Technology Trends in emotor Components for Automotive Applications. Mateo Primorac , Miba AG
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1 Technology Trends in emotor Components for Automotive Applications Mateo Primorac , Miba AG
2 Introduction Relevant market shares of electric vehicles about to happen in near future Market share trends of electric vehicles?? increasing the requirements for automotive emotors Space Efficiency Cost Quality NVH Technology Trends in emotor Components for Automotive Applications Focus of today s presentation Part 1 Development Trends of Axial and Transversal Flux Machines Part 2 Technology Trends of Radial Flux Machines (Focus: Stator Assemblies) 2
3 Part 1 Development Trends of Axial and Transversal Flux Machines emotors with Soft Magnetic Composites
4 Introduction Part 1 Development Trends of Axial and Transversal Flux Machines Axial Flux Machines Dedicated for short length requirement ( Pancake Motor) Increased torque due increase of loaded radius and superficial thrust Increased magnetic active surface Axial Flux Machine Radial Flux Machine Dimension Torque M ~ r 3 M ~ r 2 Stator Rotor 4
5 Introduction Part 1 Development Trends of Axial and Transversal Flux Machines Miba Soft Magnetic Composite (SMC) allows to conduct the magnetic field in all three dimensions without losses. This makes it possible to design compact and powerful electric motors with high power and torque density M ~ r 3 Axial Flux Machine (AFM) Transversal Flux Machine (TFM): Claw Pole 3D magnetic flux of SMC Customized solutions for electromagnetic components Auxiliary Drives Traction Drives Miba SMC components 5
6 Cooling Concepts Part 1 Development Trends of Axial and Transversal Flux Machines Double sided Axial Flux Motor high efficiency high performance cost / ratio use of ferrites instead of rare earth magnets emotors with SMC: Axial and Transversal Flux Machines Claw Pole Motor 30% more torque in the same installation space high overload capability Single sided Axial Flux Motor use as auxiliary drive (e.g. electric water pump) in-sensitive to environment temperature easy to assemble / disassemble / recycle 6
7 Part 2 Technology Trends of Radial Flux Machines Focus: Stator Assembly
8 Introduction Part 2 Technology Trends of Radial Flux Machines A representative industrial electric motor as Radial Flux Machine (RFM) not applicable for usage in automotive applications Forced Air Fan Copper Round Wire Distributed Winding Aluminum Die Casting Squirrel Cage (ASM) Cooling Concepts Stator Assembly Rotor Assembly Additionally, mentions for Functional Integration High RPM Concepts 8
9 Stator Assembly Part 2 Technology Trends of Radial Flux Machines Connection Wiring with circuit boards Lamination Improved magnetic materials Source: Kienle Spiess Source: General Motors Space Efficiency Performance Back paint lamination cores Technology Trends: Stator Assembly Winding Flat wire copper winding Quality Efficiency Cost savings Hair-Pin stator Integration Power electronics Insulation optimized materials & process Source: Coppering Inductive heating Process quality Cycle time Space 9
10 Stator Assembly Part 2 Technology Trends of Radial Flux Machines Winding: Flat wire compared to Round wire Higher copper fill factor high efficiency Higher thermal conductivity improved cooling No windings stable process & quality increase Full automation lower cost for high volumes Flat wire types: Continuous Hair-Pin Hair-Pin i-pin Image Avoid process steps Maturity level Low cycle time Process +: twist, weld, insulation +: one side process steps +: easy insertion, speed -: complex preparation -: insertion, tolerance -: double sided process Winding head Low on both sides +: installation space Low on Hair-Pin side: ~: space / cooling Higher on both sides +: cooling surface Magnetic behavior variation, slot opening Flexible winding Flexible widing, Roebel 10
11 Stator Assembly Part 2 Technology Trends of Radial Flux Machines Miba New Technology Pin Windings Hair-Pin i-pin Miba as component supplier Material experience Product know-how Miba as equipment supplier Process development Equipment design Copper Insulation paper Steel core laminations + Full assembled emotor stators Full automated Stator Assembly Lines in 3 rd Generation Holistic approach for stator assemblies 11
12 Rotor Assembly Part 2 Technology Trends of Radial Flux Machines Source: Xperion Components Source: Thyssen Krupp Bearings High RPM possibility Shaft Innovative materials & functions CFK shafts Source: Wieland-Werke InCar Plus Technology Trends: Rotor Assembly High RPM Optimized processes High RPM ASM Mech. strength Cost savings Integration Sensors & transmission Improved magnetic behavior 1. Optimized coupling rotor and stator 3. Foreign-excited synchronous motors Die casted Copper Assemblied Copper Bars 2. New designs for permanent magnets 4. Increase of reluctance moment 12
13 Cooling Concepts Part 2 Technology Trends of Radial Flux Machines Source: General Electric Rotor Spray mist cooling Stator Fluid winding head cooling Source: Karlsruhe Institute of Technology Transmission fluid Efficiency increase Space Technology Trends: Cooling Concepts Stator Direct slot cooling Performance Efficiency Installation space Shaft Hollow shafts & bearing cooling Stator Optimized housing cooling Source: Baumüller Nürnberg Extruded profile Efficiency NVH 13
14 Conclusion
15 Conclusion Axial Flux Machine SMC Technology Axial and Transversal Flux Machines High torque Short length (disc shape) Easy assembly 3D-flux flux collector Cost efficiency (optional ferrites) Radial Flux Machine Stator Assemblies Radial Flux Machines (Stator Assemblies) Change from industry to automotive Various trends, different players Material experience Automated high volume lines Holistic approach 15
16 Miba Parts for electric Vehicles Clutches Synchronizer High strength Ring Gears Lightweight and NVH optimized Gears Adaptocoat silent Gear Coating Power Resistors Questions? Battery Cooling Heat Sinks for Power Electronics Coatings for Fuel Cells Stator assemblies SMC parts Roland Hintringer,
Drive the evolution. with a wide range of Miba parts for emobility
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Stator rheostat, Autotransformer Star to Delta starter and rotor resistance starter.
UNIT-IV 1.What are the types of starters? Stator rheostat, Autotransformer Star to Delta starter and rotor resistance starter. 2. List out the methods of speed control of cage type 3-phase induction motor?
Part- A Objective Questions (10X1=10 Marks)
Dr. Mahalingam College of Engineering and Technology, Pollachi-3 (An Autonomous Institution) CCET 3(2016Regulation) Name of Programme: B.E. (EEE) Course Code&Course Title: 16EET41 & Synchronous & Induction
INDUCTION MOTOR. There is no physical electrical connection to the secondary winding, its current is induced
INDUCTION MOTOR INTRODUCTION An induction motor is an alternating current motor in which the primary winding on one member (usually the stator) is connected to the power source and a secondary winding