BU HEV Electrical Traction Drives: HEV E-Drive Development and Products. Gifhorn;
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1 BU HEV Electrical Traction Drives: HEV E-Drive Development and Products Gifhorn;
2 Overview Market Drivers EMobility Business Unit Hybrid Electric Vehicles Base Information E-Drive Development EVehicle Concepts Requirements / Motivation / Architecture Continental Axle Drive with SM Design Concept / Dimensions / Performance / PM and IM Variant 48V Belt driven Alternator Starter System (BSG) System Approach / System Parameter / Design Options Continental BSG (based on Series Product) Design Concept / Dimensions / Performance 2 / Dr. W. Hackmann / / Continental AG
3 Market Drivers EMobility 3 / Dr. W. Hackmann / / Continental AG
4 Clean Power: Key Drivers Legislation New Emissions Legislation exhaust gas emissions PM CO NOx HC Legislation Low CO 2 and Reduced Fuel Consumption (EU) in g/km US Tier2 Bin5 EU5 Sept Phase II Jan National Jan Phase III Jan EU6 Sept Market Limited Fuel Market Increasing Traffic Availability of fossil fuels is limited Peak Oil. Within the transportation sector the consumption of fuel will increase 55% by / Dr. W. Hackmann / / Continental AG
5 CO 2 Objectives: Worldwide Convergence CO 2 emissions equivalent for NEDC test in g CO 2 /km g 210g China 199g USA South Korea 227g USA proposed g 157g 187g 153g 160g 168g Japan European Union 125g 140g 130g California, 169g proposed European Union proposed 140g g Source: Passenger Vehicle Greenhouse Gas and Fuel Economy Standards: A Global Update, ICCT. March 2010 update. 5 / Dr. W. Hackmann / / Continental AG
6 Improvement of Combustion and Hybrid Electric Vehicles CO2 Reduction Rangeextender Full EV PCR2 MPI SDI Start Stop NG Mild Hybrid PDI Full Hybrid Plug-In Hybrid Turbo & Downsizing HCCI/ CAI Exhaust Heat Recovery Variable Compression Ratio Time 6 / Dr. W. Hackmann / / Continental AG
7 Business Unit: Hybrid Electric Vehicles 7 / Dr. W. Hackmann / / Continental AG
8 Organization: Continental Divisions and Business Units Continental Corporation Automotive Group Rubber Group Chassis & Safety Powertrain Interior Passenger and Light Truck Tires Commercial Vehicle Tires ContiTech Electronic Brake Systems Hydraulic Brake Systems Sensorics Passive Safety & ADAS Chassis Components Engine Systems Transmissions Hybrid Electric Vehicle Sensors & Actuators Fuel Supply Body & Security Connectivity Commercial Vehicles & Aftermarket Instrumentation & Displays Interior Modules Multimedia Original Equipment Replacement Europe Replacement The Americas Replacement Asia Two-Wheel Tires Truck Tires Europe Truck Tires The Americas Truck Tires Replacement Business Asia Industrial Tires Air Spring Systems Benecke-Kaliko Conveyor Belt Group Elastomer Coatings Fluid Technology Power Transm. Vibration Control Other Operations 8 / Dr. W. Hackmann / / Continental AG 8
9 : Business Units Engine Systems Transmission Hybrid Electric Vehicle Sensors & Actuators Fuel Supply Engine management systems and fuel components for - Piezo diesel common rail injection systems - Piezo gasoline direct injection - Solenoid gasoline direct injection - Gasoline port fuel injection - Liquefied petroleum gas (LPG) and compressed natural gas (CNG) Engine management systems and aftertreatment controllers for CV applications Turbochargers Control units for - Automatic transmission - Double clutch transmission - Automated manual transmission - Continuously variable transmission Control units for 4x4 and AWD applications - Transfer cases - Differentials - Clutch systems Systems and components for - Hybrid and electric vehicle applications - Power electronics - Electric motor - Battery systems - Energy management Power net systems Actuators for powertrain applications Components and modules for emission management Sensors for powertrain applications - NOx, MAF, transmission sensor modules, position - Pressure, temperature, knock, cylinder pressure - Flexible fuel, oil quality, oil level Door handle sensors Fuel supply units Fuel level sensors Fuel pumps Electronics for fuel pump control Modular function carrier with activated-carbon filter (in-tank ventilation system) 9 / Dr. W. Hackmann / / Continental AG
10 Business Unit Hybrid Electric Vehicles : Sites Head Office Production Location Engineering Location Berlin, Germany Nuremberg, Germany Regensburg, Germany Gifhorn, Germany Karben, Germany Dearborn, USA Seguin, USA Shanghai, PRC Tianjin, PRC Budapest, Hungary Iasi. Romania Yokohama, Japan Bangalore, India 10 / Dr. W. Hackmann / / Continental AG 1 0
11 Definition HEV / BEV Quelle: VW 11 / Dr. W. Hackmann / / Continental AG
12 Business Unit Hybrid Electric Vehicles : Applications Electrical Machines Power Electronics Battery Systems Power Net Systems Electric Vehicle Full Hybrid Mild Hybrid Micro Hybrid 12 / Dr. W. Hackmann / / Continental AG
13 Base Information E-Drive Development 13 / Dr. W. Hackmann / / Continental AG
14 Base Remarks (1) Electrical Machines Energy Conversion Motor Mode (electrical mechanical energy) Generator Mode (recuperation) (mechanical electrical energy) Conversion with Losses (Heating) E-Machine Functions Short term / continuous performance (torque-speed-characteristics) High efficiency (low losses) Sufficient cooling (no overheating) Sufficient insulation (no insulation break down over life time) Limited parasitic effects (NVH, EMC, current ripple,...) High dynamic drive (sensor quality) Life time (bearings, gears, brushes) 14 / Dr. W. Hackmann / / Continental AG
15 Base Remarks (2) Four Quadrant Operation Electrical Machines as Traction Drives Four quadrant operation Speed variable drives forward braking 110Nm 55kW 10800rpm forward driving 180Nm 70kW 10800rpm General Remarks: E-Traction Drives compared to Industrial Drives : high torque (and power) density: low volume / weight advanced cooling (water) / high sophisticated materials high requirements regarding ambient conditions / vibrations / Nm 70kW 4000rpm backward driving high drive dynamic (normally not needed for industrial drives) E-Traction Drives: performances driven / Industrial Drives: cost driven 15 / Dr. W. Hackmann / / Continental AG
16 E-Drive Development Procedure General Procedure: Step 1: E-Drive configuration Belt driven E-Machine, crank shaft mounted EM, axle drive Step 2: Selection of an E-Machine type Induction machine, PM machine, (ext. excited) synchronous machine Step 3: Development of an E-Drive system Cluster of requirements Step 4: Family concept / standard solutions Targets: design capable for industrialization and flexible application; proven and cost optimized products 16 / Dr. W. Hackmann / / Continental AG
17 E-Drive Configurations Belt driven starter generator (P0) High speed application (up to 18000rpm); limited in torque / power Cost effectiveness Crankshaft mounted E-Motor (P1) Limited maximum speed (< 7000rpm); high torque density Sharp restrictions in axial length Axle Drive (P4) High speed application (12000rpm); high performance requirements Axial length with low priority K0 = clutch (separation) K1 = clutch (start-up) Front P0 P1 P2 K0 K1 P3 Rear P4 P0 = Belt driven Starter Generator (BSG) P1 = Crankshaft mounted E- machine (CSG) P2 = E-Machine on the gear input P3 = E-Maschine on the gear output P4 = Axle Drive 17 / Dr. W. Hackmann / / Continental AG
18 E-Machine Types for Traction Applications 3phase electrical machine, converter-fed, controlled (dynamics, torque accuracy) Induction Machine / Asynchronous Machine (IM/ASM) Stator winding: distributed wire (one layer) or hair pin winding (two layer) Rotor: Squirrel cage rotor (Al die cast) Permanent excited Synchronous Machine (PSM) Stator winding: distributed or concentrated (single tooth) winding Rotor: buried permanent magnets (externally excited) Synchronous Machine (SM) Stator winding: distributed or concentrated (single tooth) winding Rotor: wound salient poles with slip ring system 18 / Dr. W. Hackmann / / Continental AG
19 Cluster of Requirements System Design Project Management Requirements 1 (Vehicle) Performance - max. Torque Characteristic - Cold Start Torque - Boost Torque - max. Generator Power - Continuous Operation - Load Cycles Mechanical Motor Design Requirements 2 Overall Volume - Drive Concept - max. Motor Length / Diam. - max. Motor Mass - mechanical Requirements (Vibrations, etc.) - Ambient Temperatures Power Electronics Requirements 3 Power Supply - max. / min. Battery Voltage - max. Converter Current - Cable Resistances - Converter Safety Concept - Insulation Requirements - Motor Noise / Vibrations Motor Simulation Motor Design Performance Curves (Control) Software 19 / Dr. W. Hackmann / / Continental AG
20 EVehicles Concepts 20 / Dr. W. Hackmann / / Continental AG
21 Requirements Electrical Vehicles Quelle: VW 21 / Dr. W. Hackmann / / Continental AG
22 Benefits of EV Motivation for EV Beneficial CO 2 balance possible Locally no emissions Low noise High vehicle dynamics up to 80km/h Change of Mind (energy saving with light and efficient cars) Technology driver for batteries 22 / Dr. W. Hackmann / / Continental AG
23 Renault Vehicles X61 ASM L38 X10 23 / Dr. W. Hackmann / / Continental AG
24 Zoe Architecture 24 / Dr. W. Hackmann / / Continental AG
25 System Overview (Electrical Power train) DC/DC converter DC- Circuit Battery DC/AC inverter Wheel (or load machine) DC- Circuit 3 (U / f) variable 25 / Dr. W. Hackmann / / Continental AG
26 Official Data Sheet for Publication 26 / Dr. W. Hackmann / / Continental AG
27 Continental Axle Drive with SM 27 / Dr. W. Hackmann / / Continental AG
28 Continental Axle Drive Concept Integrated Axle Drive with Synchronous Machine Axially parallel arranged E-Motor Two-step spur gear with fix ratio Rotor shaft = gear input shaft; no clutch Stator Design 3phase wire winding Water jacket cooled Insulation Class H Rotor Design Wound salient poles Moulded (2comp epoxy resin) Rotor position sensor Slip ring system 28 / Dr. W. Hackmann / / Continental AG
29 Continental Axle Drive Series Design Complete industrialization Proven technical solutions SOP Aug 2011 Complete DV / PV tests All system issues solved (EMC, NVH) Number of Poles 2p - 8 Stator Stack Outer Diameter d a,s mm 210 Stack Length l Fe mm 175 Air Gap Width mm 1.0 Total Active Mass (E-Motor) kg 36 Total Drive Mass (incl. Gear) kg 78 Rotor Inertia kg m² / Dr. W. Hackmann / / Continental AG
30 Performance Curves Nominal Parameter: Udc = 300V Cooling: 8l/min; 55 C T / Nm short term: 225Nm ; 70kW short term: 245Nm ; 90kW continuous: 75Nm ; 45kW continuous: 75Nm ; 35kW 300A 350A 300V 400V n / rpm 30 / Dr. W. Hackmann / / Continental AG
31 Back-to-Back Test Bench: Test Bench Set-up impact of heating capability on vehicle operation load cycle efficiency reliability of the whole system E-Machine (load machine) P-Electr. (load machine) Rack with Power Supply Measurement Equipment Torque measurement E-Machine (test machine) P-Electr. (test machine) 31 / Dr. W. Hackmann / / Continental AG
32 48V Belt driven Stator Generator System 32 / Dr. W. Hackmann / / Continental AG
33 Benefits of a 48V-System Mild Hybrid Functions Start/Stop 10,6V-16V Battery 12V up to2.5kw DC DC BAS EM 24V-60V INV Battery 48V MCU Comfort Start Cold Start Boost Sailing Recuperation Decoupling Tensioner combustion engine High Efficient Generator CO 2 Reduction Change of Mind 33 / Dr. W. Hackmann / / Continental AG
34 48V-System Approach Mild Hybrid Functionalities Customer priorities / flexibilities System Definition / System Parameter Components (battery, DC/DC-converter, DC/AC-converter, BSG) Component Harmonization Power supply Power train System Optimization Trade off system requirements cost effectiveness Vehicle simulations: variant comparison Cost reduction measures Battery size, motor type,... Motor family concept 34 / Dr. W. Hackmann / / Continental AG
35 Customer Benefits of 48V Systems (selection) customer comfort feasibility with 12V CO2 emission reduction remarks 1 Start/Stop 1.1 warm start (start/stop) x x 1.2 cold start (first start) x very low temperatures 1.3 noise reduction at start x 2 Regeneration / Recuperation 2.1 high efficient generator (x) x 2.2 recuperation during deceleration (x) x 2.3 engine operating point shift (load incr./decr.) (x) x 3 Boost / Electric Driving 3.1 boosting (beyond ICE limit) x 3.2 electric creeping / drive off x (x) dep. on battery energy content 3.3 electric hill hold support x 4 Board Net / 48V Consumer 4.1 additional board net supply via DC/DC V board net stabilisation (VSS) V components (steering, pumps, HVAC) x higher component efficiency 5 Combustion Engine Support 5.1 different functions x 35 / Dr. W. Hackmann / / Continental AG
36 Continental BSG (based on Series Product) 36 / Dr. W. Hackmann / / Continental AG
37 Continental BSG Concept Belt driven Starter Generator with Induction Machine Belt ratio: 2.5 Pulley wheel diameter applicable Stator Design 3phase hair needle winding (two layer wave winding) Water jacket cooled Insulation Class H Rotor Design Al squirrel cage rotor Speed sensor Max. speed: 18000rpm 37 / Dr. W. Hackmann / / Continental AG
38 Continental BSG (for U DC = V) Series Design Complete industrialization Proven technical solutions SOP Aug 2011 Complete DV / PV tests All system issues solved (EMC, NVH, etc.) Production in Tianjin (China) Number of Poles 2p - 8 Stator Stack Outer Diameter d a,s mm 145 Stack Length l Fe mm 70 Air Gap Width mm 0.3 Total Active Mass (E-Motor) kg 8 Total Drive Mass (incl. Gear) kg 13 Rotor Inertia kg m² / Dr. W. Hackmann / / Continental AG
39 Belt driven Starter Generator: Stator Assembly Hair pin technology Ultrasonic Welding Hairpin Welding Stator Manufacturing Lean Manufacturing Cells In-Parallel Testing (Dyno with Temperature Chamber) 39 / Dr. W. Hackmann / / Continental AG
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