电动汽车用电机及其控制系统的应用与发展

DajunConfidential,Pleasedonotdistributewithoutwrittenpermit电动汽车用电机及其控制系统的应用与发展ApplicationandDevelopmentTrendofMotorControlSystemsforEVandHEV徐性怡博士上海大郡自动化系统工程有限公司Dr.XingyiXuShanghaiDAJUNTechnologies,Inc.DajunConfidential,Pleasedonotdistributewithoutwrittenpermit内容提要Outlines•电动汽车的发展趋势以及对电机系统的要求EV/HEVtrendandrequirementforelectricdrivesystems•电动汽车用电机系统技术及其发展趋势Descriptionanddevelopmenttrendinelectricdrivesystems•电动汽车用电机系统面临的挑战与对策Challengesandsolutionsforelectricdrivesystems•大郡简介BriefoverviewofDajunDajunConfidential,Pleasedonotdistributewithoutwrittenpermit中国电动汽车的发展前景EV/HEVinChina•历史性机遇HistoricalOpportunities–汽车动力电气化已成为汽车技术发展的趋势PowertrainElectrificaitonistrendforfuture–“节能减排”的国策鼓励电动汽车及混合动力汽车的大发展EnergySavingandEmissionReductionisChina’sLongTermNationalPolicy•电动汽车发展所面临的挑战ChallengesforEV/HEV–电动汽车技术仍有待于完善，尤其是关键零部件如电池和电机制约了电动汽车的发展进程；LimitedbyKeyComponentssuchasbatteriesandmotordrivesystems–电动汽车市场受到产品可靠性、成本等因素的制约，需要一段成长周期ReliabilityandcostofEV/HEVproductsareofconcerntoconsumers–消费者对新能源汽车的积极性受油价的影响ConsumeracceptanceofEV/HEVisinfluencedbyoilprice•市场将在未来3-5年逐步上量Therewillbe3-5yearsbeforethemarketreallyrampsupDajunConfidential,Pleasedonotdistributewithoutwrittenpermit混合动力系统实现方案ExamplesofHEVSystemsBatteryTrans.ISGIPUMildHEVBatteryTrans.TractionMotorISGIPUSeriesHEV/Plug-inBatteryTrans.TractionMotorISGIPUParallelHEV/Plug-inDajunConfidential,Pleasedonotdistributewithoutwrittenpermit电动汽车应用对电机系统的要求EV/HEVRequirementsforElectricMachines•结构紧凑、尺寸小CompactinSize•重量轻LightinWeight•可靠性高HighReliability•效率高HighEfficiency•低噪声、低震动Lowaudiblenoise,LowVibration•调速范围宽WideSpeedRange•成本低LowCostDajunConfidential,Pleasedonotdistributewithoutwrittenpermit汽车电机与普通工业电机之比较项目工业应用汽车应用封装尺寸空间不受限制，可用标准封装配套各种应用布置空间有限，必须根据具体产品进行特殊设计工作环境环境温度适中（-20~+40oC);静止应用，震动较小温度变化大（-40~+105oC);震动剧烈;可靠性要求较高以保证生产效率很高以保障乘车者安全冷却方式通常为风冷（体积大）通常为水冷（体积小）控制性能多为变频调速控制，动态性能较差需要精确的力矩控制，动态性能较好功率密度较低（0.2kW/kg）较高（1–1.5kW/kg）总体性价比一般极高：既要性能好，又要价格便宜DajunConfidential,PleasedonotdistributewithoutwrittenpermitMotorSensorPowerElectronicConverterDigitalControl汽车电机系统的构成和工作原理AutoElectricDriveSystemDescriptionBattery-VinVinVoDajunConfidential,Pleasedonotdistributewithoutwrittenpermit常用交流无刷电机类型CommonTypesofACMotorsAxByzC感应电机•技术成熟•成本较低•恒功率调速范围宽•效率较高•体积较大开关磁阻电机•结构简单•恒功率调速范围宽•效率与感应电机类似•噪声大•体积比较大永磁电机•体积小•效率高•恒功率调速范围不宽DajunConfidential,Pleasedonotdistributewithoutwrittenpermit电机技术发展趋势：永磁-磁阻同步电机PM-ReluctanceSynchronous(PMRS)Motor+永磁-磁阻同步电机的特点：PMRSMotorFeatures:•弱磁容易，调速范围宽Capableoffieldweakening,wideconstantpowerrange•效率较高Highefficiency•力矩密度较高Hightorquedensity•结构复杂，优化设计较难Hardtodesign•由于饱和非线性，控制复杂ControlcomplexityDajunConfidential,Pleasedonotdistributewithoutwrittenpermit动力总成趋势：电机与变速箱的优化组合OptimalCombinationofMotorandGears•电机尺寸取决于峰值力矩（而不是功率！）以及电机的散热能力ThemotorsizeisdeterminedbytheTORQUE(notthepower!)andthemotorcoolingsystemcapability.•根据实际应用需要优化配置电机与变速箱（减速机）组合Systemoptimizationcanbeachievedthroughmotor/gearcombination速比1:1速比2:1rpmTorqueDajunConfidential,Pleasedonotdistributewithoutwrittenpermit丰田混合动力系统的改进Size/WeightReductioninToyota’sHEVsystem•通过采用减速齿轮，在电机尺寸基本不变的情况下，其功率增加了2.5倍PriusRX400/CamryHVPeakTorque：400Nm333NmMaxRPM600012400PeakPower50kW123kWDajunConfidential,Pleasedonotdistributewithoutwrittenpermit电力电子控制器发展趋势TrendinPowerElectronicsController•新控制器拓扑结构Newtopology–逆变器+大功率DC/DC•高集成度Highlevelofintegration–ISG控制器+牵引电机控制器+DC/DCIntegrationofISGcontroller,tractionmotorcontrollerandLowvoltageDC/DC–电力电子控制器与电池管理模块集成MotorcontrollerintegratedwithBatteryModule–热管理集成设计Thermalmanagement•新器件NewComponents–高集成度、智能型汽车等级IGBT模块HighlyintegratedIGBTModulewithautograde–薄膜电容ThinfilmcapacitorsDajunConfidential,Pleasedonotdistributewithoutwrittenpermit丰田混合动力系统PCU的改进Size/WeightReductioninToyota’sPCUsystem•通过提高集成度，改进散热板设计，丰田大大减小了其电力电子控制器（PCU）的体积与重量ToyotaachievedsubstantialvolumeandweightreductionthroughhigherlevelofintegrationandthermalmanagementsystemenhancementRX400GS450ImprovedVolume：30Liters11Liters63%Weight35kg20kg43%DajunConfidential,Pleasedonotdistributewithoutwrittenpermit电动汽车用电机系统所面临的设计挑战：DesignChallengesforEV/HEVMotorDriveSystems•整车重量和封装尺寸：Vehicleweightandpackagingsizeconstraint–采用永磁-磁阻电机UseofPM-ReluctanceSynchronousmotor•可靠性和耐久寿命设计：Reliabilityanddurabilitydesign–汽车应用的恶劣环境：Harshoperatingconditions•高温及宽温差循环HighTemperatureandwiderangetemperaturecycling•剧烈的震动SevereVibration–需要充分理解最差工况以及电机、电力电子器件的能力限制Fullyunderstandtheworstcaseconditionandlimitationsofmotorandpowerelectronicscomponents•电磁兼容设计：EMCDesign–需要从零部件到整车各层次进行统筹设计WorkatVehicle,system,andcomponentleveltolimitEMI•设计认证：DesignValidation–加速寿命试验AcceleratedlifetesttovalidatethedesignDajunConfidential,Pleasedonotdistributewithoutwrittenpermit成本挑战ChallengeinCostReduction•电机系统成本是电动汽车/混合动力汽车市场化的重要障碍之一TheE-drivesystemcostisamojorobstacletothecommercializationofHEV,plug-inHEV,batteryEVandFCEV•EV/HEV动力系统成本构成；MajorcostcomponentsofanE-drivesystem–电池或燃料电池；Batteryorfuelcell–电力电子；Powerelectronics(inverter,controller,andsensor)–电机；Motor–减速器/变速箱；Gearbox•需采用系统方法削减成本Systematicapproachisneededtominimizethesystemcost,notindividualcomponentcost.DajunConfidential,Pleasedonotdistributewithoutwrittenp