Hyundai Product and Technology Fair Solutions for HEV - · PDF fileHyundai Product and...
Transcript of Hyundai Product and Technology Fair Solutions for HEV - · PDF fileHyundai Product and...
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Hyundai Product and Technology FairSolutions for HEV - MotorsHyundai / Kia R&D Center - June 27 th, 2006
Raimund PillathStefan SeifertJohnny YeoSteven SW Lee
Group EA 3 / 4 / 5"Environment –
Alternate Energy / Power"
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2Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Electrical Insulation Systems ( EIS )• Wire Enamels (WE)
• Impregnating Resins (IR)
• Core Sheet Varnishes (CSV)
Where are we locatedOur headquarters for business responsibility and R & D are located in Germany and in Austria
EIS belongs to BU: DuPontDuPont Performance Performance CoatingsCoatings
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3Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - MotorsDuPont - Five Growth Platforms
DuPont Safety &
Protection
DuPont Electronic &
Communication Technologies
DuPont Coatings & Color
Technologies
DuPont Performance
Materials
DuPont Agriculture &
Nutrition
Market Leadership
Large Opportunities Strong
Capabilities
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4Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Wuppertal
Nanjing
Brazil
Canada
Mexico
Austria
DPC Production CenterLicencees
Tollmanufacturer
NagoyaShanghai
Locations Electrical Insulation Systems ( EIS )
DuPont’s Electrical Insulation Systems are available everywhere in the world.We can supply globally and offer local service.
Headquarters and R & D Centers
Service and application labs in China (Shanghai), Mexicoand Japan (Nagoya) (DKK Automotive Center)
Jiangyin
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5Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Paint and Exterior
DuPont AutomotiveThis is how you know us …today
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6Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Materials for Chassis and Structural
DuPont AutomotiveThis is how you know us …today
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7Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Materials for Under Hood Components
Electrical Insulation Systems for Electrical Motors• Wire Enamels• Impregnating Resins• Core Sheet Varnishes
DuPont AutomotiveThis is how our customers know us …today
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8Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Battery - Ni-Me-H system- Li-Ion system- Ultra-Capacitors
Inverter / Converter- DC-AC Inverter- DC-DC Converter
Electric Motor- Engine Starter - Drive to Wheel- Charge to Battery
Generator
ECU - Electronic Control Unit
for each system
Hybrid Electric Vehicle: Unique Systems
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9Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Battery• Ionic liquids, electrolyte, binder• Membranes• Housing: Engineering Polymers
Inverter / Converter• Engineering Polymers
for housings, electrical transformer, new cooling system
• Electronic Materials
Generator & Electric Motor• Magnet Wires (Wire Enamels)• Impregnating materials• Insulation materials• High temp. eng. Polymers
Electronic Control Unit• Housing: Eng. Polymers• Polymeric film for Insulation• FCM, MCM
Opportunities for Material Solutions from DuPont
Solutions for HEV - Motors
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10Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - MotorsSolutions for HEV - Motors
DuPontDuPont Materials in a MotorMaterials in a Motor
Vespel®
Delrin® (POM) Zytel® (PA)
Crastin® (PBT)
Zenite®
Teonex® (PEN)
Teflon®
Crastin®
Nomex®
Kapton® (CR) Vespel® (PI)
Voltron®
Wire Enamel
Voltatex®
Core Sheet Varnish
Impregnating Resin
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11Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - MotorsSolutions for HEV - Motors
Purpose of Wire Enamels• Primary Insulation of Round or Rectangular
Copper or Aluminum Wires
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12Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
0,4 0,3 *)
> 1000> 900 *)
297
55 *)120
54 *)2 1 *)
0,0
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Lifetime of different Magnet Wires under Inverter DutyLi
fetim
e [h
]
Standard, PEI+ AI Voltron™ Coating 1 Coating 2 Coating 3*) magnet wire with 10% pre- stretching ; coatings 1, 2 and 3 are pigmented insulation films
• VoltronTM E 3597 is a new generation of magnet wireinsulation that solves the problem of premature failures of inverter fed motors
Value for Hyundai Motor Company⇒ VoltronTM magnet wires for HEV - MotorsValue for Hyundai Motor Company⇒ VoltronTM magnet wires for HEV - Motors
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13Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
-1500
-1000
-500
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-0,002 -0,0015 -0,001 -0,0005 0 0,0005 0,001 0,0015 0,002
Time [s]
Volta
ge [V
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Voltage at the motor
Corona inception at +/- 850 V
Voltage vs. Time at the Input of an Inverter Driven Electrical Motor
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14Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Benefits when using VoltronTM magnet wire• outstanding corona resistance
• prevent premature failures caused by partial discharges
• very high V-t Lifetime (more than 1000 hrs @ 2,4 kV)
• superior thermal properties under the influence of ATF – oil
• good flexibility
• high increase of film hardness
• use of nanotechnology ( no classical fillers )
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15Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Purpose of Impregnating Resins• Mechanical Strengthening of the Winding
• Additional Electrical Insulation
• Protection against Chemical and Mechanical Attack
• Improved Heat Transfer
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16Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Graph shows excellent emission behavior compared to conventional styrene-based products
0
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0 20 40 60 80 100 120 140 160 180Curing Time (min)
Emis
sion
s (p
pm -
calc
ulat
ed a
s C
H 4)
UP-Impregnating Resinstyrene-basedE 4011, LP1006 lowemission
Comparison of Emissions 1K-Impregnating Resins: styrene-based / low emission systems
Value for Hyundai Motor Company⇒ low emission 1K-Impregnating Resins
E 4011 UV & LP 1006 UV
Value for Hyundai Motor Company⇒ low emission 1K-Impregnating Resins
E 4011 UV & LP 1006 UV
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17Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Aging Performance: comparison between conventional systems & new developed products shows excellent Bond Strength
M agne t Wire : Impreg. R e s in: Standard: IEC 61033
100 windings/ 0,315mm/twisted 720° Curing conditions date: 17.03.2006
Conditions for impre g.: Twisted Coil 10 min horizontal dipping - 10 min horizontal draining - Curing 4h in horizontal position at 150°C
Twiste d Coil:
Decrease of Bond Strength on Twisted Coils at 155°C after Aging at 260°CS H Therm 210 Grd 1 se e lege nd
4h 150°C
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0 5 10 15 20 25 30 35 40 45 50 55 60 65 70Aging Time (days)
Bon
d St
reng
th (N
)
conventional Styrene-based Impregnating Resin
E 4011
LP 1006
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18Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
What‘s so special about Electrical-UV ?
Value for Hyundai Motor Company⇒ Herberts® Electrical / UV - ProcessValue for Hyundai Motor Company⇒ Herberts® Electrical / UV - Process
State of The Art Impregnating Technology
• most environmental-friendly impregnating-technology
• amount of resin usage and impreg-nating quality can be controlledexactly from average to maximum
• draining losses and evaporationlosses are minimized
• combined with low emission productsand high pre-heat temperaturesemissions from 1-3 % only are possible
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19Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Value for Hyundai Motor Company⇒ Herberts® Electrical / UV - Process
(for Impregnation of Stators)
Value for Hyundai Motor Company⇒ Herberts® Electrical / UV - Process
(for Impregnation of Stators)
0
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Cos
ts (%
)
Plant Energy ProcessingTime
Cleaning ReductionVOC
Typical Dip & Bake Process Electrical / UV Process
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20Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Purpose & Users of Core Sheet Varnishes• Purpose:
electrical insulation of each metal sheet to another for construction of magnetizable cores in electrical machines
• Users:Producers of electrical steel and big-sized generators,worldwide
• VOLTATEX®:DuPont brand name for the family of highly sophisticated core sheet varnishes
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21Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Value for Hyundai Motor Company⇒ VOLTATEX® E 1175W:Value for Hyundai Motor Company⇒ VOLTATEX® E 1175W:
Properties5 excellent 0 not applicable
DuPont has developed the self-bonding varnish VOLTATEX® E 1175W, a waterborne system with excellent insulation and processing characteristics.These advantages make VOLTATEX® E 1175W the ideal insulation system for high performance applications, e.g. advanced HEV- Motors.
012345
Insulation
Punching
Overcoatability
Corrosion
Pressure StabilityBurnoff repair
Annealing
Welding
Bonding
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22Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Benefits when using Core Sheet VarnishVoltatex® E 1175W• Functional self-bonding varnish to hold a stack of electrical steel
sheets together and form a solid core
• Exact stack dimensions and flexibility in design
• homogeneous core stacking and no interlaminar cross-circuit in the stack
• No squeezing effect
• Excellent surface insulation
• High bond strength
• Waterborne system, environment-friendly, innovative varnish systems
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23Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
• VOLTATEX® E 1120:the innovative Titanate based C5 insulation system with high heatresistance as an environmental-friendly alternative to delicate chromiumbased varnishes (complies with the stringent RoHS standards)
• VOLTATEX® E 1175W:self-bonding varnish system based on epoxy resins allowing a very efficient fixing technology for core sheet stacks
• VOLTATEX® E 1151:pigmented and filled core sheet varnishes engineered especially for the advanced generator industry
• VOLTATEX® E 1153:unfilled systems with excellent punching performance and outstanding resistance against mechanical and chemical influences
=> all VOLTATEX® systems are waterborne systems
Product Range VOLTATEX®: The Family of Core Sheet Varnishes
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24Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
From Electrical Steel To Electrical Machinesyellow Requirements of Core Sheet Varnishes
Electrical Steel
Application
Compound Technologies
Punching
Annealing
Electrical Machines
GeneratorMotor Transformer
CorrosionInsulation
Al die castingStacking Welding Bonding
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25Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Impregnating Materials Wire Enamels Core Sheet Varnishes
DuPont Performance Coatings Electrical Insulation Systems