电动商用车趋势和eFLUID发展挑战-2024-07-商用车

InfineumDriveline

ELECTRIFIED

COMMERCIALVEHICLETRENDSANDeFLUID

DEVELOPMENTCHALLENGES

ZakZehnacker

DrivelineTechnologist

May2024

Novi,Michigan

Infneum)

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CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum

Infneum)

01

02

03

HardwareandeFluidtrends

eFluidformulationandtestmethodsConclusion

AGENDA

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Gearingupforthefuture

eCVHARDWARE

&eFluidTRENDS

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eCVADOPTIONACCELERATING

Truckandbuselectricproduction2030

Globalproductiontrendsoftrucksandbuses

11%full

electric

FuelCell

FullelectricAllother

NorthAmericaSouthAsia

SouthAmerica

ChinaEurope

Japan/Korea

20232030

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FullEVswillaccountfor~11%

oftruckandbusproduction

by2030.

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GEARTYPEIMPACTS

eFluidREQUIREMENTS

Infuneum)

KEY:AxleOilATF/eFluid

2020AxleOil

2030AxleOilandeFluids

E-Axle

AC-Socket

12/24/Battery

Li-lonBattery

Heater

A/C

DC-Socket

EM

Integratede-axle

EM2

EM1

AC-Socket

12/24/Battery

Li-lonBattery

Heater

A/C

DC-Socket

Distributedwheelspecific/hubmotors

eFluidrequirements

2020AxleOil&AutomaticTransmissionFluid(ATF)

2030eFluids

AC-Socket

RG

EM

Li-lonBattery

12/24/Battery

Heater

A/C

DC-Socket

Centraldrive

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COMPARING

REQUIREMENTS

Infuneum)

KEY:MajorMinorNotRequired

ConventionalAxle

SeparateWetMotor

IntegratedWetMotor/REDoptionalHelicalGearDifferential

Gearprotection

BearingprotectionO

Electricalproperties

Onefluidtomeetallo

Shearstability

requirements,withoutO

Coppercompatibility

hypoidgearso

Lowviscosity

Frictionclutchperformance

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Acarefulbalance

eFluidFORMULATION&

TESTMETHODS

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eFluidRequirements

Oilcoolede-motorconsiderations

eCVFLUIDDEMANDSARESIMILARTOePV

Baseoil

enabled

Thermal

conductivity

Efficiency

Hypoidorhelicalgears

HEATTRANSFER

Coolthewindings

Futurefluidrequirementswillbedrivenby:

E-motorcompatibilityintegration

Traditionaltransmissionfluidproperties

AdditiveEnabled

Antifoam

antioxidant

+

MATERIALCOMPATIBILITY

++Copper,resin,plastic

AERATION+OXIDATION

Corrosion

/Inhibitors

AdditiveEnabled

Smallersump,fillforlife

Friction

modifiers

FRICTIONALPROPERTIES

ELECTRICALPROPERTIES

Insulation

Whenclutchesareused

Polarity

resistivity

Antiwear

agents

WEARDURABILITY

Optimumbaseoilandadditive

balancebothrequiredforsustained

eFluidperformance.

Gears,bearings,pump

Baseoil

enabled

Oil/viscosity

modifiers

EFFICIENCY

Drag&churningvs.wear

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Acarefulbalance

FORMULATINGFORHEATTRANSFER

G

rpIII

GrpIV

●

GrpIII

4cStther

GrpIV

GrpIIIbaseoiliseferencefluid

PAG

Ester

GrpIII

GrpIII

RelativeMouromtseffNumber

.

GrpIII

2.0

1.0

0.0

0.02.04.06.08.0

KinematicViscosityat100°C(cSt)

TheMouromtseffnumber[M0]isusedtocomparetheheattransfercapabilityofturbulentfluids

eFluidsaresubjecttoturbulentflow

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Mouromtseffnumberforturbulentfluids:

Fluidproperties:

ρ=Density[kg/m3]ρ0.8k0.67c.33

Cp=Specificheatcapacity[kJ/(kg.K)]μ0.47

µ=Dynamicviscosity[cP]

Providesformulationguidance,largelyonbaseoilselection

Increasefluidthermalconductivity

Functionofbaseoilpurity[GrpIV>GrpIII]-small

effectonM0

Reducefluiddynamicviscosity

Lowerviscosityoil-majoreffectonM0[balancevs.wear]

k=Thermalconductivity[W/(m.K)]M0=

HEATTRANSFER

Coolthewindings

Acarefulbalance

CASESTUDY:FORMULATINGFORHEATTRANSFER

Additive

technology

Fluidproperties:

Viscosity

Radialfluxmotor(OpelAmpera-e)

Motorconfigurations:

Axialfluxmotor(YASAP400S)

VARIOUSCANDIDATEFLUIDSHAVEBEEN

EVALUATEDFORHEAT

TRANSFERPERFORMANCE.

RESULTSPROVIDEINSIGHTINTOFLUIDBEHAVIOR.

Oilflowinaradialfluxmotor

hasbeenvisualizedthroughthe

introductionofatransparentwindow.

HEATTRANSFER

Coolthewindings

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Acarefulbalance

CASESTUDY:OPELAMPERA-EE-MOTORCOOLING

EndTemperature(°C)

StatorTemperaturesAfter30min

160

0

StatorT1StatorT2StatorT3StatorT4

DIin4cStGrpIIIOilDIin4cStGrpVOilDIin2cStGrpIIIOil

140

120

100

80

60

40

20

Testfluidswerescopedunderseveraloperatingconditions:

2000rpm@50%

maxtorque

6500rpm@25%

maxtorque

HEATTRANSFER

Position4

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Coolthewindings

Acarefulbalance

LOWVISCOSITY

OUTPERFORMEDHIGHVISCOSITY.

GRPV

OUTPERFORMED

GRPIII.

HEATTRANSFER

Coolthewindings

KEY

FINDINGS

Highpowertemperaturerisetimetests:

4500rpm@60-90%maxtorque

CASESTUDY:OPELAMPERA-EE-MOTORCOOLING

Lowviscosityfluidsdelayedderatingofstatorwindingsandshowedlowersteady

statetemperatures.

RiseTime(sec)

TemperatureRiseTime@4500rpm

0

60%70%80%in4cStGrpIIIOilDIin4cStGrpVOil

90%

DIin2cStGrpIIIOil

600

500

400

300

200

100

TorqueDI

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Acarefulbalance

CASESTUDY:YASAP400SE-MOTORCOOLING

TempSteady

risestate

AvgTimeforWindingstoReach

ThermalLimitof120°C(sec)

HighPowerTest-FluidImpactonStatorWindingTemp(20LPM)

160

0

τ=73%ofmaxFluid=40°C

DIin4cStGrpIIIOilDIin4cStGrpVOilDIin2cStGrpIIIOil

τ=89%ofmaxFluid=40°C

τ=73%ofmaxFluid=60°C

τ=89%ofmaxFluid=60°C

140

120

100

80

60

40

20

Testfluidswerescopedunderseveraloperatingconditions:

1500rpm@27%

maxtorque

5500rpm@18%

maxtorque

3200rpm@73-89%maxtorque

YASAP400

CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum©2024InfineumInternationalLimited.Allrightsreserved

KEY

FINDINGS

PERFORMANCE

DIFFERENCESWEREOBSERVEDATHIGH

POWER.

Lowviscosityfluidsdelayedderatingofstatorwindings.

HEATTRANSFER

Coolthewindings

Infnneum)

Acarefulbalance

MOTORSINTRODUCENEW

MATERIALSTOTHETRANSAXLE

Insulatingmaterial

Plastics

Cu(wire,connector)

Sealant

Al(case)

MATERIALCOMPATIBILITY

++Copper,Resin,Plastic

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MATERIAL

COMPATIBILITY

ISCRITICALFOReFluids.

Insulationfailurecanleadtoshorts&corrosioncanerodeconnectionsandcircuits.

Infnneum)

Acarefulbalance

COPPERCOMPATIBILITY

ASTMD130modifiedtesting

(solutionandvaporphase)

Materialcompatibilitymustbe

Finishedfluid

Finishedfluid

consideredforadditiveselection:

CorrosioninhibitorshelpmitigateCu

corrosiondebits

fromotheradditives.

Extremepressure

additivesprotectthegearsbutincrease

Cucorrosion.

Spacer

structures

ThreadedrodNutInterdigitalcopper

Powered

Powered

Powered

Not

powered

Notpowered

Soaktests,atelevated

temperature.

EnergizedCircuitBoardtesting

AdditivecomponentsusedineFluidsmustbescreenedforcompatibility:

Energizedcircuitboardtests.

MATERIALCOMPATIBILITY

++Copper,Resin,Plastic

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InfineumScreenerDevelopment:CaseStudy

ENERGIZEDCIRCUITBOARDTESTLIVEIMAGING

KEY

DIFFERENCE

Improvingenergizedcorrosionrequiresa

fundamental

understanding.

TESTCELL

BUILTWITH

PYREXWINDOW&INTERNALHEATERTOVISUALIZETHE

MECHANISM.

MATERIALCOMPATABILITY

++Copper,Resin,Plastic

TIMELAPSEVIDEO:BADREFERENCE

47SEC=>~16HRS

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Acarefulbalance

AGING

PRODCEDURE

01

Oiltreatedwith

5000ppmwater

02

8cyclesofhigh-temp.&low-temp.shock(16days)

03

1cycle:155°Cfor40hand-45°Cfor8h

THERMALSHOCKTEST

VARNISHEDWIRE

Fresh

Aged

Fresh

Aged

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INSULATIONPAPER

FreshAged

Noveltestthatmeasuresan

oil’sabilitytoprotectawide

varietyofinsulationmaterials

underextremethermal

MATERIALCOMPATABILITY

++Copper,Resin,Plastic

cyclingconditions.

Acarefulbalance

THERMALSHOCKTESTRESULTS

FT2015/1200DielectricStrength

(mV/m)

FT2015/1200InsulationCoating

MaterialBondStrength(N)

35

30

25

20

15

10

5

0

Infineume-Fluid

CommercialReferenceATF

Infineume-MotorCoolingFluid

30

25

20

15

10

5

0

Infineume-Fluid

CommercialReferenceATF

Infineume-MotorCoolingFluid

InfineumeFluidsshowoutstandingmotormaterial

MATERIALCOMPATABILITY

++Copper,Resin,Plastic

compatibilityperformance.

CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum©2024InfineumInternationalLimited.Allrightsreserved

InfineumScreenerDevelopment:CaseStudy

HIGHSPEEDAERATIONTEST(HSAT)

InfineumHSAT

Homogenizer

ASTMSeqI-IVFoamingTest

e-Motor&

Homogenizer

GearBox

≈

+

≈

Stator

Airflow

Airflow

Sheargap

Homogenizerspinsat

Rotor

extremelyhighspeeds

(upto27,000rpm)

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KEY

DIFFERENCE

ASTMSeqI-IVdoesnothavehighrpmchurning/shear

foundineMotors.

ENTRAINEDAIRCANLEADTO

CAVITATIONWEARAND/ORLOSSOFHYDRAULIC

PERFORMANCE.

AERATION

Smallersump,fillforlife

InfineumScreenerDevelopment:CaseStudy

HIGHSPEEDAERATIONTEST(HSAT)

ControlElectronics

AirFlowControl

Aggregator&

AirFlowTubes

Camera

HeaterBlock

Homogenizer

BADREFERENCEOIL

60ׄ°C100ׄ°C140ׄ°C

GOODREFERENCEOIL

60ׄ°C100ׄ°C140ׄ°C

MixingOn

for1min

Total,mL

Total,mL

MixingOff

after5seconds

Total,mL

Total,mL

AERATION

Smallersump,fillforlife

Automaticallyrunsrangeoftemperaturesturninghomogenizer&airflowon/offwhiletakingimagesasspecified

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Acarefulbalance

MOTORSRELYONINSULATINGMATERIAL

TOISOLATEHIGHVOLTAGECOMPONENTS

Example:

Considera1cm2conductor

immersedinoilandseparatedfromgroundby1cm.

Oilwithconductivity

1x10−9S/cm(VR=10

MΩ*m)at100。Cwouldpresent1GΩresistance.

Ifdrivenby500V,

a0.5μAleakagecurrentwouldoccur.

1cm

Foroilcooledmotors,theeFluid’sresistancetocurrentflowmustbeconsidered.

HigherVRcanallowforincreasedmotorvoltageandsmallercasing,butcanleadtostaticbuild-up

andarcing.

VolumeResistivity[VR]isthe

oilresistivity[1/conductivity]multipliedbytheseparationanddividedbythearea.

Theoptimum

eFluidVRto

electric

current

isbeing

investigated.

1cm

ELECTRICALPROPERTIES

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Insulation

Acarefulbalance

FORMULATINGFORVOLUMERESISTIVITY

RELATIVEVOLUMERESISTIVITY

At80。C(ASTMD1169v)

Balancedcomponentsusedto

achieveelectricalperformance

whilemeetingotherrequirements.

VRdecreasesasmolecularpolarityofaformulation’scomponentsincreases.

BASESTOCK

BS

+Component[A]

BS

+Component[A+B]

BS

+Component[A+B+C]

BS

+Component[A+B+D]

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ActualVR[log]

Compoundscontaining1

m%O,S,N,andPinGroup3

PredictedVR[log]

Modelingreducesthe

testingneededtooptimize

theVRofaformulation.

ELECTRICALPROPERTIES

Insulation

Acarefulbalance

BALANCINGFZGWITHVR

cuffing-R1166/9

12

(FailureLoadStage)

11

10

9

8

7

6

5

4

InfineumeFluid

MTF:

HighFZGLowVR

ATF/DCTF:

LowFZG,LowtoHighVR

HighFZG&HighVR

Infineume-MotorCoolingFluid

HighVR

010