模块化和可扩展的重型电动汽车电动动力总成- Modular and Scalable Electrified Powertrains for Heavy Duty Electric Vehicles 2024

ModularandScalableElectrifiedPowertrains

forHeavyDutyElectricVehicles

AleksandarMateski,BorgWarner

Agenda

MarketAnalysis

HighLevelRequirements

VehicleClassesinvolvedinthisstudy

Optimizationinput

Optimaldesignforeachclass

OptimalModularOutput

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

MarketAnalysis

BusseswillleadtheEVpenetrationrate

Internalcombustionengine(ICE)will

continuetodominateheavytruckswithEVpenetrationrateremainingbehindlight

vehicles(cars)

Importanceofcommondesigniskeyinfacilitatingelectrificationinheavydutyvehicles.

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

SystemRequirements

RequirementforClass5CityDelivery

20

18

PeakRequirement

ContinuousRequirementCurbClimbRequirementGradeRequirement

RequirementsforCVdifferalotduetodifferentusecases.Targetsexistfor:

LaunchathighGrade

16

14

12

10

8

6

4

2

0

Highvaluesforconstructiontrucks,lowervaluesforlonghaultransportvehicles.

Continuousspeedatcertaingrades

(e.g.30km/hat6%grade)

TopSpeed

250

Upto140km/hforPickUptrucks,around105km/hfortheUSmarket

0

vehiclespeed(kph)

CurbClimb

Importantforsomeapplications

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

SystemRequirementscont.

VoltageLevel[V]

800V

PeakWheelTorque[Nm]

11000

18500

23500

18500

30500

35500

PeakPower[kW]

250

250

250

350

500

700

MaxSpeed[kph]

130

130

120

130

90

130

Range[miles]

250

250

50

100

200

400

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

1.FrameMounted

Pro

EasyofIntegration

Reusability/Quicktomarket

Cons

Efficiency

Packaging/Weight

2.AxleMount

Pro

Efficiency

Commonalityandscalability

Cons

Cost

Timetomarket

E-CVPowertrainDesignOverview

FrameMounted

AxleMount

NumberofGears

1-4

1-3

NumberofEM’s

1-2

1-3

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

Optimizationofelectrifiedmodules

LowestTCOforClass5

Inv.Design

(DieSize,#

ofdies)

GearRatioOptimization

DesignIteration

GeneratePopulation

LowestTCOforClass6

DesignIteration

GeneratePopulation

LowestTCOforClass6

DesignIteration

LowestTCOforClass7

GeneratePopulation

Lowest

TCOfor Class8a

GeneratePopulation

DesignIteration

GeneratePopulation

LowestTCOforClass8b

Balance

b/wLow

TCOand

Powertrain

Cost

SystemOptimization

Goal:MinimizeTotalCostofOwnership

EMachineLibrary:

IPM,IMandSynRel

InverterDesign

SiCwithdifferent#ofdies

Gearbox

Multiple#ofGears

DesignIteration

EMScaling

(Length,Turns,

Thermal)

GeneratePopulation

DesignIteration

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

TCOcalculationandvariablesinvolved

PowertrainCost

1.Battery

2.Inverter

3.EMCost

4.GBCostetc.

TCO

OperationCost

1.Electricityused

2.Energy/mile

3.MaintenanceCost

Inputs

1.VehicleEnergy/Mile

2.MotorSizing

3.#OfAxles

4.Payload

FuelCost

1.ElectricityPrice

2.FuelConsumption

3.Etc.

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

OptimalElectrifiedArchitectureConfigurationforeachclass

E-Machine

Gearbox

Power

Electronics

ElectricMachine

ID:SD1

Technology:IPM

MaxSpeed:16000rpm

PeakTorque:600Nm

PeakPower:250kW

Inverter

ID:BWPS2

CurrentLimit:575Arms

GearBox

NumberofSpeeds:1spd

NumberofStages:2-stage

Configuration:Planetary

Class5DeliveryTruck

E-axle

Class6-WalkInVan

E-axle

Gearbox

Power

Electronics

ElectricMachine

ID:SD09

Technology:ACIM

MaxSpeed:16000rpm

PeakTorque:600Nm

PeakPower:250kW

Inverter

ID:BWPS2

CurrentLimit:575Arms

GearBox

NumberofSpeeds:3spd

NumberofStages:3-stage

Configuration:Planetary

E-Machine

Class6-SchoolBus

CentralDrive

Power

Electronics

ElectricMachine

ID:SD09

Technology:ACIM

MaxSpeed:16000rpm

PeakTorque:600Nm

PeakPower:250kW

Inverter

ID:BWPS5

CurrentLimit:920Arms

GearBox

NumberofSpeeds:2spd

NumberofStages:3-stage

Configuration:Planetary

TransmissioE-Machinen

Class7-TransitBus

ElectricMachine

ID:SD07

Technology:IPM

MaxSpeed:12000rpmPeakTorque:740Nm

PeakPower:350kW

GearBox

NumberofSpeeds:3spd

NumberofStages:3-stage

Configuration:Planetary

Inverter

ID:BWPS4

CurrentLimit:805Arms

Power

Electronics

E-axle

E-Machine

Gearbox

ElectricMachinex2

ID:SD01SD09

Technology:IPMIM

MaxSpeed:12krpm16krpm

PeakTorque:740Nm600Nm

PeakPower:350kW250kW

Inverterx2

ID:BWPS3BWPS2

CurrentLimit:690Arms575Arms

GearBoxx2

NofSpeeds:1spd1spd

NofStages:3-stage3-stage

Conf:PlanetaryPlanetary

Class8aDumpTruck

E-axlex2

GB

GB

EM

EM

PE

PE

Class8bSemiTruck

GBPE

ElectricMachinex2

ID:SD07SD07

Technology:IPMIPM

MaxSpeed:12krpm12krpm

PeakTorque:740Nm740Nm

PeakPower:350kW250kW

Inverterx2

ID:BWPS3

CurrentLimit:690Arms

GearBoxx2

NofSpeeds:1spd3spd

NofStages:2-stage3-stageConf:PlanetaryPlanetary

BWPS3690Arms

E-axlex2

GBPE

EM

EM

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

CommonElectrifiedArchitectureStudy

SystemOptimizationOutcome

Morethen10000solutionsforeachclass

PossibleElectrifiedArchitectures

LowestTCOElectrifiedArchitecturesCommonElectrifiedArchitectures

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

CommonElectrifiedArchitectureStudy

VehicleClass

eMachineConfigurationStatorRotor

Inverter

Gearbox

Class5-

DeliveryTruck

t1

1

GBOpt1

Class6-

WalkinVan

r

otorOp

nvOpt

GBOpt2

Class6-

SchoolBus

nStato

R

I

GBOpt3

Class7-

TransitBus

Commo

t2

GBOpt4

Class8a-

DumpTruck

otorOp

nvOpt2

GBOpt5

Opt1

Opt1

Class8b-SemiTruck

Rotor

R

Inv

I

GBOpt6

CTISymposiumUSA15-16May2024,AleksandarMateski,BorgWarner

1.VehicleClass

Class5Class6Class6Class7Class8aClass8b

-DeliveryTruck

-WalkInVan

-SchoolBus

-TransitBus

-DumpTruck

-SemiTruck

CommonElectrifiedArchitectureStudy

IPMmachinestogetherwithSiCarethetopTCOwinners.

2a2in1(EM+Inv)Option1ElectricMachine

Technology