法雷奥高速电驱桥：成本、重量与封装优化

BriceLecole,Valeo-Powerdivision ctisymposium AUTOMOTIVE·POWERTRAIN·SYSTEMS PoweroftheeAxleisthepowerofitsmotorThe motorspeedandtorquerelativecontributiontothepowerisdeterminedbythereducergearratio Thetorque-speedbalance:down-speedingandhigh-speeding Down-speedingapproach g6=X:1;X>13Details in this session.Visible on Valeo booth H-9 Theeaxlekeymarketdrivers:aneedformulticriteriaoptimization Powerdensity,efficiencyandcostarethekeymarketdrivers(andco2footprintshallnotbeforgotten) Motorandgearboxdesignoptimisationtoachievetheperformancesofa15okWclasseaxle[addressedinstandardwithai83mmouterstatordiametermachine]withai58mmouterstatordiametermachine Simplifiedphysics:howhighspeedingworksatmotorlevel Speedincreaseofthemotorenableshigherpowerdensity..forgivenfluxdensityandcurrent Selectinga3pp(6poles)e-motordesignkeepstheelectricalfrequencyinthestandard rangeStrategyforinverter:Nostructuralevolutionvs8oovSicbaselineisneeded Strategyforreducerdevelopment:extendingthedesigntowardshigherratiowhilekeepinga2-stagelayshaftarchitecture Sleevedrotordesignandmanufacturingprocess Redluction ofbridge thicknessPreloaded sleeve Thecarbonsleeveallowsanoptimizedrotormagnetic design needingless magnets to generatesame magneticfield WrappinginplaceneedsCAPEXbutbringsdesignflexibility(length,diametertolerances) Onesinglesleeved2Ddesignsuitedforoptimalmagneticdesigndowntolowerspeedandmechanicawithstandingupto24krpm(28.8krpm1.2xoverspeed) Systemsimulationresults:compromiseofcriteria Gearboxdesignoverview similarcycle efficiencyvs referenceNormalized WLTP (C-Seg) Gearbox losses Layshaft2-stagesdesignoptimizedgearsdesignoptimizedbearingselectionNVHoptimisedfor3ppmotor Shafts&GearsMass:+9.2% Maskperimeter+1%Masksurface+4.4% Rectangularmasksurface+4.5%Axialthickness-1% Sleevedrotoroverview WeightandCO2footprintgains[motorlevel]:124.8mm/GR16.9 eAxlepeakperformance eAxlesystem(inverter+motor+gearbox)efficiency 40°Ccoolant-60Cactiveparts10kHzfixedswitchingfrequencyExtrapolatedreferencePM15Bfrictionlosseslconservativevsfrictoroptimisationlevers) Conclusion HighergearratioenablinghighermotorspeedseffectivelyallowstoincreaseeAxlepowerdensitythankstoasmallerandlightermotor. The higher ratiogearbox will expand in sizeand weight. Eaxleefficiencyismaintainedathighlevelthankstotechnologyleversonreducer,motorandinverter/software. Designingrotorwithcarbonsleevewrappinghelpstowithstandhighspeedmechanical constraintswithamagneticdesignoptimizedonalargespeed/ratiorangewhiledecreasingtherotormagnetcontent.Nextstepistoevaluatesleeveindustrial costvsmagnetcostreduction. Highspeed/ratioeAxledesigntogetherwithcarbonsleevebringssignificantweight(scope3downstream)andscope3upstreamCO2footprintreduction Q&A Decide now: Switch between the sessions or stay here