Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085551
A. Weber
This paper describes certain challenges in achieving a cost optimized production for power electronics in relation to product design, volume & variant scenarios, product lifecycle and upcoming manufacturing technologies and the introduction of a production system as an answer to this challenges.
{"title":"Factory of the future for powerelectronics in Hybrid & electric vehicles","authors":"A. Weber","doi":"10.1109/EDPC.2011.6085551","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085551","url":null,"abstract":"This paper describes certain challenges in achieving a cost optimized production for power electronics in relation to product design, volume & variant scenarios, product lifecycle and upcoming manufacturing technologies and the introduction of a production system as an answer to this challenges.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"120944469","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085530
H. Liess
These considerations lead to the optimal dimensions for electrical conductors in mobile systems. The work shows the dependence of the entire power consumption of electrical conductors as consequence of the vehicle speed, the material parameters, the mechanical and the electrical efficiency factors and elaborates the optimal current density in terms of low power consumption. The object of the work is to contribute to an energy efficient design of electrical power lines in all kinds of vehicles.
{"title":"Optimal dimensions for electrical conductors in mobile systems","authors":"H. Liess","doi":"10.1109/EDPC.2011.6085530","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085530","url":null,"abstract":"These considerations lead to the optimal dimensions for electrical conductors in mobile systems. The work shows the dependence of the entire power consumption of electrical conductors as consequence of the vehicle speed, the material parameters, the mechanical and the electrical efficiency factors and elaborates the optimal current density in terms of low power consumption. The object of the work is to contribute to an energy efficient design of electrical power lines in all kinds of vehicles.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116754776","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085544
E. Lamprecht, R. Graf
This paper presents investigations into the eddy current losses of laminated stator cores with electrically connected edge areas. The application of various manufacturing processes can lead to an electrical connection of the lamination core edges and therefore to additional eddy current losses. This paper considers the impact of connected core edges on the losses of a ring core sample. The analysis shows that the eddy current losses increase dramatically when connecting the core edges. Based on the results achieved by finite element analysis, a simple equivalent electric circuit model is introduced. For verification of the model, the circuit model is introduced. For verification of the model, the circuit was simulated with an analog circuit simulation software. Finally the calculated results have been validated experimentally on a ring core sample with galvanically connected edges.
{"title":"Fundamental investigations of eddy current losses in laminated stator cores created through the impact of manufacturing processes","authors":"E. Lamprecht, R. Graf","doi":"10.1109/EDPC.2011.6085544","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085544","url":null,"abstract":"This paper presents investigations into the eddy current losses of laminated stator cores with electrically connected edge areas. The application of various manufacturing processes can lead to an electrical connection of the lamination core edges and therefore to additional eddy current losses. This paper considers the impact of connected core edges on the losses of a ring core sample. The analysis shows that the eddy current losses increase dramatically when connecting the core edges. Based on the results achieved by finite element analysis, a simple equivalent electric circuit model is introduced. For verification of the model, the circuit model is introduced. For verification of the model, the circuit was simulated with an analog circuit simulation software. Finally the calculated results have been validated experimentally on a ring core sample with galvanically connected edges.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133667623","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085560
M. Hofmann, B. Eckardt, M. Mârz, L. Frey
Integrated drive-units for electric vehicles (EV) with combined electric machines and power electronic components offer the chance to achieve compact and cost-optimized traction systems. The demand for high power-densities and the requirement of a reliable system operation lead to the necessity of an enhanced thermal management. In the present paper, the build-up of an integrated drive-unit with 2×20 kW is described. A thermal simulation model of the used traction machines, based on Cauer-networks and parameterized with FEM-simulations and measurements, allows an analysis of transient temperature profiles for various driving situations as well as a determination of internal temperatures.
{"title":"Thermal characterization of an axle-twin-drive with system integrated double-inverter","authors":"M. Hofmann, B. Eckardt, M. Mârz, L. Frey","doi":"10.1109/EDPC.2011.6085560","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085560","url":null,"abstract":"Integrated drive-units for electric vehicles (EV) with combined electric machines and power electronic components offer the chance to achieve compact and cost-optimized traction systems. The demand for high power-densities and the requirement of a reliable system operation lead to the necessity of an enhanced thermal management. In the present paper, the build-up of an integrated drive-unit with 2×20 kW is described. A thermal simulation model of the used traction machines, based on Cauer-networks and parameterized with FEM-simulations and measurements, allows an analysis of transient temperature profiles for various driving situations as well as a determination of internal temperatures.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115522756","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085553
Ronny Fritsche
Today's business environment increasingly requires the capability of producing electric drives in smaller lot sizes in order to be able to respond quickly to changing customer demands without suffering from large stocks, excess capacities or challenging the company's ability to deliver. This flexibility is a crucial element of success for both, an increased customer service as well as a lean and competitive production system. A key enabler for achieving flexibility and implementing lean production is the reduction of set-up times.
{"title":"Reducing set-up times for improved flexibility in high-mix low-volume electric drives production","authors":"Ronny Fritsche","doi":"10.1109/EDPC.2011.6085553","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085553","url":null,"abstract":"Today's business environment increasingly requires the capability of producing electric drives in smaller lot sizes in order to be able to respond quickly to changing customer demands without suffering from large stocks, excess capacities or challenging the company's ability to deliver. This flexibility is a crucial element of success for both, an increased customer service as well as a lean and competitive production system. A key enabler for achieving flexibility and implementing lean production is the reduction of set-up times.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130842964","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085570
J. Hofmann
The paper presents the method to determine an optimized, robust cooling system for liquid cooled main motors. The optimization was supported by principle motorette tests to define the basic thermal parameters of different joining technologies. By using the technology tube hydroforming (THF) and orbital welding is it possible to produce the required, robust cooling-system very effective at a high quality standard. This causes reduced development and production costs, less componets and processes and last but not least improvement of processing time.
{"title":"Innovative motor design for production machines","authors":"J. Hofmann","doi":"10.1109/EDPC.2011.6085570","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085570","url":null,"abstract":"The paper presents the method to determine an optimized, robust cooling system for liquid cooled main motors. The optimization was supported by principle motorette tests to define the basic thermal parameters of different joining technologies. By using the technology tube hydroforming (THF) and orbital welding is it possible to produce the required, robust cooling-system very effective at a high quality standard. This causes reduced development and production costs, less componets and processes and last but not least improvement of processing time.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131129876","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085555
D. Jakšić
We have experienced the unprecedented copper price rises in the recent years. With increased use in the automotive industry, it will become even more serious issue, possibly slowing down the wider application of the electric drives in the new vehicles. More efficient way to use the copper would bring substantial benefits to other industries, too - every high volume inductive device application included.
{"title":"“Getting rid of the air”, or how to maximize winding fill factor (ID 81)","authors":"D. Jakšić","doi":"10.1109/EDPC.2011.6085555","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085555","url":null,"abstract":"We have experienced the unprecedented copper price rises in the recent years. With increased use in the automotive industry, it will become even more serious issue, possibly slowing down the wider application of the electric drives in the new vehicles. More efficient way to use the copper would bring substantial benefits to other industries, too - every high volume inductive device application included.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123002877","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085558
G. Heinzelmann, G. Liebhard, H. Roßkamp
Up to today, small two-stroke gasoline engines are the major power source for professional outdoor power equipment such as hedge trimmers, chain saws, blowers, cut-off saws.
时至今日，小型二冲程汽油机是专业户外动力设备的主要动力源，如树篱修剪机、链锯、鼓风机、截止锯等。
{"title":"Energy efficient drive train for a high-performance battery chain saw","authors":"G. Heinzelmann, G. Liebhard, H. Roßkamp","doi":"10.1109/EDPC.2011.6085558","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085558","url":null,"abstract":"Up to today, small two-stroke gasoline engines are the major power source for professional outdoor power equipment such as hedge trimmers, chain saws, blowers, cut-off saws.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130309950","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085559
S. Becker, T. Uffinger, E. Schlucker, S. Weiss, G. Dorr
This paper will provide an overview of different mechanisms of sound generation and present important measurement and computational techniques for the determination of the flow and acoustic field in electric drive systems. Two basic phenomena of sound generation can be distinguished: flow-induced sound created by unsteady flow fields, and vibrational sound due to moving surfaces. Besides these basic mechanisms, complex interactions of both are possible.
{"title":"Efficient and silent cooling of electric drives - basics, measurement techniques and computational approaches","authors":"S. Becker, T. Uffinger, E. Schlucker, S. Weiss, G. Dorr","doi":"10.1109/EDPC.2011.6085559","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085559","url":null,"abstract":"This paper will provide an overview of different mechanisms of sound generation and present important measurement and computational techniques for the determination of the flow and acoustic field in electric drive systems. Two basic phenomena of sound generation can be distinguished: flow-induced sound created by unsteady flow fields, and vibrational sound due to moving surfaces. Besides these basic mechanisms, complex interactions of both are possible.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127783203","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2011-11-21DOI: 10.1109/EDPC.2011.6085547
A. Huf
Although hydraulic cylinders offer certain advantages, such as high force density and easy bolt-on mechanical assembly, they also have limitations like unclean operation, high maintenance requirement and difficulty of controls. This paper presents a competing drive concept that sidesteps these problems and achieves a high force-to-weight ratio by utilizing direct drives in a parallel arrangement. The proposed module allows high acceleration and high precision controls, while avoiding the self-locking problem associated with geared drives. First, a general overview of the actuator module is provided, which includes the electrical drive, the guideway system, measurement devices, and an optionally integrated power converter. The possible solutions applying different linear drive principles are evaluated and compared. In particular, the influence of iron-core and ironless direct drives on the force-to-weight ratio are analyzed. To achieve scalability in force, a modular design is adopted. In order to reduce the weight of the module, magnetic flux simulations are conducted that enable a substantial reduction in the backflow iron required for the drives arranged in parallel. The manufacturing of the coils and the assembly of the magnetic guideway are also discussed; in particular from the point of view of dealing with difficulties caused by statistical disparities in the magnetization properties among permanent magnets from the same batch. Finally, experimental results from the completed actuator are presented, including static and dynamic mechanical measurements and thermal behavior.
{"title":"Linear actuator module based on multiple drives","authors":"A. Huf","doi":"10.1109/EDPC.2011.6085547","DOIUrl":"https://doi.org/10.1109/EDPC.2011.6085547","url":null,"abstract":"Although hydraulic cylinders offer certain advantages, such as high force density and easy bolt-on mechanical assembly, they also have limitations like unclean operation, high maintenance requirement and difficulty of controls. This paper presents a competing drive concept that sidesteps these problems and achieves a high force-to-weight ratio by utilizing direct drives in a parallel arrangement. The proposed module allows high acceleration and high precision controls, while avoiding the self-locking problem associated with geared drives. First, a general overview of the actuator module is provided, which includes the electrical drive, the guideway system, measurement devices, and an optionally integrated power converter. The possible solutions applying different linear drive principles are evaluated and compared. In particular, the influence of iron-core and ironless direct drives on the force-to-weight ratio are analyzed. To achieve scalability in force, a modular design is adopted. In order to reduce the weight of the module, magnetic flux simulations are conducted that enable a substantial reduction in the backflow iron required for the drives arranged in parallel. The manufacturing of the coils and the assembly of the magnetic guideway are also discussed; in particular from the point of view of dealing with difficulties caused by statistical disparities in the magnetization properties among permanent magnets from the same batch. Finally, experimental results from the completed actuator are presented, including static and dynamic mechanical measurements and thermal behavior.","PeriodicalId":333533,"journal":{"name":"2011 1st International Electric Drives Production Conference","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2011-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121769054","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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