??????????????????? Application and Development Trend of Motor Control Systems for EV and HEV

1
???????????????????Application and Development
Trend of Motor Control Systems for EV and HEV
????? ??????????????? Dr. Xingyi Xu Shanghai
DAJUN Technologies, Inc.
2
???? Outlines

• ???????????????????EV/HEV trend and requirement
  for electric drive systems
• ?????????????????Description and development
  trend in electric drive systems
• ?????????????????Challenges and solutions for
  electric drive systems
• ????Brief overview of Dajun

3
???????????EV/HEV in China

• ????? Historical Opportunities
• ???????????????????Powertrain Electrificaiton is
  trend for future
• ????????????????????????Energy Saving and
  Emission Reduction is Chinas Long Term National
  Policy
• ???????????? Challenges for EV/HEV
• ????????????,??????????????????????????Limited
  by Key Components such as batteries and motor
  drive systems
• ??????????????????????,????????Reliability and
  cost of EV/HEV products are of concern to
  consumers
• ???????????????????Consumer acceptance of EV/HEV
  is influenced by oil price
• ??????3-5?????There will be 3-5 years before the
  market really ramps up

4
??????????Examples of HEV Systems
5
?????????????? EV/HEV Requirements for Electric
Machines

• ???????? Compact in Size
• ??? Light in Weight
• ???? High Reliability
• ??? High Efficiency
• ??????? Low audible noise, Low Vibration
• ????? Wide Speed Range
• ??? Low Cost

6
??????????????
?? ???? ????
???? ??????,???????????? ??????,??????????????
???? ??????(-2040oC) ????,???? ?????(-40 105oC) ????
????? ????????? ??????????
???? ?????(???) ?????(???)
???? ????????,?????? ?????????,??????
???? ??(0.2kW/kg) ??(1 1.5kW/kg)
????? ?? ???????,??????
7
??????????????Auto Electric Drive System
Description
Power Electronic Converter
Battery
Motor
Sensor
Digital Control
8
?????????? Common Types of AC Motors

• ??????
• ????
• ????????
• ?????????
• ???
• ?????

• ????
• ???
• ???
• ?????????

• ????
• ????
• ????
• ????????
• ????
• ????

9
??????????-?????? PM-Reluctance Synchronous
(PMRS) Motor

• ??-?????????PMRS Motor Features
• ????,?????Capable of field weakening, wide
  constant power range
• ????High efficiency
• ??????High torque density
• ????,??????Hard to design
• ???????,????Control complexity

10
????????????????? Optimal Combination of Motor
and Gears

• ???????????(?????!)????????? The motor size is
  determined by the TORQUE (not the power!) and the
  motor cooling system capability.
• ??????????????????(???)??System optimization can
  be achieved through motor/gear combination

11
???????????Size/Weight Reduction in Toyotas HEV
system

• ????????,?????????????,??????2.5?

Prius RX400/CamryHV
Peak Torque 400Nm 333Nm
Max RPM 6000 12400
Peak Power 50kW 123kW
12
???????????Trend in Power Electronics Controller

• ???????? New topology
• ??????DC/DC
• ???? High level of integration
• ISG??????????DC/DCIntegration of ISG
  controller, traction motor controller and Low
  voltage DC/DC
• ????????????????Motor controller integrated with
  Battery Module
• ???????Thermal management
• ??? New Components
• ????????????IGBT??Highly integrated IGBT Module
  with auto grade
• ????Thin film capacitors

13
????????PCU???Size/Weight Reduction in Toyotas
PCU system

• ???????,???????,???????????????(PCU)??????Toyota
  achieved substantial volume and weight reduction
  through higher level of integration and thermal
  management system enhancement

RX400 GS450 Improved
Volume 30 Liters 11 Liters 63
Weight 35kg 20kg 43
14
?????????????????Design Challenges for EV/HEV
Motor Drive Systems

• ?????????Vehicle weight and packaging size
  constraint
• ????-???? Use of PM-Reluctance Synchronous motor
• ??????????Reliability and durability design
• ?????????Harsh operating conditions
• ???????? High Temperature and wide range
  temperature cycling
• ????? Severe Vibration
• ??????????????????????????Fully understand the
  worst case condition and limitations of motor and
  power electronics components
• ??????EMC Design
• ??????????????????Work at Vehicle, system, and
  component level to limit EMI
• ???? Design Validation
• ?????? Accelerated life test to validate the
  design

15
????Challenge in Cost Reduction

• ???????????/????????????????The E-drive system
  cost is a mojor obstacle to the commercialization
  of HEV, plug-in HEV, battery EV and FCEV
• EV/HEV ???????? Major cost components of an
  E-drive system
• ??????? Battery or fuel cell
• ????Power electronics (inverter, controller,
  and sensor)
• ?? Motor
• ???/??? Gear box
• ???????????Systematic approach is needed to
  minimize the system cost, not individual
  component cost.

16
???????Approaches to Reduce Cost

• ?????? System Optimization
• ????? Avoid over design
• ????? Increase integration level (e.g. motor and
  transmission, Inverter and DC/DC, etc.)
• ?? Manufacturing
• ????????????????????????Introduce automotive
  manufacturing know-how into motor and power
  electronics manufacturing processes
• ???? Increase the volume of EV/HEV Motor Drive
  Systems
• ????????????????Share supplier base among auto
  companies
• ????????????Share components with other industry
  and applications
• ???????????? Government incentives to increase
  the market penetration of EV/HEV

17
????????About Shanghai Dajun

• ?????????????????????Located in Shanghai
  Caohejing Development Zone
• ?????/????????????Business Focus Electric
  Drives for EV/HEV
• ?2003??????863????Participate 863 EV project
  since 2003

??????
18
??????????????Dajuns EV/HEV Motor Drive Platform
19
????2008????????????
20
???????????Dual Motor System for Full HEV Bus

• ??????????Main Features of the System
• ????ISG??????????????Integrated Diesel and ISG
  subsystem
• ???????????????Integrated traction motor and
  transmission subsystem
• ?????DC/DC???????Integrated power electronic
  unit including motor inverters, high power DC/DC,
  and low voltage DC/DC

2013-12-8
20
21
?? Summary

• ????/?????????????????????????EV/HEV is becoming
  a mainstream power train technology for auto
  industry
• ????????????EV/HEV????????Power Electronics and
  Motor Drive systems are key components for EV/HEV
• ?????????????????,????????EMC??????????EV/HEV
  applications impose challenge to power
  electronics and motor drive systems suppliers,
  especially in the areas of reliability/durability,
  EMI/EMC, size/weight reduction, and Cost
• ????????????????????????????System approach and
  close collaboration with OEM customers are
  solutions to overcome challenges
• ???????????????,????????????????????????????After
  successful use in domestic EV/HEV products,
  China-made motor drive systems will enter global
  market with high quality and very competitive cost