Joint venture produces gen-set for hybrid vehicles

Diesel Progress North American Edition, August, 2005

Hyundai-Enova Innovative Technology Center (HEITC), a joint venture between Hyundai Heavy Industries (HHI) and Enova Systems, has launched a 60 kW diesel generator set for use in hybrid vehicles. The gen-set is the first commercial product developed and produced through the alliance since HE-ITC was formed in 2003.

"The HE-ITC represents a milestone alliance for both companies," said Don C. Kang, HE-ITC president and CEO. "The combination of HHI's development and manufacturing process and Enova's experience and reputation in the hybrid propulsion system markets creates an opportunity to bring advanced products to the market faster and with more versatility."

Enova Systems is a developer and manufacturer of electric, hybrid and fuel cell-powered drive systems while HHI has business divisions in the shipbuilding, offshore and engineering, industrial plant and engineering, engine and machinery, electro electric systems and construction equipment industries.

Together, the companies have developed the 60 kW unit for use in urban delivery and transit bus applications. In these applications the hybrid system can use the battery for transient loads such as acceleration and the generator engine for cruising loads. "This configuration of an onboard smaller engine with an electric motor running at constant speed allows for significant improvements in emissions and fuel economy," Kang said.

The gen-set consists of a 2.5 L, Euro 3 compliant diesel engine rated 140.8 hp. According to Kang, who declined to identify the specific engine use& the system can be paired with any manufacturer's engine, thanks to its universal controller that is mapped to the torque prone of the engine. "By utilizing a universal controller, our system is easily configured to maximize the performance of any engine," he said. "We essentially have CAN communication capabilities with which the system controller dynamically optimizes for the best system operating point. So ours is very adaptable."

The generator's 60 kW output is conducted from the ac induction motor supplied from HHI itself or Chongqing Motor Works in China. The motor uses a variable voltage, variable frequency vector controller which allows the system to be configured to generate alternating current electricity for other applications such as plug-in power tools.

To date, HE-ITC has only built a few prototypes of the gen-set but said it has several orders for the product lined up. The company planned to begin delivery of the product during the first quarter of this year. HE-ITC also plans to introduce a parallel hybrid motor and motor controller for use by automotive OEMs. The products produced under the joint venture are manufactured by HHI in Korea and sold through Enova Systems in Torrance, Calif.

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