whale electric drive transmission, and its four core technologies: three-clutch integration technology, high-efficiency high-pressure hydraulic system, intelligent electronic dual pump technology, and S-winding winding technology.

Among them, the three-clutch integration technology integrates K0 with K1 and K2. The axial length of the entire three-clutch system is only 172mm, which can effectively solve the problem of product platform application, reduce the overall weight of the system, and ensure the efficient driving of the whole vehicle product.

In order to further improve the system efficiency of the Blue Whale iDD electric drive transmission, Changan Automobile also adopted the high-efficiency high-pressure hydraulic system and intelligent electronic dual pump technology for the first time in China.

In the efficient high-pressure hydraulic system, the hydraulic system plays the role of shifting, cooling, lubrication and other functions in the electric drive transmission. According to the functional requirements, the hydraulic system is divided into two areas: high and low pressure. The high-pressure area mainly controls the shifting action, with a maximum pressure of 60 bar and a larger pressure control range, thus ensuring higher-precision hydraulic control and further improving the shifting response and smoothness of the electric drive transmission. As the power source of the high-pressure hydraulic system, the electronic oil pump is independently controlled by the motor, and the operation of the oil pump can be adjusted in time according to demand, thereby reducing energy consumption losses.

Due to the high integration requirements, Blue Whale iDD uses the S-Winding new winding process that won the international PACE Award in the design of the drive motor. Compared with the current common process, this process does not require welding, the assembly process is simple, and the process is more robust. Under the same performance requirements, the axial length of the S-Winding winding end is shortened by 15%, the structure is more compact, and the power density reaches 10kW/kg, ensuring smooth power output under pure electric operation.

With the support of multiple core technologies, the Blue Whale electric drive transmission has a maximum transmission efficiency of over 97%, a power response of milliseconds, and a motor power density of 10kW/kg.

It is understood that the Blue Whale iDD hybrid system has been installed on models such as UNI-K iDD (configuration UNI-V iDD , and Oushang Z6 iDD (configuration | inquiry) .