volabo gmbh iscad 48 volt traction drives · introduction of iscad –the inverter 48 volt traction...

volabo GmbH • www.volabo.com

Introduction of a Safe, Cheap and Efficient Alternative

ISCAD – 48 Volt TractionDrives


Market for EVs Rapidly Growing

48 Volt Traction Drives 2

Costs for batteries dramatically decrease Sales of EVs rapidly grow

Especially Chinese market exploding

Significant share at premium class cars already obtained

0

2010 11 12 13 14 15 2016

Average battery pack price

$ per kWh

227

540

599

1,000

400

300

500

2030 forecast100

200

700

900

800

600

1,000

269

-77%

800

642

227

2020 forecast


Challenges for E-Mobility


Existing EVs use HV batteries/drives

High cost for HV safety

High servicing effort for HV drive

Unpredictable behavior of HV system in case of crash

Safe high performance

E-drives possible?


48 Volt Competition

4

Electric motors exist for over 150 years, but engineering for automotive traction has just started

High power at 48 V is unachieved by others

Our drive is a game-changer – and the industry is paying more and more attention to volabo

48 Volt Traction Drives


Why do today‘s drives operate at 400 VDC?


Three good reasons:

Adaptation of available

industry technology

Current „limit“ from

cable harness satisfied

Hand-pluggable fast-charging

made possible


Battery

Voltage up to 800 V

Many Cells in Series

Few Paths in Parallel

Isolated BMS

State-of-the-Art – Conventional Drives


Electrical Machine

Wound Copper Coils

Poor Utilization

High Thermal Resistance

Complex Production

Electrical System DC

Low Wiring Cross-Sections

Insulation Monitoring

2-Pole Circuit Breaker

Electric Field Shielding

Inverter

HV Ratings (600 V)

3 Half Bridges

PCB/DBC

Isolated Heatsink


The Stator Winding – every Manufacturer‘s Nightmare


Linearwickeln FlyerwickelnNadelwickeln Einziehen Hairpin

Quelle: PEM | RWTH Aachen


Introduction of ISCAD – The Electric Motor


No more coils. Massive stator cage

Perfect utilization of available space

• Perfect slot filling factor

• No end-windings

Great thermal behavior

• Low thermal resistance bar – iron

• Water cooled ring

Minimum production cost

Aluminum instead of copper

Simple production, e.g. die-casting, low invest

Extremely smooth rotating field

Individual bar currents

Very high efficiency


Introduction of ISCAD – The Inverter


Highly parallel setup

One half-bridge per stator bar

Moderate currents

Extra-low voltage MOSFETs

Extremely low on-resistance

High current capability

Cheap mass production devices

Intelligence inside

Dedicated control of every single phase

Optimization of

• Efficiency

• Capacitor current

• Life time

• …


Six PolesFour PolesTwo Poles

Individual bar currents

Extremely smooth air gap magnetic field

Different numbers of pole pairs possible

ISCAD – Revolution in Drive Control



Overload Area

0

0,2

0,4

0,6

0,8

1

0 0,2 0,4 0,6 0,8 1

Vo

ltag

e (

p.u

.)

Current (p.u.)

IGBT

MOSFET

ISCAD – Top Class Efficiency


Revolution in drive control

Pole pair switching

Torque/speed scaling

Multiple efficiency maps

“Electric gearbox”

Extension of operating area

Low voltage inverter

MOSFETs instead IGBTs

Synchronous rectifying

RDSon instead constant VF

Excellent partial load efficiency

↓ Losses

p1 < p2 < p3 < p4

To

rqu

e

Speed

p4

p3

p2

p1


ISCAD – Top Class Efficiency


Evaluation of driving range


ISCAD: Hochleistung-Traktionsantrieb bei 48V Systemspannung

13

Energy consumption in different driving cycles

48 V ISCAD

400 V PM-Motor

400 V Induction Motor

+24%

+37%+34%

+26%

+18% +31%

48 Volt Traction Drives


ISCAD – Reduced Energy Demand


Reduced energy

demand by ISCAD

Reduced loss in power net and battery

Reduced energy demand of lighter

vehicle

-30 %

Reduced battery size and weight for equal range

-3 %

Reduced battery size

and weight for equal range

-5 %


ISCAD – Enhanced Driving Range


P85 Standard

P85 ISCAD

424 km EPA

530 km EPA


Introduction of ISCAD – The Battery


Highly parallel setup

Reduction of module capacity variance

Reduction of balancing effort

Outstanding fault tolerance

Increased energy per cycle by around 2 %

Increased service life time

Low battery voltages

Non-isolated BMS

Simple CID

Extra-low voltage standard

No HV safety measures

Cost savings on vehicle level

Electrically safe system

0

5

10

15

20

25

30

35

40

-1 -0,9 -0,8 -0,7 -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1

Fre

qu

en

cy o

f o

ccu

rren

ce (

%)

Deviation of module capacity (%)

74p modul

547p modul


ISCAD – Safe Mobility


Electrically safe system even in case of crashes

No HV safety necessary – less cost in development, production and product

Maintenance of vehicles by conventional mechanics/workshops

Carefree vehicle maintenance/modifications by customers

Very high redundancy – failures in components do not break whole system down


Conclusion


ISCAD is a novel type of e-drive system

High performance at extra-low voltages

Extremely simple machine production

Top efficiency in whole operating area

150 kW prototype in 2016

Machine without copper and magnets

Powerful LV MOSFET inverter

48 V battery

volabo GmbH founded

Pushing ISCAD into product stage

Development from e-motor to charging infrastructure

Partners welcome


Disruption already happened in the automotive sector


5th Ave, New York, Easter 1900 5th Ave, New York, Easter 1913

„Moving Assembly Line“: 1913


THANK YOU

VIELEN DANK谢谢

MERCI

grazie

GRACIAS شكرا

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Спасибо дякую

mu

lțu

me

sctack

хв

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ва

м

cảm ơn bạn

köszönöm

teşekkür ederim

děkuji

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asa

ntem

ah

ad

sa

nid

hva

laďakujem

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tapadh leat

ਤੁਹਾਡਾਧੰਨਵਾਦ

paldiesa

čiūterima kasih

ти благодарам

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धन्यवाद

da

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رمکشمت

dziękuje

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ありがとう

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volabo gmbh iscad 48 volt traction drives · introduction of iscad –the inverter 48 volt traction...

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