Electric Powertrain Development - Venturefest East · Equipmake History 1999 2003 2007 2011 2016...

Commercially confidential - Property of Equipmake Ltd

Electric Powertrain Development


Equipmake Limited

• Based at Hethel Engineering Centre• 15 Engineers

Core Competences• System & Vehicle Simulation• Power Electronic & Control System Design• Functional Safety• Permanent Magnet Motor Design & Development

Customers• GKN• Jaguar Land Rover• AIM• Williams F1• Supported by Innovate funding

Future• Low Volume Production

Equipmake History

1999 2003 2007 2011 2016

2008 2012 2014

SignalSureNetwork Rail

Transmission Control

FlywheelEnergy Storage

Williams HybridPower

Hybrid Bus Development

Acquired by GKN

High PerformanceMotor & Inverter

EV Traction System240kW, 2,900Nm


http://www.equipmake.co.uk/featured_projects/signalsure.html

http://www.jcbdieselmax.com/html/news_detail.php?id=57&table=news

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://infomedia7.com/tag/formula-1-hybrid&ei=cQq9VKvSLOWE7gbv6oDoCA&bvm=bv.83829542,d.ZGU&psig=AFQjCNGRfK3s1r9wmeIDG5gcg8VgLp-gug&ust=1421761530406936

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.williamsf1.com/AdvancedEngineering/Media/News/Williams-Hybrid-Power-Wins-Low-Carbon-Innovation-Award/&ei=xgq9VMSTIMLfaKCHgNgM&bvm=bv.83829542,d.ZGU&psig=AFQjCNGRfK3s1r9wmeIDG5gcg8VgLp-gug&ust=1421761530406936


APM 120R

• Max Power 126kW• Max Torque 120 Nm• Max Motor Speed 12,000 rpm• Max Shaft Speed 2,000 rpm

• Motor Mass 14kg• Gearbox mass 3.5kg• Inverter Mass 5kg


Gas Turbine Motor - EV Range Extender

• Max Power 15kW• Max Torque 1.2 Nm• Max Motor Speed 120,000 rpm

• Motor Mass 3.9kg


APM 200 (Development)

• Max Power 240kW• Max Torque 530 Nm (Motor)• Max Torque 2,900 Nm (Output Shaft)• Max Motor Speed 10,000 rpm• Max Shaft Speed 1,820 rpm• Stator Cooling Oil• Rotor Cooling Water / Glycol or Oil• Integrated Inverter

• Motor Mass 37kg• Gearbox mass 9kg• Inverter Mass 7kg


Traction Motor Requirements

• High Power density• High Torque density for short durations

• Real World – Not only certification

• Wide Speed Range• High Efficiency over wide speed range• High Reliability• LOW COST NEDC Cycle

WLTP Cycle


Traction Motor Topologies

IPM Distributed Winding IPM Concentrated Winding In Wheel Hub Induction


Traction Motor Topologies

• Non Rare earth (particularly Switched Reluctance) looks attractive but• Control is more difficult • Audible noise is an issue

• To reduce active material costs of the motor we need to• Make most effective use of magnet material• Run at as high a speed as possible• Cool the rotor and stator as effectively as possible

• The motor topology needs to allow these requirements to be realised

Source : Electric Vehicle Traction Motors without rare earth magnets : Sustainbale Materials & Technologies 2015


Magnet Price History


Conventional IPM vs Spoke

MagnetsSteel Hub

Magnetic SteelLaminations

Magnetic SteelLaminations

Aluminium Hub

Magnets


Effective Use of Magnet Material

Improved Flux Path

Less Iron Saturation

Conventional IPM Spoke IPM


Effective Use of Magnet Material

Increased Flux Linkage


Analytical Comparison of Conventional IPM and Spoke

Machine: Honda Accord Electric Machine

Internal Permanent Magnet MachinePeak Torque: 135Nm @250ApkRotor Poles: 16Inverter bus voltage: 144V


Original IPM

Modified Spoke:-Unchanged Stator-Unchanged Number of Rotor Poles



Magnets Weight 0.806Kg 0.602Kg -25.2%

Reluctance Torque 19.33Nm 24.59Nm +21.3%

Magnet Torque 120.18 Nm 115.54Nm -3.8%

Max Torque 134.97Nm 136.33Nm ≈


Conclusion – Spoke architecture results in theoretical reduction of 25% magnet requirement for same output torque – but can it be designed to operate at this speed ?


Spoke Motor Architecture

• Aluminium Rotor Hub• Non Magnetic• Cost effective manufacture• High Strength at < 100 ⁰C

• Integral Rotor Cooling• Water Glycol (already available)• Magnet cooling therefore lower cost

NdFeB can be used

• Concentrated Winding• Automated winding• Low cost Stator manufacture

• Segmented Stator

Laminated Segments

Water Channels in aluminium rotor hub

Magnets


APM200

Target Specification

Mass 40 kgPeak Torque 450 NmPeak Power 220 kWContinuous Power 130kWCoolant Water / GlycolCoolant inlet Temperature 60 ⁰CDC Bus Voltage 700VMax Current 540A rms

Peak Power Density 5kW / kg

Magnet Mass 2.7 kg


APM200 – Validation Testing


Spoke Motor - Conclusions

• The Spoke Architecture IPM offers the opportunity for high torque density and reduced magnet cost compared with conventional IPM

• The architecture also offers opportunities for effective rotor cooling – increasing specific performance

• The motor including rotor can be manufacture using existing known mass manufacturing techniques


Ariel Hipercar

• Launched at LCV 2017• Prototype supported by

Innovate UK• Productionisation support

from APC• Uses 4 x APM200• SOP 2020


Electric Bus Drivetrain

• Prototype supported by Innovate UK

• Initial partner Agrale• Uses 2 x APM200• Equipmake developing

powertrain including Nissan battery moduleinstallation

• Trials begin 2019

Electric Powertrain Development - Venturefest East · Equipmake History 1999 2003 2007 2011 2016...

Documents

Transcript of Electric Powertrain Development - Venturefest East · Equipmake History 1999 2003 2007 2011 2016...