电动汽车用电机及其控制系统的应用与发展.pptx

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1、Dajun Confidential,Please do not distribute without written permit电动汽车用电机及其控制系统的应用与发展Application and Development Trend of Motor Control Systems for EV and HEV徐性怡博士上海大郡自动化系统工程有限公司Dr.Xingyi XuShanghai DAJUN Technologies,Inc.Dajun Confidential,Please do not distribute without written permit内容提要 Outline

2、s 电动汽车的发展趋势以及对电机系统的要求EV/HEV trend and requirement for electric drive systems 电动汽车用电机系统技术及其发展趋势Description and development trend in electric drive systems 电动汽车用电机系统面临的挑战与对策Challenges and solutions for electric drive systems 大郡简介Brief overview of DajunDajun Confidential,Please do not distribute withou

3、t written permit中国电动汽车的发展前景EV/HEV in China 历史性机遇 Historical Opportunities 汽车动力电气化已成为汽车技术发展的趋势Powertrain Electrificaiton is trend for future“节能减排”的国策鼓励电动汽车及混合动力汽车的大发展Energy Saving and Emission Reduction is Chinas Long Term National Policy 电动汽车发展所面临的挑战 Challenges for EV/HEV 电动汽车技术仍有待于完善，尤其是关键零部件如电池和电机

4、制约了电动汽车的发展进程；Limited by Key Components such as batteries and motor drive systems 电动汽车市场受到产品可靠性、成本等因素的制约，需要一段成长周期Reliability and cost of EV/HEV products are of concern to consumers 消费者对新能源汽车的积极性受油价的影响Consumer acceptance of EV/HEV is influenced by oil price 市场将在未来3-5年逐步上量There will be 3-5 years before

5、 the market really ramps up Dajun Confidential,Please do not distribute without written permit混合动力系统实现方案Examples of HEV SystemsBatteryTrans.ISGIPU Mild HEVBatteryTrans.TractionMotorISGIPUSeries HEV/Plug-inBatteryTrans.TractionMotorISGIPUParallel HEV/Plug-inDajun Confidential,Please do not distribute

6、 without written permit电动汽车应用对电机系统的要求 EV/HEV Requirements for Electric Machines 结构紧凑、尺寸小 Compact in Size 重量轻 Light in Weight 可靠性高 High Reliability 效率高 High Efficiency 低噪声、低震动 Low audible noise,Low Vibration 调速范围宽 Wide Speed Range 成本低 Low CostDajun Confidential,Please do not distribute without writte

7、n permit汽车电机与普通工业电机之比较项目工业应用 汽车应用封装尺寸 空间不受限制，可用标准封装配套各种应用布置空间有限，必须根据具体产品进行特殊设计工作环境 环境温度适中（-20+40oC);静止应用，震动较小温度变化大（-40+105oC);震动剧烈;可靠性要求 较高以保证生产效率 很高以保障乘车者安全冷却方式 通常为风冷（体积大）通常为水冷（体积小）控制性能 多为变频调速控制，动态性能较差 需要精确的力矩控制，动态性能较好功率密度 较低（0.2kW/kg）较高（1 1.5kW/kg）总体性价比 一般 极高：既要性能好，又要价格便宜Dajun Confidential,Please

8、do not distribute without written permitMotorSensorPower Electronic ConverterDigital Control汽车电机系统的构成和工作原理Auto Electric Drive System Description Battery-VinVinV oDajun Confidential,Please do not distribute without written permit常用交流无刷电机类型 Common Types of AC MotorsAxByzCNS感应电机 技术成熟 成本较低 恒功率调速范围宽 效率较高

9、 体积较大开关磁阻电机 结构简单 恒功率调速范围宽 效率与感应电机类似 噪声大 体积比较大永磁电机 体积小 效率高 恒功率调速范围不宽Dajun Confidential,Please do not distribute without written permit电机技术发展趋势：永磁-磁阻同步电机 PM-Reluctance Synchronous(PMRS)MotorNS+永磁-磁阻同步电机的特点：PMRS Motor Features:弱磁容易，调速范围宽Capable of field weakening,wide constant power range 效率较高High effi

10、ciency 力矩密度较高High torque density 结构复杂，优化设计较难Hard to design 由于饱和非线性，控制复杂Control complexityDajun Confidential,Please do not distribute without written permit动力总成趋势：电机与变速箱的优化组合 Optimal Combination of Motor and Gears 电机尺寸取决于峰值力矩（而不是功率！）以及电机的散热能力 The motor size is determined by the TORQUE(not the power!)

11、and the motor cooling system capability.根据实际应用需要优化配置电机与变速箱（减速机）组合System optimization can be achieved through motor/gear combination 速比 1:1 速比 2:1rpmTorqueDajun Confidential,Please do not distribute without written permit丰田混合动力系统的改进Size/Weight Reduction in Toyotas HEV system 通过采用减速齿轮，在电机尺寸基本不变的情况下，其功

12、率增加了2.5倍Prius RX400/CamryHVPeak Torque：400Nm 333NmMax RPM 6000 12400Peak Power 50kW 123kWDajun Confidential,Please do not distribute without written permit电力电子控制器发展趋势Trend in Power Electronics Controller 新控制器拓扑结构 New topology 逆变器+大功率DC/DC 高集成度 High level of integration ISG控制器+牵引电机控制器+DC/DCIntegratio

13、n of ISG controller,traction motor controller and Low voltage DC/DC 电力电子控制器与电池管理模块集成Motor controller integrated with Battery Module 热管理集成设计Thermal management 新器件 New Components 高集成度、智能型汽车等级IGBT模块Highly integrated IGBT Module with auto grade 薄膜电容Thin film capacitorsDajun Confidential,Please do not di

14、stribute without written permit丰田混合动力系统PCU的改进Size/Weight Reduction in Toyotas PCU system 通过提高集成度，改进散热板设计，丰田大大减小了其电力电子控制器（PCU）的体积与重量Toyota achieved substantial volume and weight reduction through higher level of integration and thermal management system enhancementRX400 GS450 ImprovedVolume：30 Liters

15、 11 Liters 63%Weight 35kg 20kg 43%Dajun Confidential,Please do not distribute without written permit电动汽车用电机系统所面临的设计挑战：Design Challenges for EV/HEV Motor Drive Systems 整车重量和封装尺寸：Vehicle weight and packaging size constraint 采用永磁-磁阻电机 Use of PM-Reluctance Synchronous motor 可靠性和耐久寿命设计：Reliability and du

16、rability design 汽车应用的恶劣环境：Harsh operating conditions 高温及宽温差循环 High Temperature and wide range temperature cycling 剧烈的震动 Severe Vibration 需要充分理解最差工况以及电机、电力电子器件的能力限制Fully understand the worst case condition and limitations of motor and power electronics components 电磁兼容设计：EMC Design 需要从零部件到整车各层次进行统筹设计W

17、ork at Vehicle,system,and component level to limit EMI 设计认证：Design Validation 加速寿命试验 Accelerated life test to validate the designDajun Confidential,Please do not distribute without written permit成本挑战Challenge in Cost Reduction 电机系统成本是电动汽车/混合动力汽车市场化的重要障碍之一The E-drive system cost is a mojor obstacle t

18、o the commercialization of HEV,plug-in HEV,battery EV and FCEV EV/HEV 动力系统成本构成；Major cost components of an E-drive system 电池或燃料电池；Battery or fuel cell 电力电子；Power electronics(inverter,controller,and sensor)电机；Motor 减速器/变速箱；Gear box 需采用系统方法削减成本Systematic approach is needed to minimize the system cost,

19、not individual component cost.Dajun Confidential,Please do not distribute without written permit削减成本的途径Approaches to Reduce Cost 系统优化设计；System Optimization 避免过设计；Avoid over design 提高集成度；Increase integration level(e.g.motor and transmission,Inverter and DC/DC,etc.)制造；Manufacturing 借用汽车制造能力提高电机及电力电子系统

20、的制造效率Introduce automotive manufacturing know-how into motor and power electronics manufacturing processes 增加产量；Increase the volume of EV/HEV Motor Drive Systems 整车客户之间分享共同的供应商资源Share supplier base among auto companies 与工业应该分享零部件资源Share components with other industry and applications 政府在市场起步时提供资助 Gov

21、ernment incentives to increase the market penetration of EV/HEVDajun Confidential,Please do not distribute without written permit上海大郡公司简介About Shanghai Dajun 地处上海漕河泾国家级经济技术开发区浦江园区Located in Shanghai Caohejing Development Zone 以混合动力/电动汽车用电机系统为主业Business Focus:Electric Drives for EV/HEV 从2003年起承担国家863

22、重大专项Participate 863 EV project since 2003新办公地照片Dajun Confidential,Please do not distribute without written permit大郡电动汽车电机系统产品平台Dajuns EV/HEV Motor Drive Platform混合动力乘用车ISG 系统ISG System大功率电机系统High Power SystemFor Buses混合动力乘用车双电机系统Dual Motor System电动汽车牵引电机系统EV Traction DriveDajun Confidential,Please d

23、o not distribute without written permit成功参与2008奥运会新能源汽车示范运营配有大郡牵引电机系统的上海大众燃料电池轿车配有大郡 ISG系统的长安杰勋牌混合动力轿车配有大郡双电机系统的一汽强混合动力轿车Dajun Confidential,Please do not distribute without written permit强混合客车用双电机系统Dual Motor System for Full HEV Bus2023/5/12 20混合动力系统主要功能Main Features of the System 柴油机与ISG互补叠加的混合动力发动

24、机总成Integrated Diesel and ISG subsystem 一体集成的变速箱与牵引电机总成Integrated traction motor and transmission subsystem 包括大功率DC/DC的电力电子总成Integrated power electronic unit including motor inverters,high power DC/DC,and low voltage DC/DCDajun Confidential,Please do not distribute without written permit 电动汽车/混合动力汽车正

25、在成为汽车工业未来的主流动力系统技术EV/HEV is becoming a mainstream power train technology for auto industry 电力电子和电机驱动系统是EV/HEV的关键零部件技术Power Electronics and Motor Drive systems are key components for EV/HEV 中国电机系统供应商面临着巨大的挑战，尤其是在可靠性、EMC、轻量化以及成本方面EV/HEV applications impose challenge to power electronics and motor driv

26、e systems suppliers,especially in the areas of reliability/durability,EMI/EMC,size/weight reduction,and Cost 系统方法以及主机厂与供应商之间的紧密协作是破解挑战的良策System approach and close collaboration with OEM customers are solutions to overcome challenges 在经过中国电动汽车市场的洗礼后，中国电机系统供应商有机会成为世界电动汽车市场的主要供应商After successful use in domestic EV/HEV products,China-made motor drive systems will enter global market with high quality and very competitive cost结语 Summary