Electrified driving technology promotes new energy vehicles to achieve "double points" target

Electronic and electrical is the key technology for new energy vehicles. At the 2017 China Electric Vehicles 100-person meeting, experts at the conference stressed that in the future, new energy vehicles will be “six-in-one” (high-frequency, integrated, modular, intelligent, systematic, green and full). Digital control) development, performance, reliability and intelligent application of new energy automotive electronic and electrical devices, the development of new high-frequency devices, power electronic equipment and system development technology will become the focus and core of industry innovation, the impact of electronic and electrical technology progress New energy vehicles are moving towards electrification and intelligence.

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Starting from 2017, with the new energy vehicle subsidy policy declining, China's new energy vehicle market officially entered the transition from “policy-driven market” to “market-driven market”. The Chinese government's forthcoming "Parallel Management Measures for Average Fuel Consumption and New Energy Points for Passenger Vehicle Enterprises" also takes new energy vehicle production and bicycle driving mileage as the core scoring targets. Under the general trend of national policy drive and automobile electrification, in addition to the driving range of bicycles, the power and comfort of electric vehicles have also been put forward higher requirements. Motors replacing internal combustion engines have opened a wide variety of drive structure schemes for car manufacturers. Flexible to respond to a variety of drive technologies, global auto parts supplier BorgWarner has developed a new electrification professional solution - eDM electric drive module to meet the automotive industry technology upgrade needs.

eDM electric drive module for power and comfort in one

BorgWarner has developed an eGearDrive transmission electronic drive axle and motor reducer integrated drive motor module eDM (Electric Drive Module) for pure electric vehicles, which not only meets the power and comfort requirements of electric vehicles, but also brings More compact, lighter and more cost effective.

Compared with the speed of the traditional engine of up to five or six thousand revolutions per minute, the maximum speed of the motor can reach about 10,000 rpm. The high speed achieves the power and the gear performance of the reducer is very high. In order to adapt to the high-speed characteristics of the motor, BorgWarner acquired Remy Motors in 2015 and developed an eDM electric drive module that integrates the integrated motor and its advanced eGearDrive transmission electronic drive axle.

The BorgWarner eDM electric drive module inherits BorgWarner's high-precision gear technology and uses an aluminum die-cast housing to further simplify the components and reduce the weight of the vehicle to 75kg by using a compact and lightweight design. Compared with the competing drive module, the weight loss is 15kg and the length is shortened by 104mm. It not only meets the requirements of current new energy vehicles for light weight and green energy saving, but its expandable and compact design can help OEMs achieve higher transmission efficiency of vehicles. Zhang Xianghong, director of the Wuhan Engineering Center of BorgWarner Power Drive Systems, said that the eDM electric drive module integrated with the eGearDrive transmission and the HVH250 motor is very compact in structure, excellent in terms of maximum torque, volume and efficiency, and further weight reduction. , to bring great convenience to the installation, maintenance and operation of customers."

BorgWarner eDM electric drive module

From the structural point of view, the larger part of the right side of the eDM electric drive module is the motor (as shown in the figure above), and the left side passes through the fixed gear ratio gear to transmit the power to the differential, and then the differential is distributed to the wheels on both sides. . The module uses high-precision helical gears, the gears are designed with helical teeth, and the tooth shape is improved. The total meshing tolerance is > 4, and the lower backlash effectively reduces the noise. At the same time, the flash point temperature is reduced by surface polishing to further improve the high-speed performance, and the transmission efficiency of the gear portion is >97%.

eDM electric drive module high precision helical gear

The eDM electric drive module finally realizes the module transmission torque up to 315Nm, the continuous torque on the wheel and the peak torque on the wheel reach 1450Nm and 2500Nm respectively, the highest input speed reaches 12000r/min, and the system transmission efficiency is greater than 93%, which is more stable. Sex, traction and low noise performance bring a smooth and quiet driving experience to electric car drivers.

eDM electric drive module motor provides powerful power for vehicle acceleration

The motor of the eDM electric drive module uses the Remy HVH250 motor acquired by BorgWarner. The motor can be used in hybrid and pure electric vehicles, featuring high efficiency, small size and light weight. For the structural design of the motor, Zhang Xianghong said, “By using the oblique pole design, the torque ripple is less than 5%, achieving good noise reduction.”

The HVH250 motor uses a permanent magnet rotor and uses advanced high-voltage hairpin rectangular copper wire stator winding technology (HVH) to achieve industry-leading power density, torque and power density. Due to the neat and compact arrangement of the wires, the surface area is large, which facilitates the conduction of heat and can effectively cool. High efficiency and high continuous power can be achieved. “The motor itself can be used in different configurations. The modular design of the HVH250 motor allows for different combinations of specifications and performance depending on the application.”

Flat copper wire stator winding technology (HVH) improves motor efficiency and performance and reduces noise

Noise is also an important performance indicator for electric vehicles during driving. The order of eDM noise is different from that of the engine. To reduce the noise inside the vehicle, BorgWarner optimized the integrated eDM noise. Zhang Xianghong said, “By the rotor pole, the gear profile is optimized, and the casing stiffness is enhanced. The motor noise level of the eDM currently reaches a near-field noise of 85 decibels and a cab noise of 35 decibels.”

In terms of motor cooling, Zhang Xianghong said frankly that oil cooling or water cooling can be used. According to the application requirements, CFD analysis and test verification can be carried out to reduce the temperature rise of the motor and achieve the best continuous product power. “The use of oil-cooled pair stator and bearing cooling is a high-performance and high-endurance feature of BorgWarner products, but domestic use of stator water cooling is more common, which will limit the continuous power of the motor to 2/3 of oil cooling, so as not to occur. Demagnetization occurs when the rotor temperature is exceeded."

Motors used in pure electric vehicles require greater power, force, and continuous power. The HVH250 water-cooled motor has a continuous power of 60 kW and a peak power of 140 kW, which provides good support for the acceleration of the vehicle.

eGearDrive transmission electronic drive axle extends mileage with efficient transmission

The eGearDrive transmission electronic drive axle system of the eDM electric drive module is designed for the electric vehicle market and can be applied to electric vehicles of different models and different energy efficiency ratios. The eGearDrive transmission electronic drive axle features an efficient gear mechanism that is compact and low in weight. The efficient gearing and compact and lightweight design significantly extend the mileage of the electric vehicle, thus reducing the battery capacity requirements of the car. Due to its high torque performance, the system is suitable for a wide range of electric vehicles, including high-performance electric sports cars, electric bridges and electric commercial vehicles.

BorgWarner's earliest eGearDrive 31-01 was developed with Tesla. The Tesla Roadster Sport version accelerates from standstill to 96km/h in just 3.7s, and the high efficiency of the drive train is indispensable. The 31-01 eGearDrive is now acquired by Tesla. In 2011, BorgWarner supplied the 31-03 eGearDrive for Ford's first mass-produced pure electric vehicle, TransitConnect. Ford Motor's pure electric car is based on the global version of TransitConnect, the "North America 2010 Truck", designed to be equipped with a city logistics fleet with a top speed of 121km/h and a full charge of 129km.

This product is also used in CODA pure electric vehicles, which can achieve a torque transfer of 300Nm peak and a high input speed of 14000r/min. Thanks to the splash-type lubrication method of the oil-free pump, the structure is simple and the assembly quality is only 32.5 kg. The Model 31-03 eGearDrive is fully qualified for the predecessor's Class A and Class B electric vehicle transmissions. It is also available with a wide range of reduction ratios. The reduction gears have a degree of overlap of more than 4 for high load capacity and operating efficiency. To facilitate the mechanical interface with the motor, the Model 31-03 eGearDrive uses a unique flanged connector to connect to the motor housing and can be adjusted to suit the needs of different models.

In addition to the single-speed 31-XX series for electric cars, BorgWarner has also developed the 32-XX series for commercial vehicles that can be placed vertically and the three-position for electric buses. -XX series products. eGearDrive combines BorgWarner's patented technology with more than 100 years of powertrain experience. Thanks to its outstanding performance, eGearDrive won the 2010 US Automotive News PACE Award.

In addition to the electric drive products described above, BorgWarner also has a rear-drive integrated motor drive (eRDM) for 48V systems and an integrated four-wheel drive (eAWD), which are currently in development and are expected to be realized by 2020. Mass production. For the future trend of eDM electric drive module, Zhang Xianghong said, “eDM is now the integration of motor and eGearDrive. The next step will be the integration of controller, motor and gearbox. In the future, BorgWarner will bring more comprehensive system to customers. Electric solution."

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IDC Series Centronic Connector

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IDC Series Centronic Connector

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