Development and Optimization of Electric Drivetrains
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BorgWarner
Development and Optimization of Electric Drivetrains The necessary reduction of carbon dioxide and particulate emissions leads to a rapidly expanding range of vehicles with electrified drivetrains. BorgWarner is helping automotive companies to meet this demand by leveraging its expertise in power electronics, electrical machines, and transmissions to produce highly optimized components and systems. There is no one-size-fits-all solution and so a range of tailored solutions are needed to best match the needs of the vehicle and the electrification technology.
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A U T H O RS
Dr. Peter Barrass is Engineering Director at BorgWarner in Gateshead (UK).
Steve Stover is Senior Manager Product Strategy at BorgWarner in Noblesville, Indiana (USA).
Dave Fulton is Director of Electric Drive Innovation at BorgWarner in Noblesville, Indiana (USA).
VEHICLE REQUIREMENTS
It is vital that vehicle requirements are fully understood when starting to design the best possible powertrain for an application. This is a process that starts with the initial customer enquiry and builds substantially with the OEM customer requirements spe cification. However, the requirements really only become properly under stood when the various engineering teams have talked to each other and agreed on the details. This process is especially important for an electric drivetrain which will be designed to meet the Functional Safety standard ISO 26262. Compliance with this standard demands not only a high degree of rigor, but also means that the OEM can only satisfy the standard at the vehicle level if the drivetrain subsystem (known as an ‘item’ in ISO 26262) meets all of the requirements placed on it. Conversely, the drivetrain developer needs to understand parts of the wider vehicle system and how they may impact the operation of the drive train. Having a highly skilled and ex perienced engineering team is vital to understanding the customer’s unwrit ten needs and nuances as well as those in the published specifications.
From a performance point of view, the starting point is to understand the vehicle dynamics, most importantly the top speed, the required acceleration and the maximum gradient. When combined with the vehicle mass and wheel diame ter, these parameters can be used to cal culate the required torque at the wheel and the maximum rotational speed of the wheels. Knowing the vehicle architecture is important in order to match the wheel torque and speed to the electric drive train. In P0 and P1 systems the electric drivetrain cannot be decoupled from the combustion engine, FIGURE 1. But in P2, P3 and P4 architectures, the ve hicle can be driven by electric power alone with the combustion engine de activated. BorgWarner has a wide range of products covering all these archi tectures, some of which are shown in FIGURE 2. This article focuses on the P4 hybrid and pure electric architectures. SYSTEM DESIGN
Having established the vehicle level re quirements, the next step in the design of an optimized powertrain i
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