The requirements for four-wheel drive have increased, learn about card-issuing asynchronous motor-Xinda Motor- electric motors and EV accessories supplier|INDEX--

The requirements for four-wheel drive have increased, learn about card-issuing asynchronous motor

Date：2023-03-08　　　Author：XINDA MOTOR

The high-end development of new energy vehicles, the pursuit of stronger power, put forward higher requirements for acceleration from 100 kilometers. In particular, some high-end models are selling well, and the power index has become the focus of competition in the industry. The four-wheel drive scheme has become the standard configuration of high-end cars, and different four-wheel drive architectures have emerged in the industry, especially the auxiliary drive motor scheme. Different OEMs have different choices, including permanent magnet synchronous machines and permanent magnet synchronous machines. Mechanism, asynchronous machine auxiliary drive scheme, etc.

Stronger acceleration capability, higher cruising range, and better cost-effective models. These voices from end customers sound simple. In fact, it requires continuous extreme design in vehicle development and the introduction of new technologies and processes to launch products that are more competitive than the industry. Competitive models. Inovance United Power's leading electric powertrain (including power system) solutions can effectively solve this problem.

Inovance United Power 4WD electric drive system solution

As the second driving force besides the main drive, the auxiliary drive is currently positioned mainly for use in acceleration conditions, while other conditions are mainly used in anti-drag, which puts forward high requirements for zero torque loss in the scheme. Because the rotor has no magnetic steel, the asynchronous motor has low drag loss, and there is no sense of frustration when the permanent magnet synchronous machine plus disconnection mechanism scheme suddenly cuts in. The driving experience is better, and it has gradually become the mainstream of the industry. Based on the industry's latest technology and latest technology, Inovance United Power deeply explored the solution requirements, and pioneered the card-issuing asynchronous motor solution, which has stronger power performance, smaller drag loss, higher operating efficiency, and higher power density.

01 Stronger power and shorter acceleration time

With the same size and the same voltage and current input, the peak torque is increased by 9%, and the peak power is increased by 25%.

Inovance United Power relies on a mature card-issuing design platform to innovatively design asynchronous motor products, and the stator winding scheme is upgraded from traditional scattered wires to multi-layer card-issuing. The external characteristics are better, the vehicle is more powerful, and the acceleration time is shorter:

The flat wire solution has a higher split ratio, and a smaller ratio of leakage inductance to mutual inductance. Under the same size and same voltage and current input conditions, the peak torque is increased by 9%, and the acceleration performance at low speed is better. It is tailor-made for auxiliary drive;
4 pairs of poles scheme design, compared with the mature 2 pairs of poles scattered wire scheme in the industry, the end winding span is small, less copper is used and less heat is generated. In addition, the heat dissipation at the end of the hairpin winding in the oil cooling scheme is better, and the continuous working condition capability and frequent acceleration and deceleration capabilities are further enhanced, effectively supporting the multiple rapid acceleration and deceleration requirements of the vehicle;
By increasing the thickness of the winding paint, the flat wire can greatly increase the PDIV value, improve the insulation reliability, meet the needs of the high-voltage vehicle platform, and realize the extraordinary experience of fast charging for 200km after charging for 5 minutes. It can effectively solve the problem that the PDIV value of loose wire windings has limited room for improvement and it is difficult to meet the insulation requirements of 800V high-voltage platforms;

Hairpin asynchronous motor stator

Outer characteristics of hairpin asynchronous motor

02 Small dragging loss, high operating efficiency and longer battery life

The drag loss is less than 2kW, the maximum efficiency of the motor is increased by more than 1.5%, and the cruising range of the vehicle is increased by more than 2%.

From the design of the multi-layer card issuance scheme to the in-depth selection of cast aluminum materials, the operating efficiency of the motor is continuously improved. At the same time, the multi-dimensional optimization design of mechanical loss reduces the zero torque loss of the scheme. Achieve high efficiency during operation and low loss during non-operation, and comprehensively improve the cruising range of the vehicle:

Innovative use of new cast aluminum alloy material, conductivity ≥ 50% IACS, effectively reducing the resistance value of the rotor aluminum strip;
Multi-layer card issuance scheme design, the slot full rate has been greatly increased to about 70%, and the peak efficiency of the motor has increased by more than 1.5% compared with the industry's loose line scheme;
Cooperate with the asynchronous motor assembly to optimize the mechanical loss in multiple dimensions, including the development of a small aspect ratio solution, the precise optimization of the cooling oil circuit and the flow rate, etc., effectively reducing the zero torque loss of the assembly, dragging loss below 2kW@15krpm, and effectively improving the cruising range of the vehicle2 %above;

Hairpin asynchronous motor rotor

Issue card asynchronous motor efficiency map

03 Higher power density, smaller size and lighter weight

The power density of the motor is increased by 20%, and the weight of the whole vehicle is reduced by 10kg.

Innovative design of cast aluminum rotors, from the selection of cast aluminum materials to in-depth research on mass production processes, innovative use of new cast aluminum alloy materials, with better mechanical properties. Based on this, a 20krpm high-speed platform can be developed, with higher power density, small size, light weight, and better cost performance:

Yield strength ≥ 90Mpa, the maximum speed of the platform is 20krpm, the power density is 20% higher than that of the industry's 16krpm loose wire motor solution, and the weight of the whole vehicle is reduced by 10kg;
Optimize the height of the end wire package, which is more than 5mm lower than the traditional loose wire, and further improve the power density of the motor;
The peak speed of the motor reaches 20krpm, matching the peak speed of customer A up to 250km/h, which meets the export demand of overseas models and lays the foundation for subsequent models to expand overseas markets;

Structural Strength Simulation of Card Asynchronous Motor Rotor

At present, the asynchronous motor issued by Inovance United Power has been matched with multiple customer models, and batches will gradually start in 2023. Effectively boost the development of new energy vehicles and contribute to the early realization of the industry's dual carbon goals.

The requirements for four-wheel drive have increased, learn about card-issuing asynchronous motor

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