ESKAM. Electrically Scalable Axial-Module

Transcription

1 The Idea Electrically Scalable Axial-Module

2 The Idea The Concept The Design The Possibilities The Characteristics / Advantages The Project status

3 The Idea Medium-weight delivery vehicle for inner City Vehicle Characteristics: Overall weight 2,000 kg (Unladen weight 1,300 kg + Load 700 kg) Wheel size: 195/65R15 Maximum speed: 120 km/h Maximum climbing performance: 30% Driving characteristics of the target vehicle Design for an actual driving cycle (inner City-, outside of City- and motorway-cycles) guidelines of speed and acceleration: The vehicle should be able to manage a permanent ascending slope of 0.5 % when driving on motorways at speed up to 120 km/h be able to manage a longer ascending slope of 12 % when driving in the inner City at a permanent speed of 50 km/h also be able to manage an up-ramp drive of 30% (approx.)

4 The Concept Front axle / Rear axle

5 The Realisation Motor: Technical data: motor-diameter: active iron: max. rotations: 180 mm incl. cooling jacket 150x150 mm min-1

6 The Realisation Basic concept of the motor 2p = 4 Z 1 = 30 D a = 150 mm l Fe = 150 mm

7 The Realisation Axial reducer gear: Technical Data: Max. Drive speed: 20,000 min-1 Max. Drive torque: 45 Nm Ratio: Single reduction gear, 2-steps

8 The Realisation Model design / manufacturing Cast and mechanical machining

9 The Realisation Electronic mudule: Combined design with piggy-back electronics

10 The Realisation Electronics: Power supply motor 1 Main supply battery Power supply motor 2 Power element motor 1 Control armature, separately excited Power supply electronics Accelerator pedal Feedback from motor Controller module for speed control

11 The Realisation - series-flexible incremental forming processes Processes of cogging technologies Example-Process chain for planetary wheel z18 Hole-pushing - hollow preforming Cutting pipe section - electro-magnetic - adiabatic Cold-roll-forming High-profile cogging - both as loose or fixed wheel Rundrollenwerkzeug Mehrfach- Spannverband Semi-finished part: solid matter Effects: - Raw material up to 25 % (more compact built, increased stability) - cost of component 15 % through shortened process chain Roughness of cutting surface Furthermore: Max. serial flexibility through scalable number of teeth-/ Ø-range Texture-analysis Same process: Planetary wheels + uninterrupted material fibre flow + smaller distances, smaller Ø. + Residual compressive stress + therm. deformation acc. to WBH + Loading capacity of parts

12 The Realisation - series-flexible incremental forming processes Hollow shaft technologies for serial production Example-Process chain for drive shaft Hole-pushing - hollow preform Rotary swaging shaft feeder Axial forming - spline Druckrollen Werkstück Druckstempel Verzahnungsmatrize Spannbacken Werkzeugsegment Keilschieber Semi-finished part: solid matter Effects: - Raw material up to 30 % - Cost of components 25 % through shortened process chain Läuferring Werkstück Furthermore: Max. serial flexibility and scalability, e.g. through modular design Links with increased power transmission capacity Dorn Forming-technical pre-forming production and joining technologies

13 The Realisation - series-flexible incremental forming processes Component development: axle tube for subframe demonstrator vehicle - Development of variants - Integration into vehicle - Design of subframe and axle tube - Simulation, feasibility analysis - Further development of axle tube - Definition primary pipe material, machining - New Data status and tooling - Design suitable for production - Alteration requests Final-data status for subframe production

14 The Realisation - series-flexible incremental forming processes Axle tube for subframe demonstrator vehicle Final geometry status Primary pipe material used: Important worksteps: - Dimension: Ø 63 x 2.25 mm - Bending - Material: QST340+N - Stamping - Inner-high-pressure-forming Result of simulation: The component can be produced Diagram of formimg limits Finished shape of component

15 The Possibilities Possible attachments 10-75

16 The Possibilities Scalability: in this project means: Extension of active iron in the motor Enlargement of motor (diameter) without changing technology Use of adapted wheel sets in reducer gear Enlargement of reducer gear through use of adapted wheel sets Use of adapted electronic components Enlargement of control electronics by using additional electronic components Extension of power electronics (e.g. around HV-DC/DC-controller or HV/12 V-DC/DC-modifier) while maintaining the design-principle Assembly of drive unit possible in front axle, rear axle or both axles

17 The Characteristics / Advantages Relatively small-sized motor with min-1 Water-cooling for electronics Oil-cooling (rotor, stator and gear) for heat dissipation of drive Twin-drive concept, saving differential (torque vectoring) Redundant drive concept, assuring highest mobility Integrated heat exchanger for oil-cooling Plug & Play-concept for completed axle Consistent usage of lightweight components Compact built Integrated solution Scalable Omission of permanent magnets Axial module, can be adapted and customized

18 Project status A Concept complete drive, incl. axes Gro, REFU, Vo, FDH, Aa, ILEA B1 Concept Motor Gro, FDH B2 Concept gear box Vo, IWU B3 Concept Electronic REFU, ILEA C1 Development of validation sample motor Gro, FDH C2 Development of performance transmitting parts of the gear box Vo, IWU C3 circuit topology, control and operating concept REFU, ILEA D Development of scalable axes Aa, SZH, WU E Evaluation of suitable and cost-effective lightweight forming technologies IWU, HiVo F1 Development of components for motor, 1st prototype Gro, FHD F2 Development of components for reducer gear, 1st prototype Vo, IWU F3 Component selection, Circuit diagram REFU, ILEA G Design of axle-variants, Definition of tools, jigs and fixtures Aa, SZH, IWU H Testing and optimising of forming technologies IWU I Development of moulding techniques, draft of housing Funke J Discussion and evaluation of sensible variants, definition of demonstrator vehicle all K1 Manufacturing of demonstrator motor Gro, FHD K2 Manufacturing of demonstrator reducer gear Vo K3 Structure and testing of electronics REFU, ILEA L Manufacturing of a complete demonstrator axle Aa, SZH, IWU M Manufacturing of cost- and weight-optimised components by forming-techniques HiVo, SZH, IWU N Provision of remaining components for finished axle Aa O Final definition and design of drive demonstrator(s) all P Detailed optimisation and fitting of components in demonstrator Aa Q Launch of drive demonstrator all R Dokumentation and presentation of project results all III IV I II III IV I II III IV I II

19 Thank you for your attention Open for questions!?