Schaeffler officially entered the field of motor manufacturing with a modular, highly integrated technology platform. The new motor series covers the voltage level range from 48V to 800V and the power level range from 15kW to 300kW. It has high efficiency and cost-effective characteristics. It can be used in hybrid modules, special hybrid transmission (DHT) and electric Drive axle and other system products. The motor will be put into mass production in 2021 and will cover Schaeffler's global customer projects. Schaeffler's global factories, special equipment and mold manufacturing facilities will fully support and cooperate with the establishment and operation of motor production lines. Schaeffler will publicly showcase its self-developed and mass-produced motor products at the Frankfurt Motor Show for the first time.
Motor capacity continues to increase
In 2018, through the acquisition of Elmotec Statomat, a manufacturer of motor production equipment, Schaeffler has mastered the core technology of motor stator manufacturing, filling the last technological gap in the field of motor production technology, and has all the capabilities of motor industrialization. Schaeffler's capabilities in the fields of mechanical parts, manufacturing processes and motor winding, combined with its extensive expertise in vehicle systems, can not only greatly shorten the development cycle of motor products, but also ensure stable production processes. Dr. Jochen Schröder, Head of the Electric Drive Business Unit of the Schaeffler Group, explained: "Schaeffler not only has expertise in the fields of gearboxes, motors and power electronics, but can also use these capabilities Develop a complete drive system. "
Efficient modular system
Because the speed of the motor in the P2 hybrid module is the same as that of the internal combustion engine, the technical solution has special requirements for the motor. Not only the axial length of the motor is required to be as small as possible, but also sufficient space must be reserved inside the motor rotor to install the clutch and its actuator system, which requires a very compact motor design. Schaeffler single-tooth concentrated winding motors have the advantage of minimal axial installation space. They can provide 48V and high-voltage motor solutions with rated power levels covering 15 to 120kW. For dry hybrid modules, the motor stator is actively cooled by a cooling water jacket. For hybrid module systems using wet clutches, in order to achieve better cooling results, Schaeffler uses a common cooling oil method to increase the continuous output power of the motor. Schaeffler's pursuit of reducing power loss is endless. By continuously optimizing the efficiency spectrum of the motor's wide range of working areas, higher motor operating efficiency is achieved.
The same concept applies to dedicated hybrid transmissions. In such applications, the motor has more axial installation space and faster speed. Typical output power is 80 to 140 kW. In this application, the motor works as a drive motor (or generator) to work with the internal combustion engine, so the efficiency characteristics of the motor can be optimized according to the working mode of the gearbox and the powertrain system to achieve the purpose of improving the efficiency of the powertrain system. In the pure electric drive mode of plug-in hybrid, the noise level of the motor becomes a key indicator, and distributed winding is usually used to solve the noise problem. To this end, Schaeffler has defined and developed a flat wire wave winding, which is a new standard winding solution. The corresponding winding production equipment has also been developed in-house by Schaeffler. The technology is continuously improved and optimized. In order to promote the application of this technology, Schaeffler has developed a drive motor with a total axial length of 137 mm, with a power and torque of 125 kW and 310 Nm, respectively.
In addition, Schaeffler motor products can also be used for bridge drives, covering high voltage 2 (400 V) and high voltage 3 (800 V) voltage levels, with power ranges from 100 to 300 kW. Under the conditions allowed by the system, the motor speed can reach 20,000 rpm, which makes full use of the advantages of flat wire wave winding. This winding technology can greatly increase the number of stator slots, so it can effectively increase the heat dissipation capacity of the winding and reduce the content of magnetic field rotation harmonics, thereby significantly improving the power density and efficiency of the motor.
Matthias Zink, Chief Executive Officer of the Schaeffler Group Automotive Engine Division, said: "While gaining motor development and production capabilities, we have not only broadened our product portfolio, but also continuously implement our efforts in the field of electric drives. Strategy. With comprehensive system expertise and solutions, Schaeffler is committed to becoming a customer-recognized and trusted supplier, providing customers with tailor-made products and solutions. "
Schaeffler motors have a wide range of applications, with power levels ranging from 20 to 300 kW. They can be used in hybrid modules, dedicated hybrid gearboxes, and purely electric drive axles.
The belt-driven start-stop motor reduces engine fuel consumption by up to 7%.