Voltage ranges from 48V to 800V and performance classes from 15kW to over 300kW are possible. Volume production for a range of customer projects worldwide is set to begin in 2021.
Since the last remaining technology gap, stator manufacture, was closed by the acquisition of Elmotec Statomat at the end of 2018, the company can now fully cover the industrialisation of electric motors. Comprehensive expertise in mechanical components, manufacturing processes and winding technologies, as well as an in-depth understanding of all vehicle systems, guarantee short development times and ensure smooth processes in the production of technologically sophisticated electric motors.
Electric motors for P2 hybrid modules are subject to special requirements, as their design means that they run at the same speed as the internal combustion engine. Minimal axial length and ample free space inside the rotor for the integration of clutch and release system ensure the necessary high packing density for this application. Single-tooth winding allows extremely small axial installation spaces. Both 48V and high-voltage motors with ratings of 15 to 120kW are available. As the hybrid module is designed as a dry system, the stator is actively cooled using a cooling jacket. In systems with a wet clutch, the oil that is available can also be used to lower the temperature of the electric motor, which leads to significantly better heat dissipation and thus higher continuous output levels.
Depending on the design envelope, the same can apply for electric motors in dedicated hybrid drives. These transmissions are usually designed in such a way that more axial installation space is provided for the electric motors, which rotate faster. Output levels of 80 to 140kW are common. Depending on the transmission and powertrain operating mode, these motors work together with the internal combustion engine as motors or generators, and their efficiency characteristics are optimised in accordance with the utilisation profile. As a result of the all-electric driving modes of plug-in hybrids, their acoustic behaviour becomes a prominent factor. In many cases, the use of distributed windings is the right solution. To this end, Schaeffler has defined a second standard winding solution. To provide a specific application, a traction machine was developed that has an overall axial length of 137mm and delivers 125kW of power and 310Nm of torque.
The portfolio is completed by a range of electric motors for driving electric axles. These cover both high-voltage 2 (400V) and high-voltage 3 (800V) ranges, and outputs of 100kW to 300kW are possible. If the system design permits, these motors are configured for high maximum speeds of up to 20,000rpm. The high number of stator grooves means that the temperature is lowered effectively and leads to a rotating field with a low number of harmonics, which brings two benefits: a high power density and excellent efficiency.
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www.schaeffler.co.uk
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