AFL Germany Electronics, formerly trading as AFL Stribel, has for many years been developing power control systems for items with large electric loads in a wide range of passenger-car and truck applications. This article gives an overview of the options for optimizing control systems for electric motors used in internal-combustion-engine cooling systems. It also describes some of the key insights gained over the many years of development work. Most automobiles use conventional DC motors to drive the forced-draught fans used for engine cooling. Developing, designing, testing and building a prototype for the electronic module for this system took about 10 man years. The 'cooperative design' succeeded in reducing the system's power dissipation. Once the industry transitlons to a higher voltage - and hence a lower current while retaining the same power output - this design will produce a further significant efficiency improvement. Integrating power control circuitry into electric motors is a huge challenge, especially given the unique requirements of the automotive industry. This article shows that development efforts that focus on the electronic and mechanical components as a single, integrated system are capable of achieving significant improvements. The technical performance of the single, integrated system surpasses that of all previous solutions in all areas - despite the enormous space constraints, The fact that the single, integrated system is more than 600 g lighter and more than 1000 cubic centimeters smaller than conventional solutions further underscores its cost neutrality. Producing the electronic circuitry and the motor does entail higher manufacturing, testing and logistics costs. The single, integrated system delivers greater electric efficiency than other solutions. The system is ready for the changeover to 42 Volt.
42V and 14V power-electronics integration into electric motors
Integration von 42V- und 14V-Leistungselektronik in elektrischen Motoren
2003
10 Seiten, 4 Bilder, 1 Tabelle, 4 Quellen
Conference paper
English
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