高速车桥：法雷奥在电动汽车中优化成本、重量和封装的系统级方法

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 每日免费获取资料 每日微信群内分享7+最新行业报告： 每周分享当周华尔街日报、经济学人： 行业报告均为公开版，权利归原作者所有，参参一江湖仅分发做内部学习。 关注公众号领取粉丝福利 行业报告丨英语外刊丨行业社群丨参一江湖·聚焦行业前沿 Q&A Decide now: Switch between the sessions or stay here