The paper describes the powertrain and electric system design of a rear wheel driven 800-Volt e-Car which was built into the vehicle platform of a Mercedes C-Class Coupe. The e-Car concept is characterized by the following core innovations: All traction components (E-Motor; Inverter; HV-Battery) operate on a nominal voltage level of 675 Volt with 1200 Volt IGBT Modules being used. Avoidance of active short circuit (ASC) in case of inverter malfunction: due to withstand voltage of power electronics (1200 Volt) and respective E-Motor system design the powertrain can be operated in "free-wheeling" at any inverter malfunction, avoiding negative torque on the traction axle. The traction motor (PSM) features a direct liquid cooling concept of the stator windings, which guarantees highest power density in automotive applications. HV-Battery: Highest power and energy density due to an innovative and multiply patented cooling concept (liquid cooled busbar) on the one hand side and the usage of pouch cells on the other side. The publication describes in detail the advantages and disadvantages of using 1200 Volt IGBT technology in sporty and powerful vehicle concepts as well as its general impact on component and system design. The presented paper clearly demonstrates that a higher voltage level (1200-Volt-IGBT-Technology) appears to be a promising trend in the development of fully electrified e-Cars with powerful and sporty traction systems. Not only the reduced powernet-current in the complete wiring harness, power electronics, traction motor and HV-battery but also the additional degrees of freedom in system design (e.g. avoiding Active Short Circuit) approve the future development potential of this technology. Apart from the "800 V core innovation" the Coup-e 800 features additional innovations in e-Car component design. The direct fluid cooling of the stator winding of the traction motor as well as the use of pouch-cells in the HV-battery are promising development steps in order to increase power density of those powertrain components respectively bringing down weight of those "eCar-core-Components". Developing all three major powertrain components as well as the necessary controller intelligence (BMS, ICU) in-house AVL offers a sustainable engineering experience in the development of "800-Volt electric powertrain technology".
Coup-e 800: powertrain and electric system design of a rear wheel driven 800-Volt e-Car
2012
13 Seiten, 8 Bilder, 1 Tabelle, 5 Quellen
Aufsatz (Konferenz)
Datenträger
Englisch
Personenkraftwagen , Coupe , Hinterradantrieb , Elektroantrieb , Kfz-Bordnetz , Hochspannungsanlage , Leistungselektronik , Kraftfahrzeugbatterie , Wechselrichter , Batteriemanagement , Kühlung , elektrische Leistung , Energiedichte , IGBT-Modul , elektronische Steuerung und Regelung , Antriebsstrang
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