電動(dòng)汽車用電機(jī)及其控制系統(tǒng)的應(yīng)用與發(fā)展

電動(dòng)汽車用電機(jī)及其控制系統(tǒng)的應(yīng)用與發(fā)展

ApplicationandDevelopmentTrendofMotorControlSystemsforEVandHEV徐性怡博士上海大郡自動(dòng)化系統(tǒng)工程有限公司Dr.XingyiXuShanghaiDAJUNTechnologies,Inc.內(nèi)容提要Outlines電動(dòng)汽車的發(fā)展趨勢(shì)以及對(duì)電機(jī)系統(tǒng)的要求

EV/HEVtrendandrequirementforelectricdrivesystems電動(dòng)汽車用電機(jī)系統(tǒng)技術(shù)及其發(fā)展趨勢(shì)

Descriptionanddevelopmenttrendinelectricdrivesystems電動(dòng)汽車用電機(jī)系統(tǒng)面臨的挑戰(zhàn)與對(duì)策

Challengesandsolutionsforelectricdrivesystems大郡簡(jiǎn)介

BriefoverviewofDajun中國(guó)電動(dòng)汽車的發(fā)展前景

EV/HEVinChina歷史性機(jī)遇HistoricalOpportunities汽車動(dòng)力電氣化已成為汽車技術(shù)發(fā)展的趨勢(shì)

PowertrainElectrificaitonistrendforfuture“節(jié)能減排”的國(guó)策鼓勵(lì)電動(dòng)汽車及混合動(dòng)力汽車的大發(fā)展

EnergySavingandEmissionReductionisChina’sLongTermNationalPolicy電動(dòng)汽車發(fā)展所面臨的挑戰(zhàn)ChallengesforEV/HEV電動(dòng)汽車技術(shù)仍有待于完善，尤其是關(guān)鍵零部件如電池和電機(jī)制約了電動(dòng)汽車的發(fā)展進(jìn)程；

LimitedbyKeyComponentssuchasbatteriesandmotordrivesystems電動(dòng)汽車市場(chǎng)受到產(chǎn)品可靠性、成本等因素的制約，需要一段成長(zhǎng)周期

ReliabilityandcostofEV/HEVproductsareofconcerntoconsumers消費(fèi)者對(duì)新能源汽車的積極性受油價(jià)的影響

ConsumeracceptanceofEV/HEVisinfluencedbyoilprice市場(chǎng)將在未來(lái)3-5年逐步上量

Therewillbe3-5yearsbeforethemarketreallyrampsup混合動(dòng)力系統(tǒng)實(shí)現(xiàn)方案

ExamplesofHEVSystemsBatteryTrans.ISGIPUMildHEVBatteryTrans.TractionMotorISGIPUSeriesHEV/Plug-inBatteryTrans.TractionMotorISGIPUParallelHEV/Plug-in電動(dòng)汽車應(yīng)用對(duì)電機(jī)系統(tǒng)的要求

EV/HEVRequirementsforElectricMachines

結(jié)構(gòu)緊湊、尺寸小CompactinSize重量輕LightinWeight可靠性高HighReliability效率高HighEfficiency低噪聲、低震動(dòng)Lowaudiblenoise,LowVibration調(diào)速范圍寬WideSpeedRange成本低LowCost汽車電機(jī)與普通工業(yè)電機(jī)之比較項(xiàng)目工業(yè)應(yīng)用汽車應(yīng)用封裝尺寸空間不受限制，可用標(biāo)準(zhǔn)封裝配套各種應(yīng)用布置空間有限，必須根據(jù)具體產(chǎn)品進(jìn)行特殊設(shè)計(jì)工作環(huán)境環(huán)境溫度適中（-20~+40oC);靜止應(yīng)用，震動(dòng)較小溫度變化大（-40~+105oC);震動(dòng)劇烈;可靠性要求較高以保證生產(chǎn)效率很高以保障乘車者安全冷卻方式通常為風(fēng)冷（體積大）通常為水冷（體積小）控制性能多為變頻調(diào)速控制，動(dòng)態(tài)性能較差需要精確的力矩控制，動(dòng)態(tài)性能較好功率密度較低（0.2kW/kg）較高（1–1.5kW/kg）總體性價(jià)比一般極高：既要性能好，又要價(jià)格便宜MotorSensorPowerElectronicConverterDigitalControl汽車電機(jī)系統(tǒng)的構(gòu)成和工作原理

AutoElectricDriveSystemDescription

Battery-VinVinVo常用交流無(wú)刷電機(jī)類型

CommonTypesofACMotorsAxByzCNS感應(yīng)電機(jī)技術(shù)成熟成本較低恒功率調(diào)速范圍寬效率較高體積較大開關(guān)磁阻電機(jī)結(jié)構(gòu)簡(jiǎn)單恒功率調(diào)速范圍寬效率與感應(yīng)電機(jī)類似噪聲大體積比較大永磁電機(jī)體積小效率高恒功率調(diào)速范圍不寬電機(jī)技術(shù)發(fā)展趨勢(shì)：永磁-磁阻同步電機(jī)

PM-ReluctanceSynchronous(PMRS)MotorNS+永磁-磁阻同步電機(jī)的特點(diǎn)：

PMRSMotorFeatures:弱磁容易，調(diào)速范圍寬

Capableoffieldweakening,wideconstantpowerrange效率較高

Highefficiency力矩密度較高

Hightorquedensity結(jié)構(gòu)復(fù)雜，優(yōu)化設(shè)計(jì)較難

Hardtodesign由于飽和非線性，控制復(fù)雜

Controlcomplexity動(dòng)力總成趨勢(shì)：電機(jī)與變速箱的優(yōu)化組合

OptimalCombinationofMotorandGears電機(jī)尺寸取決于峰值力矩（而不是功率?。┮约半姍C(jī)的散熱能力

ThemotorsizeisdeterminedbytheTORQUE(notthepower!)andthemotorcoolingsystemcapability.根據(jù)實(shí)際應(yīng)用需要優(yōu)化配置電機(jī)與變速箱（減速機(jī)）組合

Systemoptimizationcanbeachievedthroughmotor/gearcombination

速比1:1

速比2:1rpmTorque豐田混合合動(dòng)力系系統(tǒng)的改改進(jìn)Size/WeightReductioninToyota’’sHEVsystem通過(guò)采用用減速齒齒輪，在在電機(jī)尺尺寸基本本不變的的情況下下，其功功率增加加了2.5倍PriusRX400/CamryHVPeakTorque：400Nm333NmMaxRPM600012400PeakPower50kW123kW電力電子子控制器器發(fā)展趨趨勢(shì)TrendinPowerElectronicsController新控制器器拓?fù)浣Y(jié)結(jié)構(gòu)Newtopology逆變器+大功率DC/DC高集成度度HighlevelofintegrationISG控制器+牽引電機(jī)機(jī)控制器器+DC/DCIntegrationofISGcontroller,tractionmotorcontrollerandLowvoltageDC/DC電力電子子控制器器與電池池管理模模塊集成成MotorcontrollerintegratedwithBatteryModule熱管理集集成設(shè)計(jì)計(jì)Thermalmanagement新器件NewComponents高集成度度、智能能型汽車車等級(jí)IGBT模塊HighlyintegratedIGBTModulewithautograde薄膜電容容Thinfilmcapacitors豐田混合合動(dòng)力系系統(tǒng)PCU的改進(jìn)Size/WeightReductioninToyota’’sPCUsystem通過(guò)提高高集成度度，改進(jìn)進(jìn)散熱板板設(shè)計(jì)，，豐田大大大減小小了其電電力電子子控制器器（PCU）的體積積與重量量ToyotaachievedsubstantialvolumeandweightreductionthroughhigherlevelofintegrationandthermalmanagementsystemenhancementRX400GS450ImprovedVolume：30Liters11Liters63%Weight35kg20kg43%電動(dòng)汽車車用電機(jī)機(jī)系統(tǒng)所所面臨的的設(shè)計(jì)挑挑戰(zhàn)：DesignChallengesforEV/HEVMotorDriveSystems整車重量量和封裝裝尺寸：：Vehicleweightandpackagingsizeconstraint采用永磁磁-磁阻電機(jī)機(jī)UseofPM-ReluctanceSynchronousmotor可靠性和和耐久壽壽命設(shè)計(jì)計(jì)：Reliabilityanddurabilitydesign汽車應(yīng)用用的惡劣劣環(huán)境：：Harshoperatingconditions高溫及寬寬溫差循循環(huán)HighTemperatureandwiderangetemperaturecycling劇烈的震震動(dòng)SevereVibration需要充分分理解最最差工況況以及電電機(jī)、電電力電子子器件的的能力限限制Fullyunderstandtheworstcaseconditionandlimitationsofmotorandpowerelectronicscomponents電磁兼容容設(shè)計(jì)：：EMCDesign需要從零零部件到到整車各各層次進(jìn)進(jìn)行統(tǒng)籌籌設(shè)計(jì)WorkatVehicle,system,andcomponentleveltolimitEMI設(shè)計(jì)認(rèn)證證：DesignValidation加速壽命命試驗(yàn)Acceleratedlifetesttovalidatethedesign成本挑戰(zhàn)戰(zhàn)ChallengeinCostReduction電機(jī)系統(tǒng)統(tǒng)成本是是電動(dòng)汽汽車/混合動(dòng)力力汽車市市場(chǎng)化的的重要障障礙之一一TheE-drivesystemcostisamojorobstacletothecommercializationofHEV,plug-inHEV,batteryEVandFCEVEV/HEV動(dòng)力系統(tǒng)統(tǒng)成本構(gòu)構(gòu)成；MajorcostcomponentsofanE-drivesystem電池或燃燃料電池池；Batteryorfuelcell電力電子子；Powerelectronics(inverter,controller,andsensor)電機(jī)；Motor減速器/變速箱；；Gearbox需采用系系統(tǒng)方法法削減成成本Systematicapproachisneededtominimizethesystemcost,notindividualcomponentcost.削減成本本的途徑徑ApproachestoReduceCost系統(tǒng)優(yōu)化化設(shè)計(jì)；；SystemOptimization避免過(guò)設(shè)設(shè)計(jì)；Avoidoverdesign提高集成成度；Increaseintegrationlevel(e.g.motorandtransmission,InverterandDC/DC,etc.)制造；Manufacturing借用汽車車制造能能力提高高電機(jī)及及電力電電子系統(tǒng)統(tǒng)的制造造效率Introduceautomotivemanufacturingknow-howintomotorandpowerelectronicsmanufacturingprocesses增加產(chǎn)量量；IncreasethevolumeofEV/HEVMotorDriveSystems整車客戶戶之間分分享共同同的供應(yīng)應(yīng)商資源源Sharesupplierbaseamongautocompanies與工業(yè)應(yīng)應(yīng)該分享享零部件件資源Sharecomponentswithotherindustryandapplications政府在市市場(chǎng)起步步時(shí)提供供資助GovernmentincentivestoincreasethemarketpenetrationofEV/HEV上海大郡郡公司簡(jiǎn)簡(jiǎn)介AboutShanghaiDajun地處上海海漕河涇涇國(guó)家級(jí)級(jí)經(jīng)濟(jì)技技術(shù)開發(fā)發(fā)區(qū)浦江江園區(qū)LocatedinShanghaiCaohejingDevelopmentZone以混合動(dòng)動(dòng)力/電動(dòng)汽車車用電機(jī)機(jī)系統(tǒng)為為主業(yè)BusinessFocus:ElectricDrivesforEV/HEV從2003年起承擔(dān)擔(dān)國(guó)家863重大專項(xiàng)項(xiàng)Participate863EVprojectsince2003新辦公地地照片大郡電動(dòng)汽汽車電機(jī)系系統(tǒng)產(chǎn)品平平臺(tái)Dajun’sEV/HEVMotorDrivePlatform混合動(dòng)力乘用車ISG系統(tǒng)

ISGSystem大功率電機(jī)系統(tǒng)

HighPowerSystemForBuses混合動(dòng)力乘用車雙電機(jī)系統(tǒng)

DualMotorSystem電動(dòng)汽車牽引電機(jī)系統(tǒng)

EVTractionDrive成功參與2008奧運(yùn)會(huì)新能能源汽車示示范運(yùn)營(yíng)配有大郡牽引電機(jī)系統(tǒng)的上海大眾燃料電池轎車配有大郡ISG系統(tǒng)的長(zhǎng)安杰勛牌混合動(dòng)力轎車配有大郡雙電機(jī)系統(tǒng)的一汽強(qiáng)混合動(dòng)力轎車強(qiáng)混合客車車用雙電機(jī)機(jī)系統(tǒng)DualMotorSystemforFullHEVBus2022/12/2520混合動(dòng)力系系統(tǒng)主要功功能MainFeaturesoftheSystem柴油機(jī)與ISG互補(bǔ)疊加的的混合動(dòng)力力發(fā)動(dòng)機(jī)總總成IntegratedDieselandISGsubsystem一體集成的的變速箱與與牽引電機(jī)機(jī)總成Integratedtractionmotorandtransmissionsubsystem包括大功率率DC/DC的電力電子子總成Integratedpowerelectronicunitincludingmotorinverters,highpowerDC/DC,andlowvoltageDC/DC電動(dòng)汽車/混合動(dòng)力汽汽車正在成成為汽車工工業(yè)未來(lái)的的主流動(dòng)力力系統(tǒng)技術(shù)術(shù)EV/HEVisbecomingamainstreampowertraintechnologyforaut