Continental is developing a new 48 V hybrid system with a 30 kW electric motor

Continental is developing a new 48 V hybrid system with a 30 kW electric motor. This innovative powertrain will make its public debut at the Frankfurt Motor Show, held in September. According to the company itself, its cutting-edge transmission system includes a 30 kW water-cooled electric motor placed between the combustion engine and the gearbox.

The system also includes power electronics optimised to handle higher currents than standard units, while also being more efficient.

Several car manufacturers have launched vehicles with 48-volt mild-hybrid systems in recent years, but Continental does not see its solution as a mild-hybrid system, since it can operate exclusively in electric mode at speeds of up to 90 km/h.

Continental also claims that its drive system is considerably cheaper than the high-voltage systems used by most hybrids.

How Continental’s new mild-hybrid system works

Andreas Wolf, Continental’s Executive Business Director for Powertrain, has stated that “thanks to its extensive systems experience, Continental Powertrain is mastering all variants of electric drive, from 48-volt systems to hybrid technologies and high-voltage components. We offer experience and state-of-the-art technology from a single source.”

The manufacturer has not yet disclosed how efficient its hybrid propulsion system is, but says it expects to see a 30% reduction in CO2 emissions compared with cars with combustion engines, and an improvement of 10% over the current 48-volt mild-hybrid systems already on the market.

Furthermore, it has added that with this new architecture, fuel savings increase and, in certain situations, such as zones limited to under 30 km/h, the vehicle could be propelled using only the electric motor. The high power of this 48-volt system achieves the same result as today’s full hybrids, non-plug-in hybrids, and, theoretically, purely electric propulsion is possible up to a speed of 90 km/h.

The company previewed the system in a specially equipped Ford Focus prototype in Germany, but has not yet said which car manufacturers it intends to sell its 48-volt hybrid powertrain to. With the new regulation for certifying fuel consumption and emissions under the WLTP cycle, which came into force on 1 September 2018, Continental’s high-power 48-volt technology could be developed further. By integrating a larger battery and an onboard charger, it would be possible to fit a plug-in hybrid unit with 48-volt technology, thanks to its capacity to drive the vehicle in fully electric mode.

The power electronics integrated into the system also use a new technology that allows it to handle significantly higher currents, resulting in an electrical efficiency level that surpasses the previous system by almost 10%. Losses in the electric drive system have been halved during energy recuperation.