高功率密度电驱动单元，配备30000转电机和高度集成的环形逆变器

David Crecelius AAMDetroit, Michigar TopicsOverview AAMisaLeadingGlobalDrivelineSupplier Global leader in design, engineering and manufacturing of automotive propulsion systemsand technologies to support electric, hybrid and ICE vehicles 2t24 Ssins By Basines Uriht TrendsinElectricPropulsior Benefits of High-Speed Motors POWER =TORQUE x SPEED Highar speec enables lower Icrque fcr the sama pcweLoer torcue enatlas a physically smaller motor Less Bctive ma:grial+ Less Iresses ed se+Less vust Eame power, smaller (motor,less cosl AAM's High-Speed Motor Reduces EDU size.mass,andcost Barriers to High-Speed Motors Motor Barriers-Heavy Rare Earth (HRE) Materials AAM30kRPMHigh-SpeedEDU 224kw Induction Motor wf Copper RotorMax Operating Speed: 30k RPMDual Layshaft 23:1 Gear ReductionSiC Ring Inverter @ 650VdcDielectric Oil Cocling: Motor, Inv. Gear BoxMotor & Inverter Volurrie: 9.07 LitersPower Density: 24.7 kw/L (Motor + Inv)Tesla Model 3 Pcwer Density: 10.02 kiLHeavy Rare Earth (HRE) Mineral Free MotorProject partially funded by Departrmerit of InductionMotorDesignSpecification Utilized Tesla Mcdel 3 as simulation platform Constructed high-speed rmator specs based on vehicle performance (Front & Rear Developed array of EM motor designs and selected optimal High-Speed Motor EM Design Cross-SectionofMotorOnly&FullEDU StatorDesignandEncapsulation Encapsulated Stator Desiqn Encapsularec Stator Hareware Phase Iormines sreapsu'zlcOver ma dac enc turns w th integraced tins tor imgrored ocnve:licn cool ngMddkedl sedirg strfacts an ex bures kax ci luInjecticn over mc iced enca;eulstor High-SpeedRotorDesign&Build Ring InverterAssembly Inverter Design & Components DC Lirk wollage E55Wdcklsx Pnsse Curre"t 35UAr"sPcec [xtire: 3K 1200V, 70.247 (24)Peak Culsul Puwsr: 280kvAIrerter rolume: 1,15 ilere tlnclud na Cap) Dual Layshaft High-Speed Gearbox Comcound Helical1e.) Ovrl reli 23:↑18° glnisear locadon crnels axa kcadon tor shRirg gcar ocntinces lied fru d.al he ical gsarsFeded axiallaad anrctar gear erabs low-ooe high-seed Esering Full EDU buld with high-speed motor, ring inverter, and dual laysnaft gear reduction Motor Only Testing Tested mlor to 33kRPM uncer nc-ced condition erd to 15kRPM lbaded cue to dyno imitalionCcmpleted testing sccorcing to estsblished test planMctor drivgn by Sgnkron SKAl irverler MotorOnlyTestResults Peek Tcrcue: 200.6 NmPeck Power: 223.4 kVPesck Moior Effici*y = 95 35% MotorEfficiencyTestResults Full EDU Dyno Testing DOEEDUPeakTestResults Motor Speed: Q 30k RPMPeak Ax e Torque: 4265 NmPeak Power: 154 kwPeak System Eficiency = 91.4%Mctcr + geer:ox + insrter EDU Axle Torque Outputmw EDUAxleOutputPowerMap ProjectSummary Key Accomplishments > Devebsed high power censily EDU w DOE tunding assisianoe> High eficiency ircuction motor with 3Ck RPM o3erationInjedian twer maiced sialor encepsulalion> Copper sintered t/OSF=T heat sink assamblies on TO-247 packageDual lavshaft geartox wilh rotar shaft Icac canceling- Dyna lesting algnment wth expected mctcr slmi:lationAchieuaale marLfacturirng plan 'or the develaped EDU Next Steps: Further High-Speed Development > Nrw k RPM I'V motcr cesig> Ne 39.G:1 dual layshafi geer-box> Ne 890Ams, 900 ring nverl9*> Prajeced power censity of ~6CkwiL Q&A Decidenow: Switchbetweenthesessionsorstayhere