electric powertrain development - venturefest east · equipmake history 1999 2003 2007 2011 2016...
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Commercially confidential - Property of Equipmake Ltd
Equipmake Limited
• Based at Hethel Engineering Centre• 15 Engineers
Core Competences• System & Vehicle Simulation• Power Electronic & Control System Design• Functional Safety• Permanent Magnet Motor Design & Development
Customers• GKN• Jaguar Land Rover• AIM• Williams F1• Supported by Innovate funding
Future• Low Volume Production
Equipmake History
1999 2003 2007 2011 2016
2008 2012 2014
SignalSureNetwork Rail
Transmission Control
FlywheelEnergy Storage
Williams HybridPower
Hybrid Bus Development
Acquired by GKN
High PerformanceMotor & Inverter
EV Traction System240kW, 2,900Nm
Commercially confidential - Property of Equipmake Ltd
Commercially confidential - Property of Equipmake Ltd
APM 120R
• Max Power 126kW• Max Torque 120 Nm• Max Motor Speed 12,000 rpm• Max Shaft Speed 2,000 rpm
• Motor Mass 14kg• Gearbox mass 3.5kg• Inverter Mass 5kg
Commercially confidential - Property of Equipmake Ltd
Gas Turbine Motor - EV Range Extender
• Max Power 15kW• Max Torque 1.2 Nm• Max Motor Speed 120,000 rpm
• Motor Mass 3.9kg
Commercially confidential - Property of Equipmake Ltd
APM 200 (Development)
• Max Power 240kW• Max Torque 530 Nm (Motor)• Max Torque 2,900 Nm (Output Shaft)• Max Motor Speed 10,000 rpm• Max Shaft Speed 1,820 rpm• Stator Cooling Oil• Rotor Cooling Water / Glycol or Oil• Integrated Inverter
• Motor Mass 37kg• Gearbox mass 9kg• Inverter Mass 7kg
Commercially confidential - Property of Equipmake Ltd
Traction Motor Requirements
• High Power density• High Torque density for short durations
• Real World – Not only certification
• Wide Speed Range• High Efficiency over wide speed range• High Reliability• LOW COST NEDC Cycle
WLTP Cycle
Commercially confidential - Property of Equipmake Ltd
Traction Motor Topologies
IPM Distributed Winding IPM Concentrated Winding In Wheel Hub Induction
Commercially confidential - Property of Equipmake Ltd
Traction Motor Topologies
• Non Rare earth (particularly Switched Reluctance) looks attractive but• Control is more difficult • Audible noise is an issue
• To reduce active material costs of the motor we need to• Make most effective use of magnet material• Run at as high a speed as possible• Cool the rotor and stator as effectively as possible
• The motor topology needs to allow these requirements to be realised
Source : Electric Vehicle Traction Motors without rare earth magnets : Sustainbale Materials & Technologies 2015
Commercially confidential - Property of Equipmake Ltd
Conventional IPM vs Spoke
MagnetsSteel Hub
Magnetic SteelLaminations
Magnetic SteelLaminations
Aluminium Hub
Magnets
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Effective Use of Magnet Material
Improved Flux Path
Less Iron Saturation
Conventional IPM Spoke IPM
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Effective Use of Magnet Material
Increased Flux Linkage
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Analytical Comparison of Conventional IPM and Spoke
Machine: Honda Accord Electric Machine
Internal Permanent Magnet MachinePeak Torque: 135Nm @250ApkRotor Poles: 16Inverter bus voltage: 144V
Commercially confidential - Property of Equipmake Ltd
Original IPM
Modified Spoke:-Unchanged Stator-Unchanged Number of Rotor Poles
Analytical Comparison of Conventional IPM and Spoke
Commercially confidential - Property of Equipmake Ltd
Magnets Weight 0.806Kg 0.602Kg -25.2%
Reluctance Torque 19.33Nm 24.59Nm +21.3%
Magnet Torque 120.18 Nm 115.54Nm -3.8%
Max Torque 134.97Nm 136.33Nm ≈
Analytical Comparison of Conventional IPM and Spoke
Conclusion – Spoke architecture results in theoretical reduction of 25% magnet requirement for same output torque – but can it be designed to operate at this speed ?
Commercially confidential - Property of Equipmake Ltd
Spoke Motor Architecture
• Aluminium Rotor Hub• Non Magnetic• Cost effective manufacture• High Strength at < 100 ⁰C
• Integral Rotor Cooling• Water Glycol (already available)• Magnet cooling therefore lower cost
NdFeB can be used
• Concentrated Winding• Automated winding• Low cost Stator manufacture
• Segmented Stator
Laminated Segments
Water Channels in aluminium rotor hub
Magnets
Commercially confidential - Property of Equipmake Ltd
APM200
Target Specification
Mass 40 kgPeak Torque 450 NmPeak Power 220 kWContinuous Power 130kWCoolant Water / GlycolCoolant inlet Temperature 60 ⁰CDC Bus Voltage 700VMax Current 540A rms
Peak Power Density 5kW / kg
Magnet Mass 2.7 kg
Commercially confidential - Property of Equipmake Ltd
Spoke Motor - Conclusions
• The Spoke Architecture IPM offers the opportunity for high torque density and reduced magnet cost compared with conventional IPM
• The architecture also offers opportunities for effective rotor cooling – increasing specific performance
• The motor including rotor can be manufacture using existing known mass manufacturing techniques
Commercially confidential - Property of Equipmake Ltd
Ariel Hipercar
• Launched at LCV 2017• Prototype supported by
Innovate UK• Productionisation support
from APC• Uses 4 x APM200• SOP 2020