HEADS (RIP08/3)(Hybrid and Electric Advanced Drive

Systems)

Project partners:

Iskra Avtoelektrika d.d.

Hidria Rotomatika d.o.o.

HIDRIA Inštitut za materiale in tehnologijo d.o.o.

Hidria AET d.o.o.

Razvojno tehnološki center za vžigne sisteme in elektroniko d.o.o.

About project partners Iskra Avtoelektrika d.d.

◦ Iskra Avtoelektrika is a global supplier of starter motors and generators for internal combustion engines, electric motors and electrical drive and mechatronic systems for working machinery, means of transport and use of the renewable sources of energy.

Hidria Rotomatika d.o.o., industry of rotary systems◦ Within the Hidria Corporation, the manufacturing programme of Hidria Rotomatika

is located in the industrial pillar with an emphasis on automotive technologies, more precisely steering and drive train systems. The main products are die-cast aluminium components and electrostatic sheet metal and steel components.

HIDRIA Inštitut za materiale in tehnologijo d.o.o. (Hidria Institute for Materials and Technologies)◦ The Institute represents the main R&D basis for Hidria Rotomatika in the field of

automotive technologies.

Hidria AET d.o.o.◦ Important producer of innovative systems for diesel cold start, fuel heaters and

mechatronics parts for diesel engines generation up to EURO 6 and beyond.

Razvojno tehnološki center za vžigne sisteme in elektroniko d.o.o.◦ Supports mother company Hidria AET with research, development and validation

activities.

Project description Global chalenges – EU policy:

◦ 20% increase of energy efficiency◦ (Anticipated 10% increase in the use of el. and hybrid drive systems

by 2020)◦ 20% renewable energy share by 2020◦ 20% reduction in greenhouse gases (CO2, HC, NOx, Particulate

matter-PM)

Expected development direction of these products: introduction of high system voltage, high output power, speed and output torque.

Requirements: high fill factors above 70%, high efficiency above 95% and high specific power, for electrical motors 2kW/kg and for electronic controller over 10kW/liter

Solutions must provide high IP protection and EMC compatibility.

Project results1. Cold start system for diesel engine

◦ System for cold start for diesel engines including glow plug with pressure sensor either with metal or ceramics heater is assembled into diesel engine on the vehicle with corresponding control unit. Pressure sensor in the glow plug enable in-time control of combustion parameters in the cylinder and consequently achieving optimal conditions which lead to lower fuel consumption and lower emissions (NOx).

2. Electric machines - motor generators◦ Studies and practical solutions for contactless electrical machines with inserted

rare earth permanent magnets, induction generators, motors and alternators for hybrid and electric vehicles with system voltages from 12V up to 500V. The motor generators range from 2 kW to 50 kW of output power. The systems have integrated or separately installed control electronics. The studies also consider the advantages and disadvantages of direct drive inwheel electric motors to drive vehicles . With partners on this project a new vital parts such as stator and rotor laminated stacks were developed and have a defined production process with some real tooling trial run.

Project results3. Electronic controllers

◦ A group of controllers or more precisely motor inverters of different voltage levels (24 VDC ÷ 80 VDC or 600 VDC) for different powers (of a few kW to tens of kW) intended for driving AC induction motors or synchronous IPM (Inserted Permanent Magnets) BLPM (brushless) electric motors. The controllers are designed primarily for the use on hybrid and electric vehicles or vessels and they all support the four-quadrant mode of operation: in a suitable system with an electric motor/generator they allow energy recovery during braking of the vehicle or charging of the batteries while driving with internal combustion engines on vessels.

4. BAS (Belt Alternator Starter)◦ The BAS (Belt Alternator Starter) Start–Stop system was developed. Final tests

showed that the BAS Start–Stop system is capable of cranking the ICE (Internal Combustion Engine) and a stable operation in generator operation mode. Tests also confirmed that the ECU (Electronic Control Unit) aluminium housing is providing the sufficient cooling for controlers internal components.

5. Transmission, Cooling System end Electric Energy Storage Studies◦ Studies of Transmission, Cooling System end Electric Energy Storage provide

the basic guidelines for a successful development and the design solutions for the integration of electrical machines and ECU's in electric and hybrid driving systems.

Glow plug with integrated pressure sensorConnector Power line to the heater and feedback signal line from pressure sensor.

ASIC – Electronic circuit enable processing of signal from pressure sensor and send analog signal to engine control unit

Pressure sensor is integrated into glow plug body and detects pressure forces and transform them into electrical signal which ASICS can read

Heater function is to glow and consequently causes burning process of the fuel. It could be metal or ceramics type.

Ceramic heater

Metal heater Hidria AET

Innovative glow plug with piezo type of pressure sensor which significantly differs from existing solutions on the marked. Total system, heater and closed-loop control of combustion are critical factors to reduce fuel consumption and emissions of diesel engine. Market interest (important producers of diesel engines) for this system is enormous, so ambitious plans of Hidria AET to became one of 3 leading players in this segment is real.

BLPM electric motor - ERAD Electric Rear Axel Drive

Iskra Avtoelektrika d.d.SBU- Driving systems

Electric motor convenient to drive electric and hybrid vehicles is designed to fit in the rear axle together with the differential gearbox :• Electric motor output power of 50kW on 300V to

400V system voltages.• Two working modes: Vehicle Propulsion and

Braking • During braking the kinetic energy is recuperated to

electric energy and stored to the battery.• Brushless solution without maintenance• Integrated high energy NdFeB permanent magnets

for working efficiency over 92%• Reduces the vehicle fuel consumption to an extent

of more then 30% and accordingly reduces the environmental pollution .

Iskra Avtoelektrika d.d.SBU- Driving systems

Electric generator for hybrid vehicles suitable to be mounted on the Internal Combustion Engine:• Works as High Voltage DC generator with

10kW continuous electric power output on 300V to 400V systems.

• Intended for belt drive similar to alternators• Regulated output voltage is controlled with

correspondent Electronic Control Unit.• Brushless solution without maintenance.• Integrated high energy NdFeB permanent

magnets for working efficiency over 92%• Reduces the vehicle fuel consumption and

accordingly reduces the environmental pollution .

BLPM generator - HVG High Voltage Generator

AC electric motor-generator

Superpiki (Andrej Pečjak) with electric motor from Iskra Avtoelektrika d.d.

Iskra Avtoelektrika d.d.SBU- Driving systems

Electric motor suitable to drive electric vehicles:• Works as a propulsion motor with 15kW

output power on 48V DC system voltages.• Motor to be driven with vector control mode

provided with correspondent Electronic Control Unit

• Brushless solution without maintenance.• Provides zero emission vehicle drive.

Stator lamination and rotor package

Basic materialELECTROSTATIC SHEETMETAL

Prototype

Rotor package HRB

Additional accompanying operations

Product analysis and measurements

Stator lamination quality check

Prototype Stator lamination HRB

Stator lamination and rotor package manufacture on a progressive stamping tool

Stamped-out stator laminationand rotor package

Preparations, equipment

Preparations, equipment

Preparations, equipment Additional procedures androtor package validation

Material analysis

Product industrialization case – HRB product

HIDRIA Rotomatika d.o.o.HIMIT d.o.o.