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PackardElectrical/ElectronicArchitectureDelphi/SGMConfidentialHighVoltageElectricalSystemforHybridandElectricVehiclesMingLiE/EArchitectureChiefEngineer,AsiaPacificDelphiPackardElectricSystems15March2011PackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December2010AgendaBackground–DelphiPackardHEV/EVDevelopment–HEV/EVElectrical/ElectronicsArchitectureHighVoltageElectricalSystems–Highvoltagewiringharnessandrequirements–Connectionsystemandrequirements–PowerdistributionandcircuitprotectionPackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December2010DelphiExperiencesonHEV/EVDevelopmentGMEV1,Early1990Delphihasa20yearhistoryinElectricandHybridElectricVehiclesInvolvedinthedesignandmanufactureofGM’sEV1powerdevices,controlelectronics,andenergystoragesystemHybridElectricPropulsionArchitectsformultiplevehiclesOver100PatentsissuedinHEVsince2000PackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December2010PureEV5555Hybrid/ElectricVehicleArchitectureComparisonRangeExtendedEV4444Plug-InHEV4444FullHEV3333MildHEV2222MicroHEV1111PowerIntegrationFuelConsumptionCO2ReductionEfficiencyCostPowerIntegrationFuelConsumptionCO2ReductionEfficiencyCostPowerIntegrationFuelConsumptionCO2ReductionEfficiencyCostPowerIntegrationFuelConsumptionCO2ReductionEfficiencyCostPowerIntegrationFuelConsumptionCO2ReductionEfficiencyCostPowerIntegrationFuelConsumptionCO2ReductionEfficiencyCostPackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December201012VBatteryMonitorTractionMotorsSupervisoryControllerHCUInverterDC/DCConverterElectricPowerSteeringBatteryControllerChargingStationChargerCouplerHighPowerWiringHarnessChargerTransmissionControlHybridandElectricVehicle–NewComponentsElectricalA/CCompressorPowertrainControllerBatteryPackStarter-GeneratorHighVoltagePowerDistributionHighVoltageConnectionSystemPowerConnectorPackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December2010MicroandMildHEVHighVoltageElectricalSystems3WTransInverterICEEC12VBatteryBAS14V/100A14V/100AMicroHybridMildHybrid•Engineoffatidle•Enginesize(2.0Lgas,1.6Ldiesel)•Replacesstartermotor•MOSFETInverter•4–7%impinfueleconomy•Engineoffatidle•Powerboost–enginedownsizing•Regenerativebraking•15-25%improvementinfueleconomy12vDCCircuitVoltagesUn-ShieldedConnectorHVShield/SealedConnectorConnectionsHVDCHVACHighCurrentShieldedConnectorRingTerminalTubing/ChannelHighVoltageBatteryInverterConverterPower-box3W12V175AFuse2W36-120V100-125A3WTransICEEC12VBatteryBASPackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December2010Full/Plug-inHEVHighVoltageElectricalSystem3wHighVoltageBatteryElectricA/CElectricP/SMG1ICE2W2W2WEC12VBattery14V/40AConverterInverterBPCM/BDU500-650V/100A500V/20A300-400V200A14V/175A2WPDSMG23wTransferSwitch5PIN5PINCharger3w3w300V/6A110VAC/15A220VAC/15A2w•Engineoffatidle•LimitedEVmode•Regenerativebraking•Dual60kWIGBTinverter•DC–DCconverter•25–50%improvementinfueleconomy12vDCCircuitVoltagesUn-ShieldedConnectorHVShield/SealedConnectorConnectionsHVDCHVACHighCurrentShieldedConnectorRingTerminalTubing/ChannelPackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December2010HighVoltageBatteryA/CCompressor5PINCharger12VBatteryTractionMotorDC/DCConverterInverterCabinHeaterGearBoxElectricalVehicleHighVoltageElectricalSystem12vDCCircuitVoltagesUn-ShieldedConnectorHVShield/SealedConnectorConnectionsHVDCHVACHighCurrentShieldedConnectorRingTerminalTubing/ChannelPackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December2010HEV/EVHighVoltageHarnessDesignChallenges:Robustdesignforharshenvironmentapplications–Mechanicalprotectiontoensureflexibleroutine–MinimizestressappliedonharnessandimprovefatiguelifeLightweightdesignSafetyconsiderationsRequirements:Highvoltage,highcurrentelectricalsystem–Upto600voltsand300A–Highperformancecomponentsforrobustapplication–ProtectionforsafeoperationsHighfrequencyACapplications–ElectricalmagneticinterferesandshieldingPackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December2010DelphiHighVoltageHarnessSolutionsProductDescription–Highvoltageharnessfrommainbatterytoenginecabinet–Protectionforunderbodyrouting–Bendingflexibilitytofitvehicleunderfloorstructure–Heavycablesizecrimping–ShieldingandEMC/EMIoptimizationValuetotheCustomer–Highperformanceproductsforhighpowerapplications–Robustprotectionenablesflexibleharnessmounting–Lightweightmaterialanddesign–RobustmanufacturingtechnologytoenablevolumeproductionDelphiadvantage–Uniquetubebendingprocess–Physicalshapesimulationtoanalyze»Minimumbendradiusconstraint»Bundlestiffnessconstraint»Vibrationandbendingstress–ChinabaseddevelopmentandmanufacturingcapabilityStatus–NowPackardElectrical/ElectronicArchitectureDelphi/SGMConfidential8December2010HighPowerConnectionSystemsDesignChallenges:HighcurrentcapabilitySealeddesignforunder-hoodACapplicationShieldingandEMC/EMIoptimizationRobustdesigntoensuresafeconnectionanddisconnectionsRequirements:ConnectiontohighpowerdevicesWet,dustandvibrationenvironmentEle
本文标题:High Voltage Electrical System for Hybrid and Elec
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