Professional Documents
Culture Documents
Dieter Gerling
low costs
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48V Traction Drive for Electric Vehicles
standard system up to now
=
3 M
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48V Traction Drive for Electric Vehicles
stator winding evolution
Quelle:
derkonstrukteur.de
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48V Traction Drive for Electric Vehicles
possible system architecture with low voltage DC circuit
battery
24V 48V electrical machine
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48V Traction Drive for Electric Vehicles
electrical machine: concept
The m-phase stator winding supplied with multiphase inverter
Conv. distributed winding
0.5
0.8
MMF [ p.u. ]
MMF [ p.u. ]
0
0.6
-0.5
0.4
-1
0.2
-1.5
0 1 2 3 4 5 6 0
theta [rad. degree] 0 5 10 15 20
Space Harmonics
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48V Traction Drive for Electric Vehicles
electrical machine: cooling
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48V Traction Drive for Electric Vehicles
electrical machine: benchmark with Tesla Model S
375 V
Comparison of results
* Aluminum material for the ISCAD-ASM and Copper material for the Tesla-ASM
** Total Joule losses for the stator cage winding including skin and proximity effect
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48V Traction Drive for Electric Vehicles
electrical machine: temperature distribution for T=600Nm, n=5300 rpm
conventional stator frame cooling with hc = 2000W/(Km)
Tesla ASM ISCAD ASM
stator slot
700
600
T [ C ]
500
400
ISCAD-asm
300
tesla-asm
200
100
0
0 40 80 120 160 200 240
time [s]
600
rotor slot
500 ISCAD-asm
tesla-asm
T [ C ]
PLosses ,Tesla 400
Losses: 2
PLosses , ISCAD 300
200
*
Loss pLosses
density: *
,Tesla
4 100
p Losses , ISCAD 0
0 40 80 120 160 200 240
time [s]
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48V Traction Drive for Electric Vehicles
power electronics: concept
requirements from the ISCAD motor with 60 slots:
DC supply: 24V
AC phase voltage (rms): 8.5V
AC phase current (rms): 620A
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48V Traction Drive for Electric Vehicles
power electronics: exemplary power switches
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48V Traction Drive for Electric Vehicles
power electronics: losses at partial load
advantages of MOSFETs in relevant driving cycles
lower forward voltage at partial load (,() 1 instead )
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48V Traction Drive for Electric Vehicles
power electronics: gate drivers
assumptions
3 MOSFETs IRFS7430-7PPbF in parallel for every switch
total gate charge 3 = 1380 nC
switching frequency = 20 kHz
gate voltage = 10 V
required channel power 0,3 W
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48V Traction Drive for Electric Vehicles
first functional prototype
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48V Traction Drive for Electric Vehicles
power electronics: concept
Aluminum plate
MOSFETs
Driver board
Capacitor pack
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48V Traction Drive for Electric Vehicles
power electronics: cooling concept
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48V Traction Drive for Electric Vehicles
battery and DC electrical system: concept
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48V Traction Drive for Electric Vehicles
losses and voltage drop of DC-bus
ca. 2W
ca. 0.04V
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48V Traction Drive for Electric Vehicles
battery and DC electrical system: benchmark with Tesla Model S (battery set-up)
design constraint:
ISCAD: using the same voltage span per cell of 2.9V to 4.2V and
realizing a DC-link voltage of 24V gives 8 cells in series: s 24V 2.9V 8
the same battery capacity leads to 888 cells in parallel p 7104 s 888
the battery losses are independent from the configuration
(the current per cell is identical)
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48V Traction Drive for Electric Vehicles
EMC: magnetic field
field produced by pure DC currents for sandwich structure (well below limit 500mT)
field exposure due to passing automobile (200km/h, 20cm distance well below limits)
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48V Traction Drive for Electric Vehicles
EMC: magnetic field
field due to AC currents on the DC bus: is to be investigated;
main differences to HV-system:
no coaxial cable in HV-system
higher switching frequency
higher number of phases
different leakage capacitances
different voltage transients (MOSFET)
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48V Traction Drive for Electric Vehicles
changing the number of pole pairs during operation (schematic)
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48V Traction Drive for Electric Vehicles
efficiency (for optimized design higher potential likely)
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48V Traction Drive for Electric Vehicles
cost estimation (for optimized design higher potential likely)
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48V Traction Drive for Electric Vehicles
additional advantages
12V-supply can be realized simply and very cost-efficiently (low voltage DC/DC-converter)
(improved efficiency, lower costs)
drop out of single battery cells does not result in large power reduction
drop out of single half-bridges (power electronics) does not result in large power reduction
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48V Traction Drive for Electric Vehicles
conclusion
low costs
large driving range (i.e. high efficiency, especially at partial load)
high power (example Tesla Model S: 600Nm @ 5300min-1, i.e. 330kW)
low voltage (UDC 60V, UAC,rms 25V)
modularity / principle of building blocks
high reliability, high availability
ease of integration of electrical machine and power electronics
good resources efficiency, good recyclability
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