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48V E-Motor and Inverter
Solutions for CO2 Reduction and Traction AssistThomas Hackl, Magna Powertrain
1
What is Driving 48 V?
LegislationEnd Consumers
Global OEMs
Which Functional Trends will Impact 48 V?
Seite 3
• Redundant power source• Enables high computer power• 48 V power actuation -> safety
increase
• No derating of functions• Additional high power functions• Improved Start Stop Comfort
48 V enables much more than only CO2 Reduction
48 V
Increasingnumber of
simultaneousfunctions
Automateddriving
CO2 andexhaust
emission, performance
• 48 V Hybrid• 48 V Turbo charger • 48 V Rear Axle Drive
ChassisComfort
4
48V Motor Generations with high speed concept
Advanced
Gen 1n = 50.000 rpmPpeak = 19kW3,22kW/kg(Benchmark 1,6kW/kg)
Platform development
Gen 2n = 35.000 rpmPpeak = 25kW3,52kW/kg
Scalable platform development
2016 2017 2018 2019 2020
Gen 2 scalablen = 21.000 - 35.000 rpmPpeak = 17 - 25kW
Platform EM D125 EM D153
Stator Outer
Diameter125 mm 153 mm
P4
P3 HPP3 CE
P2.5
P4 co-ax
Stator cooling
Rotor cooling
Advanced development 48V Gen 1 e-Axle
n=50.000 rpmPSM 3 phase Double planet 3-step
gearseti≈60T > 1200 Nm
High speed concept 50.000 rpm with PSM+ High power density / better package / less weight+ Material advantage (magnets, copper, steel)
Challenges of high speed concept-Mechanical stress rotor (LV147)-Sealings-Bearings-NVH gears-Thermal management
PSM concept
Active length 120 mm
Stator OD 97 mm
Rotor OD 54 mm
Air gap 0.5 mm
Poles 4
Stator slots 24
Turns per coil 4
Parallel wires per coil 4
Wire diameter 0.95 mm
PSM concept
Peak torque 22 Nm @ 5.500 rpm
Peak power 19 kW
Max. phase current 500 Arms
Max. operating speed 50000 rpm
Burst speed 70000 rpm (LV147)
Copper weight 0.96 kg
Stator lamination weight 3.33 kg
Rotor lamination weight 1.35 kg
Magnet weight 0.30 kg
Total weight active parts 5.84 kg
6
Advanced development 48V Gen 1 motor details
System Test bench
– Function tests
– Performance, efficiency
and drag torque
– Acoustics
– Short durability 230 h
Transmission
– lubrication and breather test
– Back to back durability
Engineering tests / simulation correlations:
– Efficiency and drag torque
– Cooling / thermal management
– NVH
– Rotor dynamics
– Rotor burst done (>70.000 rpm)
Methods fine-tuned for critical topics
All eMotor tests fullfilled functional requirements
7
Advanced development 48V Gen 1 e-Axle
Efficiency e-Axle upto 90%
Engineering Methodology
Multi-Objective / Multi-Physics Design Optimization
8
• Multi-objective, multi-physics optimization framework
Optimization Objectives:– EMAG design / efficiency / max torque
– Thermal situation / losses
– Mechanics / Rotor strength
– Torque ripple / acoustics
– Dynamic run-up simulation
– Cost model
– Cycle Efficiency
• Highly parallelized direct/genetic/ANN (artificial neuronal network) optimization
• Generate efficiency maps
• Generate motor model for system- and thermal simulation
• Calculate torque ripple as excitation for subsequent NVH simulation
Hybrid genetic and ANN
optimization algorithm
CFD
SPH
Gen 1 Gen 2 platform
9
Typical Benchmark GEN 1 GEN 2
Machine TypePSM PSM
3 phasesPSM
6 phases
Max. SpeedCircumferential speed
18.000 rpm85,8 m/sec
50.000 rpm141 m/sec
35.000 rpm141 m/sec
Peak torque 55Nm 22Nm 45Nm
Peak power (gen) 16 kW 19,1 kW 25 kW
Weight (active Parts) 10 kg 5.9 kg 7,1 kg
Power Density(active parts) [kW peak/kg act]
1.6 kW/kg 3,22 kW/kg 3,52 kW/kg
D=
97
mm
D=1
25
mm
Applicationswith hollowshaft
Applicationsw/o hollowshaft
10
Application specific part
Interface part w/ platform feature
Common parts
Part categories
• Common parts:
– Inverter
– Motor – active parts
– Planetary gear set – 1st stage
– Decoupling unit
Example offset w/o hollow shaft
Example co-axial with hollow shaft
Gen 2 platform approach
Gen 2: Verification
11
Gearbox Durability TestLubrication / Speed Principle Testing Gearbox Lubrication Test
Continuous / Peak Curve Test (75°C cooling water)System Efficiency Test (25°C cooling water)
• Testing performed, high speed bearings and sealings evaluated• Component selection for A-sample build up performed
• Testing in horizontal position and with inclinations performed• Conclusion Rework for satisfactory lubrication / build up of
optimized A- sample units
• Durability run performed successfully• Conclusion ok, gearing strength, load capacity of oil confirmed
• SW parametrization performed• Efficiency map measured with good correlation
• Continuous- and Peak- curve measurement with 48V and 75°Ccooling water temperature performedthermal performance OK
System NVH Testing
• NVH testing performed, results evaluated• Airborne noise compared to specification for electric axle drives
OK• Structure-borne noise vs. spec. slightly outside borderlines
OK
Description
Features/Specifications
ContactInnovation Pillars
eRAD 48 Volt Traction Assist
The 48 Volt torque assist eAxle with a high-speed
eMachine offers significant CO2 reduction potential due to
high recuperation capability and a minimized efficiency
chain.
• Extended Mild Hybrid functions ( Mild Hybrid plus)
due to high power and torque to wheel to touch on
full hybrid functions.
Integrated Decoupling unit for increased torque to wheel
and optimized efficiency.
• Efficiency improvements up to 23% CO2 @ WLTP
• Max. power 25 kW
• Inverter up to 36-52 Vdc, up to 350 Arms
SMARTER CLEANER
BMW 550i with 48V ePower Split
High Performance Transfer Case
• Features/Specifications– BMW 550i
– Engine Type: 4.4 l gasoline
– Engine Power: 340 kW
– Engine Torque: 650 Nm
– Transmission: 8 speed automatic transmission
– Ratio FA: 2.81
– Ratio RA: 3.23
– Magna Powertrain Technology• 48V ePower Split
• High Performance Transfer Case
13
14
Gen 2 Scalability
17kW
17kW
D=1
25
mm
D=1
53
mm
25
kW
25
kW
Gen 2 Scalable:• Package options
• D= 125mm /35.000 rpm• D= 153mm /21.000 rpm
• Co-ax option with hollow shaft• Cooling options EM
• Water• Oil
• Peak power options• 17kW• 25kW
• High speed concept up to 35.000 rpm with PSM
– High power density / better package / less weight
– Material advantage (magnets, copper, steel)
Challenges of high speed concept
– Mechanical stress rotor (LV147)
– Sealings
– Bearings
– NVH gears
– Thermal management
15
Gen 2 Scalability Platform decisions
CFDSPH
• Insertion winding
– Very good flexibility scalability
– Low high frequency losses (skin and proximity effects)
– Synergies with MPT HV platform
Challenges of insertion winding
– Maximum torque
16
Gen 2 Scalability Platform decisions
• 6 phase control
– Low phase current
– Low capacy of DC link due to low current ripple in DC link
– Robust MosFet load (no parallel MosFets)
– Good scalability up to 25kW
Challenges of 6 phase control
– Control algorithm 2x3 phases
17
Gen 2 Scalability Platform decisions
MPT eDS48V Product Overview
18
FWD / AWDTransversal Architecture
RWD / 4WDLongitudinal Architecture
eDS48V 4WD HPEM153
eDS48V P4EM153
eDS48V RWD / AWD CE
EM153 & EM125
Platform EM D125 EM D153
Stator Outer
Diameter125 mm 153 mm
Vehicle Segments:B, C, D
Vehicle Segments:C, D, E
Gen 2 scalable
eDS48V P3 CEEM125
7HDT 48V P2.5EM153
MPT eDS48V System Platform
Approach MPT eDS Platform Approach
MPT platform approachconsiders 2 individual geometrical designs with same scalable power requirements. Based on these designs the complete MPT 48V product portfolio will be supplied.
EM125Application: P3aPeak Power: 17 - 25[kW]Dimension (D x L): 125 mmPower Electronics: bolt onCooling: waterStatus: B-Sample
EM153wApplication: P4Peak Power: 17 - 25[kW]Diameter: 153 mmPower Electronics: bolt onCooling: waterStatus: Design Study
EM153oApplication: P2.5Peak Power: 17 - 25[kW]Diameter: 153 mmPower Electronics: separatedCooling: oilStatus: A-Sample
MPT platform approach considers 2 power electronic concepts (bolt on and separated to system). The core components shall be identical for all applications. Costumer interfaces (plugs & housings) will be adapted according costumer requirements.
48.1Power electronic direct attached to system
48.2Power electronic separated from system
• Platform 25kW E-Motor − Peak torque 75Nm
− Max. rotor speed 21.000 rpm
• Platform Power Electronics
• Scalable Gearbox− Gear ratio 16,8 – 21,1
− Max. axle torque 1.200 Nm – 1.500 Nm
− Max. coupled axle speed 995 rpm – 1.250 rpm
• Decoupling (normally open)− Via dog clutch and 48V solenoid for actuation
• Total weight <35kg (oil filled)− Excl. DC cables
− Excl. vehicle bearing rubber
− Excl. side flange shaft with cv-joint
− Excl. bracket for vehicle integration
20
eDS48V-P4 co-ax Product Features
System incl. Gearbox (19.5kg)Inverter (4.5kg)
Motor (11.0kg)
48V E-Motor and Inverter
Solutions for CO2 Reduction and Traction AssistThomas Hackl, Magna Powertrain
21
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