Hybrid Powertrains for Sustainable Fuels 2035 (in collaboration with FVV)

Plug-in electric vehicles (PHEVs) and extended-range electric vehicles (EREVs) offer significant potential for reducing CO₂ emissions in the passenger car sector. To achieve maximum CO₂ savings over the entire vehicle lifecycle, a high proportion of electric driving is required, supplemented by the use of low-CO₂ fuels for trips powered by the internal combustion engine. The goal of this research project is to maximize the efficiency and performance potential of future spark-ignition (SI) internal combustion engines in PHEV and EREV powertrains using low-CO₂ and CO₂-neutral drop-in fuels. Particular emphasis is placed on the co-optimization of the engine and fuel for different powertrain topologies and test cycles in order to simultaneously ensure high efficiency, performance, compliance with emission standards, durability, and minimal costs.

The project begins with a comprehensive analysis of existing propulsion technologies and fuels. Building on this, 0D/1D simulations are combined with single-cylinder engine test benches and fed back iteratively to gradually optimize the engines through various technological measures. The validated engines are then integrated into a vehicle simulation platform to evaluate realistic vehicle configurations and perform a life cycle assessment (LCA) of selected configurations. The project delivers concepts for a particularly efficient design and operating strategy for hybrid powertrains using fully renewable fuels based on E20, E85, and methanol, with the goal of achieving the corresponding technology readiness level (TRL) by 2030 while also identifying pathways for the use of carbon-neutral fuels (CNF) by 2035. In addition, the project specifically promotes the use of low-CO₂ and CO₂-neutral fuels and includes the development of a Digital Fuel Twin, which enables the systematic collection and management of individual fuel properties and parameters and makes this information available for model-based engine development and adaptive engine calibration.