WO2018210510A1

WO2018210510A1 - Assembly for a vehicle, and method for dimensioning the assembly

Info

Publication number: WO2018210510A1
Application number: PCT/EP2018/059746
Authority: WO
Inventors: Wolfgang Bäck
Original assignee: Magna powertrain gmbh & co kg
Priority date: 2017-05-15
Filing date: 2018-04-17
Publication date: 2018-11-22
Also published as: DE102017208140A1

Abstract

The invention relates to an assembly for a motor vehicle comprising an electric machine (EM) in the low-voltage range and a converter (INV), the electric machine (EM) being operated at a rotational speed of between 30.000 and 60000 rotations/min and the assembly (BG) is dimensioned to the space according to at least one design rule.

Description

Assembly for a vehicle and method for designing the assembly

The invention relates to an assembly for a motor vehicle consisting of an electric machine (EM) in the low-voltage range and a converter (INV), wherein the electric machine (EM) is operated at a speed between 30,000 and 60,000 revolutions / min and the assembly (BG) dimensioned in the space according to at least one design rules. The invention further relates to a method for designing the assembly.

PRIOR ART In the production of drives, in particular for vehicles, the aim is to provide an integrated, space-and weight-optimized drive group with corresponding interfaces to the vehicle (CAN, LIN, etc.). Thus, with little integration effort on the user side, a fully integrated electric drive would be available, for example for the following applications: hybrid vehicles with ERAD (electric rear axie drive), battery-electric vehicles with front or rear wheel drive (BEV) and modular system for simple hybridization of conventional ICE (internal combustion engine ) Vehicles.

In a hybrid electric vehicle, an electric motor and most often an Ottooder diesel engine are the two energy converters; an accumulator and a fuel tank or gas tank are the two energy stores.

The individual motors can work together in different ways: When the drive is parallel, both the combustion engine and the electric motor drive the drive wheels. In this case, a power addition of the drive units takes place. The power flow takes place in parallel from internal combustion engine and / or Electric motor. With the serial drive, the combustion engine drives a generator. The electric motor in turn uses this electrical energy of the generator to drive the vehicle. The power pressure takes place in series: internal combustion engine, generator, engine.

A power-split drive combines the serial and the parallel concept. Here, the drive can either only by the electric motor (serial energy conversion by internal combustion engine and generator) or by the electric motor with a parallel internal combustion engine.

Another option for hybrid technology is the use of a range extender. It is a small combustion engine with generator. When the battery is discharged, it supplies the power for the electric drive.

For the design of the drive system, the challenge is to accommodate electrical machines with high performance in small installation spaces.

When installing an electrical machine, the automobile manufacturer has strong space limitations, since currently the body components are still used for a variety of drive.

At the same time, the electrical power of the engine should be high. The power of an electric machine can be increased in various ways. The electrical machine can be extended or increased in diameter of the stator. Another alternative is to increase the speed of an electrical machine of certain size.

In addition to the electrical machine, the inverter or inverter is a large component that must be installed for the electrical drive assembly. Inverters are designed to convert a direct current into a multiphase alternating current. This makes it possible, for example, to supply high-efficiency AC drives with DC batteries. Of course, the converter can also be a converter with frequency conversion, a rectifier for converting AC voltage into DC voltage or a DC-DC converter (DCDC). Converter). A converter is also understood to mean a combination of two or more of the individual judges mentioned above.

In DE 10 2013 208 976 A1, the space problem is solved by an integration of the inverter functions in the electric motor.

In EP 2 910 55 A1, the electric motor and the inverter are constructed wall-to-wall with respect to one another and installed to form an overall block.

It is therefore an object of the invention to propose an electrical assembly for the drive train in a vehicle that meets an optimized design of sizes and outputs for a predefined space.

The task is solved with a module with an electrical machine and a converter. Such a solution can be used for the sole electrical operation in a vehicle.

In particular, the object is achieved with an assembly for a motor vehicle consisting of an electric machine (EM) in the low-voltage range and a converter (INV), wherein the electric machine (EM) at a speed between 30,000 and 30,000 and 30,000 revolutions per minute is operated the assembly (BG) in the installation space is dimensioned according to at least one of the following rules:

• The diameter of the electric machine D_EM should be up to 1.6 times the height HJNV of the inverter,

· The diameter of the electric machine D_EM should be designed to 1,6 times the width of the inverter BJNV

• The length of the electrical machine, based on the total length of the housing with the housing part for receiving the first gear stage L_EM should be greater or approximately equal to the length of the inverter LJNV, • The length of the active parts L_EMact of the electrical machine including the winding heads of the stator should be up to 0.36 times the length of the inverter LJNV,

• The enveloping volume V_EM_env of the electrical machine, calculated with outside diameter ^A 2 ^* pi / 4 ^* outside length, taking into account the housing part for receiving the first gear stage, should be up to twice the enveloping volume V_INV_env of the inverter,

• The enveloping volume V_EM_env, with outer diameter

A2 ^* pi / 4 ^* external length, the active parts of the electric machine enclosing the windings of the stator should be up to 0.47 times the enveloping volume of the inverter V_INV_env.

The rules for the design of the components of the module allow optimum utilization of the installation space while maintaining high power density. It is an advantage if the ratios of the quantities mentioned in the rules are exact. Thus, the ratios are changed e.g. the diameter of the electric machine D_EM is exactly 1.6 times the width of the inverter BJNV. These conditions include an optimum of space utilization and performance.

Advantageously, only one rule is used, wherein the diameter of the electric machine D_EM should be designed to be 1.6 times the height HJNV of the converter.

This is an optimal utilization of the height H of the space through the

Total of D EM and H INV achieved. Advantageously, only one rule is used, wherein the diameter of the electric machine D_EM should be designed to be 1.6 times the width of the converter BJNV.

Thus, an optimal utilization of the width B of the installation space is achieved by the sum of D_EM and BJNV.

Advantageously, only one rule is used, wherein the length of the electric machine, based on the total length of the housing with the housing part for receiving the first gear stage L_EM is greater or approximately equal to the length of the inverter LJNV. So that optimal utilization of the depth T of the installation space is achieved by L_EM and LJNV.

Advantageously, only one rule is used, wherein the length of the active parts L_EMact of the electric machine including the winding heads of the stator should be up to 0.36 times the length of the converter LJNV. This achieves an optimal ratio for the active components of the electrical machine to the installation depth, into which the converter with its length LJNV is fitted.

Advantageously, only one rule is used, wherein the enveloping volume V_EM_env of the electrical machine, which is calculated with external diameter ^A 2 ^* pi / 4 ^* outside length, taking into account the housing part for receiving the first gear stage up to twice the enveloping volume VJNV_env the inverter should be.

The volume rule ensures that much more volume is made available in the installation space for the electrical machine than for the inverter. Advantageously, only one rule is used, wherein the enveloping volume V_EM_env, which is calculated with outside diameter ^A 2 ^* pi / 4 ^* outside length, of the active parts of the electrical machine, which encloses the winding heads of the stator, should be up to 0,47 times the enveloping volume of the converter V_INV_env.

The volume rule ensures that the active part of the electric machine is optimized.

The inventive method is suitable for the design of an assembly for a motor vehicle consisting of an electric machine (EM) in the low voltage range and a converter (INV), wherein the electric machine (EM) is operated at a speed between 30,000 and 60,000 revolutions / min and the Assembly (BG) in the installation space is dimensioned according to at least one of the following rules:

• The diameter of the electric machine D_EM is rated up to 1.6 times the height HJNV of the inverter.

· The diameter of the electric machine D_EM is designed to be 1.6 times the width of the BJNV inverter.

• The length of the electrical machine, based on the overall length of the housing with the housing part for receiving the first gear stage L_EM is adapted approximately to the length of the inverter LJNV,

· The length of the L_EMact active parts of the electrical machine, including the stator windings, is designed to be up to 0.36 times the length of the LJNV converter.

• The enveloping volume V_EM_env of the electrical machine, calculated with outside diameter ^A 2 ^* pi / 4 ^* outside length, taking into account the housing part for receiving the first gear stage, is designed to double the enveloping volume V_INV_env of the inverter,

• The enveloping volume V_EM_env, with outer diameter

A2 ^* pi / 4 ^* external length, the active parts of the electric machine what encloses the windings of the stator, is up to 0.47 times the envelope volume of the inverter V_INV_env designed.

Description of the invention

The invention will now be described by way of example with reference to the accompanying drawings.

Fig. 1 shows a schematic representation of the exemplary embodiment Fig. 2 shows an exemplary arrangement of the assembly in the vehicle

Fig. 3 shows the conditions in the assembly.

FIG. 1 shows a section through an axis A. An inverter INV and an electric machine EM form an assembly BG and are arranged along the Fahrzeugkardanwelle, or a side shaft. The distance of the installation space BR from the earth's surface XE / YE is determined by the ground clearance of the vehicle. The installation space BR is available to the assembly BG from the inverter INV and the electrical machine EM. The height H of the installation space is determined approximately by the external dimensions of the electric motor with inverter. The inverter is arranged in this embodiment in the z-direction above the electric machine, but it can also occupy any other position on the electric machine, especially below the electric machine. On the eclectic machine, a transmission component GB is schematically indicated on the left along the axis A.

The simplified schematic representation in Fig. 2 shows a vehicle in rough outlines with two non-steerable or steerable wheels R1 and R3 on a rear axle or a front axle. The vehicle is shown in plan view in FIG Relation to a terrestrial coordinate system with the main axes XE, YE and ZE, wherein the main axes XE and YE a plane parallel to the earth's surface on which the vehicle moves and the third main axis ZE out of the viewing plane, facing the viewer. The vehicle level is aligned parallel to the earth's surface XE / YE.

In the axis A of the vehicle, an inverter INV and an electric motor EM is installed. In the area of the axle, a construction space BR is defined whose dimensions in this example in the vehicle longitudinal axis LA are limited to approximately one third of the vehicle, relative to the overall length of the vehicle.

With conventional 48V electric machines, the typical voltage level below 60V, working in the speed range up to 20,000 rev / min, only a limited power density is possible. In hybrid or pure electrical applications, however, the power requirement with requirements up to 100 kW is higher. Currently, 48V-operated permanent-magnet synchronous machines and asynchronous machines with speeds up to 20,000 rpm with an outer diameter of the active parts of at least 155 mm are installed at outputs of more than 20 kW. However, these machines are much too big for the limited installation space BR.

The space BR for the assembly BG in the vehicle is limited in width B, height H and depth T and extremely small.

In order to meet the requirements, the required power is achieved at a voltage of less than 60 V by raising the engine speed to a value between 30,000 rpm and 60,000 rpm, whereby the diameter of the electric machine is not increased beyond the installation space specification. In order to cope with the electrical machine with the high power density, the converters must be adapted in size and volume. The invention defines an optimal design of the components of the assembly, wherein the group of trees consists of the electric motor EM and the inverter INV, but optionally also has a first gear stage on the electric motor.

In order to achieve an optimal adaptation, the following rules are set up, which determine the dimensioning of each other in a defined space. The electric machine is described as a cylinder, the inverter as a cuboid. The six design rules listed do not have to be applied simultaneously, but can be realized in combinations to produce optimal results. However, at least one of the rules must apply. 1 . Diameter of the electric machine to height of the inverter

The diameter of the electric machine with a speed of 30,000 to 60,000 rpm D_EM should be designed to 1,6 times the height HJNV of the inverter.

2. Diameter of the electric machine to width of the inverter The diameter of the electric machine D_EM should be designed to 1,6 times the width of the inverter BJNV.

3. Length of the electrical machine to length of the inverter

The length of the electrical machine, based on the overall length of the housing with the housing part for receiving the first gear stage L_EM, should correspond approximately to the length of the converter LJNV.

4. Length of the active parts of the electric machine (including end windings) to length of the inverter

The length of the active parts L_EMact of the electrical machine including the winding heads of the stator should be up to only 0.36 times the length of the inverter LJNV. 5. Enveloping volume of the electric machine to enveloping volume of the inverter

The enveloping volume V_EM_env of the electrical machine, which is calculated with outside diameter ^A 2 ^* pi / 4 ^* outside length taking into account the housing pitch for receiving the first gear stage, should be up to twice the enveloping volume V_INV_env of the converter.

6. Enveloping volume of the active parts of the electric machine to enveloping volume of the inverter

The enveloping volume V_EM_env, calculated with outside diameter ^A 2 ^* pi / 4 ^* outside length, of the active parts of the electric machine, which includes the winding heads of the stator, should be up to 0.47 times the enveloping volume of the converter V_INV_env.

In the application of individual rules already advantageous embodiments are achieved. If you apply more than one rule, the design is optimized and the available space is used optimally.

The method of interpretation therefore begins with the application of a rule to then optionally apply one or more other rules to arrive at a solution.

LIST OF REFERENCE NUMBERS

A axis

R wheels

EM electric machine

BR space

BG assembly

LA longitudinal axis

T deep space

H height of installation space

B Wide space

INV inverter / inverter

D_EM diameter of the electric machine

HJNV height of the inverter

BJNV width of the inverter

L_EM length of the active parts of the electric machine

LJNV length of the inverter

L_EMact length of the active parts of the electric machine V_EM_env enveloping Vo ^¬ lumen of the EM

V INV env Enveloping volume of the inverter

Claims

claims

1 . Assembly for a motor vehicle consisting of an electric machine (EM) in the low-voltage range and a converter (INV), characterized in that the electric machine (EM) with a rotational speed between 30,000 and

60000 revolutions / min is operated and the assembly (BG) in the installation space according to at least one of the following rules:

• The diameter of the electric machine D EM should be up to 1.6 times the height HJNV of the inverter,

• The length of the electrical machine, based on the total length of the housing with the housing part for receiving the first gear stage L_EM, should be greater or approximately equal to the length of the LJNV inverter. · The length of the active parts L_EMact of the electrical machine including the winding heads of the stator should be up to 0.36 times the length of the inverter LJNV,

• The enveloping volume V_EM_env of the electrical machine calculated with outside diameter ^A 2 ^* pi / 4 ^* outside length, taking into account the housing part for receiving the first gear stage, should be up to twice the enveloping volume V_INV_env of the inverter,

• The enveloping volume V_EM_env, with outer diameter

A2 ^* pi / 4 ^* external length, the active parts of the electric machine, which encloses the winding heads of the stator, should be up to 0.47 times the enveloping volume of the inverter V INV env.

2. An assembly for a motor vehicle according to claim 1, characterized in that the ratios of the sizes which are mentioned in the rules, exist exactly.

3. assembly for a motor vehicle consisting of an electric machine (EM) in the low voltage range and a converter (INV), characterized in that the electric machine (EM) is operated at a rotational speed between 30,000 and 60,000 revolutions / min and the assembly (BG ) is dimensioned in the installation space according to the following rule:

· The diameter of the electric machine D_EM should be up to 1.6 times the height HJNV of the inverter.

4. assembly for a motor vehicle consisting of an electric machine (EM) in the low-voltage range and a converter (INV), characterized in that the electric machine (EM) is operated at a rotational speed between 30,000 and 60,000 revolutions / min and the assembly (BG ) is dimensioned in the installation space according to the following rule:

The diameter of the electric machine D_EM should be designed to be 1.6 times the width of the converter BJNV.

5. assembly for a motor vehicle consisting of an electric machine (EM) in the low voltage range and a converter (INV), characterized in that the electric machine (EM) is operated at a rotational speed between 30,000 and 60,000 revolutions / min and the assembly (BG ) is dimensioned in the installation space according to the following rule:

The length of the electrical machine, based on the total length of the housing with the housing part for receiving the first gear stage L_EM should be greater or approximately equal to the length of the inverter LJNV.

6. assembly for a motor vehicle consisting of an electric machine (EM) in the low voltage range and a converter (INV), characterized in that the electric machine (EM) is operated at a rotational speed between 30,000 and 60,000 revolutions / min and the assembly (BG ) is dimensioned in the installation space according to the following rule:

The length of the active parts L_EMact of the electrical machine including the winding heads of the stator should be up to 0.36 times the length of the inverter LJNV.

7. assembly for a motor vehicle consisting of an electric machine (EM) in the low voltage range and a converter (INV), characterized in that the electric machine (EM) is operated at a rotational speed between 30,000 and 60,000 revolutions / min and the assembly (BG ) is dimensioned in the space according to the following rule: The envelope volume V_EM_env the electrical machine, which is calculated with outside diameter ^A 2 ^* pi / 4 ^* outside length, taking into account the housing part for receiving the first gear stage is to double the enveloping volume V_INV_env of Inverter amount.

8. assembly for a motor vehicle consisting of an electric machine (EM) in the low voltage range and a converter (INV), characterized in that the electric machine (EM) is operated at a rotational speed between 30,000 and 60,000 revolutions / min and the assembly (BG ) is dimensioned in the installation space according to the following rule:

The enveloping volume V_EM_env, which is calculated with outside diameter ^A 2 ^* pi / 4 ^* outside length, the active parts of the electric machine which encloses the winding heads of the stator should be up to 0.47 times the enveloping volume of the inverter V INV env.

9. A method for designing an assembly for a motor vehicle consisting of an electric machine (EM) in the low voltage range and a converter (INV) wherein the electric machine (EM) is operated at a rotational speed between 30,000 and 60,000 revolutions / min and the assembly (BG ) in the space according to at least one of the following rules:

• The diameter of the electric machine D_EM is designed to be 1.6 times the width of the BJNV inverter.

• The length of the L_EMact active parts of the electrical machine, including the stator windings, is designed to be up to 0.36 times the length of the LJNV converter.

• The enveloping volume V_EM_env of the electrical machine calculated with outside diameter ^A 2 ^* pi / 4 ^* outside length, taking into account the housing part for receiving the first gear stage, is designed up to twice the enveloping volume V_INV_env of the inverter,

• The enveloping volume V_EM_env, with outer diameter

A2 ^* pi / 4 ^* external length, the active parts of the electric machine, which includes the winding heads of the stator, are rated up to 0.47 times the enveloping volume of the inverter V_INV_env.