2018 8th International Electric Drives Production Conference (EDPC)最新文献

{"title":"Ex-Ante Process-FMEA for Hairpin Stator Production by Early Prototypical Production Concepts","authors":"A. Kampker, Patrick Treichel, K. Kreisköther, Maximilian Krebs, M. Büning","doi":"10.1109/EDPC.2018.8658288","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658288","url":null,"abstract":"The worldwide demand for electric vehicles is on the rise and production capacities for electric powertrains need to keep pace with this development. The innovative hairpin stator technology, in which solid copper bars are used instead of flexible round wire for coil production, promises valuable unique selling points on both the product and process side, but also confronts automotive manufacturers and plant manufacturers with major challenges. Due to the cost-intensive and only slightly variant flexible production lines, the optimum product and process concepts must be developed and defined at an early stage. The key for industrialization of hairpin stators is an effective process development and technology selection, especially for the necessary bending and contacting technologies. To systematically break down the technological challenges of process development, a process failure mode and effects analysis (FMEA) is used in this paper with the aim of a scalable, ramp-up-optimized and economical production line. Therefore, the FMEA-method is applied to the partially unknown process technologies of hairpin stators through the investigation of results from early prototypical production concepts especially for the necessary bending and contacting technologies. The analysis lists processes with possibly insufficient process capabilities due to process interdependencies that have been derived using early production prototypes for hairpin stators. In conclusion, this paper presents a method that applies the FMEA-method to early prototypical production concepts of hairpin stators and makes it possible to integrate the results into the final process development and technology selection.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"70 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127356244","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Evaluation of an Integral Injection Molded Housing for High Power Density Synchronous Machines with Concentrated Single-Tooth Winding","authors":"Andreas Langheck, S. Reuter, Oleg Saburow, R. Maertens, Florian Wittemann, L. Berg, M. Doppelbauer","doi":"10.1109/EDPC.2018.8658324","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658324","url":null,"abstract":"The implementation of electric drivetrains into passenger vehicles is one of the promising ways for the automotive industry to reduce CO2fleet emissions. The most important aim for the current developments is to increase range and performance while assuring affordability for the customer. In the field of electric motor development for traction applications, great efforts are necessary in order to improve electrical machines in terms of efficiency, power density and costs. The optimization of each individual field is a subject of research. Typically, there is a conflict of interest in simultaneously optimizing efficiency, power density and costs. This work presents a new approach to optimize the three fields for electric traction motors. The new approach combines an efficient direct cooling concept with the possibility of using lightweight polymer composites for the electric motor housing. The cooling concept increases the efficiency in a wide range of operation while enabling a high maximum continuous power output from the motor. To estimate the potential of the used cooling topology, the winding is optimized for using stator slot cooling. The electric motor is thermally simulated to verify the concept. These findings are used to design the cooling channels. Finally, a molded prototype stator is built and the newly designed concept was validated in a component test setup. The direct cooling with its short thermal path between the area of heat generation to the cooling system, enables the use of thermally insulating thermosetting composite materials for the electric motor housing. In this work the feasibility and potential of manufacturing the stator housing of an electric motor in an injection molding process is investigated. The design freedom of this manufacturing process enables complex and extensive functional integration such as the direct incorporation of the cooling channels in the stator slots, the phase connectors and the coolant supply.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"45 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122787319","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Comparison of Performance and Manufacturing Aspects of an Insert Winding and a Hairpin Winding for an Automotive Machine Application","authors":"C. Du-Bar, Alexander Mann, O. Wallmark, M. Werke","doi":"10.1109/EDPC.2018.8658331","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658331","url":null,"abstract":"In this paper, two stators with different winding concepts but with the same rotor of an interior permanent magnet synchronous machine (IPMSM) type are presented. Both concepts are investigated based on their performance and their respectively stator cost and stator manufacturing aspects for a yearly production rate of 1 million units.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"58 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114450261","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"FE-Based Simulation of Hairpin Shaping Processes for Traction Drives","authors":"F. Wirth, Tarik Kirgör, J. Hofmann, J. Fleischer","doi":"10.1109/EDPC.2018.8658278","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658278","url":null,"abstract":"Based on the present change in mobility, there are novel requirements on production technologies of electric drives regarding process reliability, ability for automation, productivity as well as mechanical and electric filling factors. Providing significant advantages compared to conventional winding technologies, the hairpin technology combined with the usage of flat copper wire is a promising opportunity to fulfill the upcoming standards. Hence, the AnStaHa project aims the qualification of the hairpin technology for application in mass production. In spite of numerous advantages, the application of the hairpin technology also shows weaknesses. In particular, the shaping of hairpins is considerably more complex than corresponding process sequences of other winding technologies. The main reasons for this are the rectangular cross section and resulting directional properties of flat copper wires, significant springback effects as well as process-related damage of the wire insulation. Therefore, basic knowledge about the deformation behavior of the wire is required for process dimensioning within the context of system design. This paper handles the numerical simulation of hairpin shaping using the commercial finite element software suite Abaqus FEA. The FE-based approach is validated by experiments for different geometries and includes the complete forming process of hairpins, which is considered to be implemented in two following steps - U-bending and 3-D-shaping. Because the numerical analysis takes wire springback into account, the results can be used for a digital evaluation of hairpin shaping processes during the period of system design.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"28 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125783471","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of Hysteresis and Eddy Current Losses on Electric Drive Energy Balance in Driving Cycle Operation","authors":"M. Kitzberger, G. Bramerdorfer, S. Silber, H. Mitterhofer, W. Amrhein","doi":"10.1109/EDPC.2018.8658302","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658302","url":null,"abstract":"This article investigates the influence of electrical steel sheet hysteresis and eddy current losses as well as the related lamination thickness on total electric energy consumption for accumulated load points present in machine operation for standardized driving cycles. The considered machine geometry's main dimensions are based on the rotor and stator geometry of the 2010 Toyota Prius Motor/Generator MG2 originally used in a hybrid electric vehicle application (HEV). Three different standardized driving cycles namely CADC, NEDC and WLTC are applied. For evaluation of the cycle specific energy consumption a nonlinear machine model based on finite element analysis (FEA) is directly coupled with a purely electric vehicle (EV) power train model. The entire model is embedded into the general purpose simulation and optimization software SyMSpace. This allows fast model evaluation via interfaces to distributed computing platforms.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"139 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129075397","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Morphology of Testing Technology and Selection Advice for Automotive Process Qualification of Electric Motor Production","authors":"A. Kampker, Benjamin Dorn, K. Kreisköther, Frederik Jakob, M. Büning","doi":"10.1109/EDPC.2018.8658303","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658303","url":null,"abstract":"Electric mobility poses new challenges for electric motors in the traction sector. Until now, electric motors have been used mainly for applications such as actuators, or for fixed operating points such as for industrial or household applications. Driving cycles of vehicles characterized by pronounced dynamics require a robust and high-quality powertrain. This results in an increase in the complexity of the production of the electric motor and thus, adequate quality assurance and testing processes are required in order to be able to manufacture and assemble the products with minimum scrap rate and in a quality that meets automotive requirements in corresponding production level scenarios. The aim of this paper is to present a holistic morphology of essential testing processes along the electric motor production process as well as to develop a planning guide for the selection of necessary testing processes for the design of electric motor production to reach economic production and quality. For this purpose, a morphological box including suitable features and characteristics is defined. Summarizing, the procedure outlined should sharpen the understanding of necessary testing processes for effective quality assurance within electric motor production and subsequently, make the selection of suitable testing processes more efficient in the course of designing an electric motor production system by deriving evaluated selection recommendations from numerous technological alternatives of testing processes.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129456488","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Intelligent Rotor Assembly Enabling Positive Balancing Concepts for High-Performance Permanent Magnet Rotors","authors":"Wilken Wöβner, Johannes T. Stoll, Max Oliveira Flammer, Peter Wurster, Manuel Peter, J. Fleischer","doi":"10.1109/EDPC.2018.8658367","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658367","url":null,"abstract":"The increasing electrification of vehicles poses new challenges to the automotive industry. Especially in highperformance applications, the drive system is designed for high rotational speeds, best dynamic behaviour and optimal power-to-weight ratio. However, most rotor designs for drivetrain application are commonly designed for negative balancing. In that case, balancing discs are used to enable the subtraction of a small amount of mass, thus balancing the rotor. The excessive mass of the balancing discs must cover all production deviations and leads to massive balancing discs with a weight ratio of up to 10% for the overall rotor system. In order to reduce the weight and the installation space for permanent magnet rotors, this article presents an approach that allows to avoid excessive masses by using a rotor components arrangement with minimized unbalance followed by a positive balancing process. In preliminary investigations, the initial rotor unbalance occurring in a state-of-the-art assembly process was therefore significantly reduced by using an optimized selective assembly. Based on researched state-of-the-art positive balancing concepts, new positive balancing concepts are systematically developed, tested and evaluated for applicability in high-performing motors. It shows that the required balancing quality in high-performance applications (usually <G2.5) can be achieved with a positive balancing concept. The results are discussed within this article and integrated into improvement measures for the design of permanent magnet rotors.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"54 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124275676","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Techno-Economic Evaluation of Strategic Solutions to Extend the Range of Electric Vehicles","authors":"M. Weigelt, A. Mayr, M. Masuch, Kilian Batz, J. Franke, Peter M. Bican, A. Brem, J. Russer, P. Russer","doi":"10.1109/EDPC.2018.8658329","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658329","url":null,"abstract":"The spread of electric mobility in Germany lags far behind government's targets. High vehicle and energy prices, the limited vehicle range and obligatory time-consuming conductive charging processes are the main obstacles to mass adoption. Strategic mobility concepts, such as electric vehicles with high performance batteries (BEV), hydrogen technologies (FCEV), or dynamic inductive charging (IPTEV), i.e. a constant energy supply while the vehicle is in motion, can overcome those obstacles in Germany and beyond. Numerous studies investigated the different energy sources and compared potential drive technologies. However, in most prior studies, only partial aspects of a specific technology are considered. The contribution of this study is in providing a comprehensive technology comparison, enabling a thorough analysis and evaluation of various technological alternatives for solving the range problem of electric vehicles. For this purpose, a general framework as well as technology-specific key indicators and aspects are presented. The holistic evaluation of the technologies is carried out on the basis of specially defined evaluation criteria, with the focus on passenger car and commercial vehicle applications. In order to ensure a comparison that is as unbiased and objective as possible, measures are adjusted to avoid bias of key figures. Finally, the consideration of foreseeable macroeconomic and technological developments should ensure that long-term valid statements can also be derived from the results of the investigation.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"66 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123469171","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Additive Manufacturing of Neodymium-Iran-Boron Permanent Magnets","authors":"N. Urban, A. Kühl, M. Glauche, J. Franke","doi":"10.1109/EDPC.2018.8658348","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658348","url":null,"abstract":"Additive Manufacturing (AM) process technologies gain increased degree of technical maturity through the implementation of quality control mechanisms, fully automated production systems as well as increasing knowledge about the effects during the build-up processes. Nevertheless, the main focus of current research and development activities is set on the processing of conventional construction materials with sufficient mechanical properties. The implementation of additional, mechatronic features, e.g. optic or magnetic functions, is not well investigated yet. But as already demonstrated with printed electronics, which are decisive for manufacturing antenna structures in modern consumer electronics like smartphones, additional functionality can lift the potentials of AM to a new level. Mechatronic functionalities require a smart combination of different functional materials that are not commercially available for AM processes yet. Within this paper, a survey of the possibilities of printing rare earth permanent magnets with different process technologies is presented. The technology with the highest magnetic performance is presented more in detail and a concept for further increasing the magnetic performance is outlined.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"58 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129572405","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Manufacturing Imperfections in Electric Motor Production with Focus on Halbach Array Permanent Magnet Rotor Assembly","authors":"A. Meyer, Johannes von Lindenfels, A. Mayr, J. Franke","doi":"10.1109/EDPC.2018.8658282","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658282","url":null,"abstract":"In the production of electric motors, various manufacturing imperfections occur. These production-related deviations influence the product characteristics concerning power output, efficiency, vibration, noise and lifetime. However, measures to minimize manufacturing deviations are involved with several challenges such as additional measurements, advanced process control and above all costs. Thus, the benefit of possible improvement measures has to be carefully evaluated since not every production-related deviation has a significant impact on the product quality. Consequently, research is proceeding in this direction to quantify the actual influence of the various manufacturing imperfections on the motor characteristics as well as the whole drive system. To support the evaluation process, this paper gives a concise overview of the manufacturing imperfections in the production of permanent magnet synchronous motors (PMSM). A special focus is set on Halbach array rotors since these are particularly sensitive to magnetic deviations. As follows from first experiments, considerable deviations in magnitude and direction of the magnetization of the single magnets occur. The effects of these deviations are simulated on a specially developed Halbach test motor. Based on this, further effects will be investigated and practically tested using different motor configurations.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"51 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121086496","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}