Next Generation 800V SiC High-Speed eDrive Technology for Electrified Propulsion

Mitsuru Ishihara･Harsha Nanjundaswamy･Andi Diko･Joel Deussen･Aaron Sinka･Aleksandar Mateski･James Bourn (BorgWarner)

The design of the new iDM180-HF begins with a system level requirements analysis for the 100kW to 250kW passenger vehicle segments from which component level performance targets are established. The system housing of iDM180-HF is designed to package both low and high-performance motor variants to enable an ultra-compact 3-in-1 platform solution that leverages economies of scale for cost reduction. A unique packaging strategy of iDM180-HF architecture is also discussed with an emphasis on the cooling strategies improving the system peak performance.

Consideration on Lubrication of High-Speed Rotating Gear (Third Report)
-Case Study of Efficient Tooth Surface Lubrication Method-

Kensuke Suzuki･Tomoyuki Hara･Kaori Sakai･Masayoshi Ohno･Kazuki Sakai･Rian Setyo Adi･Junji Yamada (Univance)

Through previous reports, it became evident that the input gear in a typical eAxle experiences the most rapid temperature increase in Loss lubrication conditions. This report presents a means to minimize the impact on transmission efficiency and improve the lubrication environment, validated through visualizations using high-speed cameras and Computational Fluid Dynamics (CFD) analysis coupling airflow and oil flow.

Cool System, Lasting Power - an Outstanding E-Powertrain Meets MX Dirt Track

Thomas Arnold･Jan Böhme･Matthias Krause･Mirko Leesch･Masataka Aoki (IAV)

The E-Powertrain development is a balancing between power, range and weight. Motocross (MX) racing requires a holistic system approach that redefines current development limits. A key innovation technology is the direct phase-change cooling of the E-motor and the power electronics, which allows a significant increase in continuous power without thermal power reduction. Combined with a replaceable, immersion-cooled lithium-ion battery and a motorcycle weight on a par with a 450cc four-stroke, a minimum 35-minute run time on a dirt track (race conditions) is a reality. This article details the design, integration and thermal management of a new E-powertrain for a race-tested prototype motorcycle.

Development of Low-Loss Technology using Continuous Wave Winding

Makoto Ito･Tetsuya Suto (Hitachi)･Akeshi Takahashi (Hitachi Astemo)

We are developing a small and lightweight direct-drive system to realize in-wheel EVs. This drive system aims to improve the torque density of the motor by making the stator larger in diameter, thinner and flatter. In this presentation, we will report the concept of a low-loss technology using a continuous wave winding structure with a flat cross-section coil as a key technology.

Development of High-Density Coil Mounting Technology by Beam Welding

Tetsuya Suto･Makoto Ito (Hitachi)･Akeshi Takahashi (Hitachi Astemo)

We are developing a small and lightweight direct-drive system towards realization in-wheel EVs. In this drive system, the torque density of the motor is improved by flattening the stator with a large diameter and thin thickness. In this presentation, we report the concept and prototype results of high-density mounting technology using flat section coil and beam welding, which are key technologies.