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Shaping the future - Romax R&D projects

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Originally presented in October 2013 at the Romax European Summit 2013

Originally presented in October 2013 at the Romax European Summit 2013

Published in: Automotive, Technology, Business
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  • 1. Shaping the future: An insight into Romax’s latest cutting-edge R&D projects Barry James – Chief Technical Officer 15th October 2013
  • 2. ETI HDV Project: Lower Drivetrain Parasitic Loss Reduction Project • Romax Technology leads £2.1m 4-year project funded by the UK Energy Technologies Institute (ETI) • The aim of this Project is to develop cost effective platform technologies targeting vehicle level efficiency improvements of 2-5% • Lead Partner – Driveline simulation, gear design for efficiency, advanced lubrication control • Development of new oil technology platform • Development of efficient bearings and gear surface coatings • Oil churning simulation and method development (CFD) • The demonstrator application is a heavy duty articulated truck axle Slide 2 CONFIDENTIAL © Copyright 2013
  • 3. LDV Project Objectives • The aim of this Project is to develop cost effective platform technologies targeting vehicle level efficiency improvements of 2-5%. • The project will focus on reducing losses through the following measures: Improved lubrication management to reduce churning losses Reduction of sliding friction of gears and bearings through improved coatings and surface finish Development of new oil technology platform increasing efficiency Reduction of gear mesh losses through enhanced gear geometry Slide 3 [Caterpillar/Magna/Klingelnberg] CONFIDENTIAL © Copyright 2013
  • 4. Tilt rig set up • Torque-to-turn measurement and oil flow visualisation • Variation of temperature, fill level, roll and tilt angle Slide 4 CONFIDENTIAL © Copyright 2013
  • 5. Axle rig set up Slide 5 CONFIDENTIAL © Copyright 2013
  • 6. ANSYS CFD Simulation and Romax Testing Slide 6 CONFIDENTIAL © Copyright 2013
  • 7. ANSYS CFD Simulation and Romax Testing Slide 7 CONFIDENTIAL © Copyright 2013
  • 8. MAGSPLIT: Magnetic Power Split Technology for Parallel Hybrid Electric Vehicles Funding body: UK Technology Strategy Board. Project partners: Magnomatics (lead), Ford Motor Company, Romax Technology, Arnold Magnetic Technologies. Duration: 2 years (2012-2014). Aim: Optimise Magnomatics’ magnetically controlled variable transmission (mCVT) for use in a power-split hybrid electric vehicle. Romax responsibilities: • Define the mCVT specification using Romax’s concept vehicle simulation tool, • Use energy flow analysis on test rig measurements to validate the simulation model. Slide 8 CONFIDENTIAL © Copyright 2013 Distribution Allowed
  • 9. The Problem: Sensitivity to Driving Conditions Slide 9 CONFIDENTIAL © Copyright 2013
  • 10. Driveline Efficiency Prediction and Optimisation against multiple drive cycles Key Activities 60 • 50 • 40 Speed [km/h] • 2000 HEV drivelines analysed against efficiency within 2 weeks Sensitivity against different drive cycles included in this analysis 30 20 10 Trends from Romax’s driveline efficiency calculation matched with Bosch’s more time consuming method 0 0 100 200 300 400 500 600 Time [s] 700 800 900 1000 Outcome • Romax’s driveline efficiency calculation can be used at concept selection stage to assess sensitivity to driving styles • No limit to the number of drive cycles that can be considered • Accuracy of method proven to be suitable for concept selection Slide 10 CONFIDENTIAL © Copyright 2013 Distribution Allowed
  • 11. Optimised Electric Drivetrain by Integration Funding body: European Union, through Framework Programme 7. Project partners: Robert Bosch (lead), Renault, GKN Driveline, ISEA / RWTH Aachen, Romax Technology, Fuchs, CIE Automotive. Duration: 3 years (2012-2015). Aim: Develop an electric vehicle drivetrain system with a highly integrated electric machine and transmission design. Interconnection to power electronics Romax responsibilities: Magnetless rotor Rotor sleeve Construction of housing Speed sensor • Carry out the concept gearbox design, Rotor dynamics Rotor oil cooling • Model the drivetrain to select the gearbox ratios for best overall efficiency, FEM calculation • Perform dynamic modelling of the complete drivetrain. Slide 11 Stator oil cooling Bearing technology Interface to transmission CONFIDENTIAL © Copyright 2013 Distribution Allowed
  • 12. Gearbox Concept Design 15000rpm – PP, 1 speed H:184.3 Height = Z axis Key Activities • Romax “reverse engineered” previous electric vehicle designs to get appropriate torque/size relationships W:384.2 Use of RomaxConcept to investigate a wide range of different design options (16 gearboxes in total) for packaging, weight and efficiency Width =X axis • L:431.8 Length = Y axis Outcome • RomaxConcept is validated as a capable tool for rapidly creating design concepts • Early stage assessment of designs for weight, packaging and efficiency 1-speed, 2 stage design Slide 12 2-speed, 3 stage design CONFIDENTIAL © Copyright 2013 Distribution Allowed
  • 13. Gearbox Efficiency Prediction and Optimisation Key Activities • 2010: Efficiency prediction validated against test data • 2010: Redesigned gears led to 2% improvement in gearbox efficiency, confirmed by test data • 2012: Romax predicted efficiency of all 16 concepts as input for concept selection Outcome • RomaxDesigner can has validated gearbox efficiency prediction • Capability for improving gear efficiency confirmed by test data • Early stage assessment of designs for weight, packaging and efficiency Slide 13 CONFIDENTIAL © Copyright 2013 Distribution Allowed
  • 14. Noise Prediction • Normal practice is to discover NVH problem during testing, then to create simulation model to discover “why” o Too late to do any work; too difficult to change anything System Concept System test System Detailing/ Sub-system design Sub-system test Sub-system Detailing/ Component Selection Component Test Component Detailing Slide 14 CONFIDENTIAL © Copyright 2013
  • 15. Noise Prediction: The Target • Avoid/eliminate the problem rather than identify it when it is too late • Provide insight to the design at a time when you can make a difference • Understanding/elimination is more important than accuracy early on System Concept System test System Detailing/ Sub-system design Sub-system test Sub-system Detailing/ Component Selection Component Test Component Detailing Slide 15 CONFIDENTIAL © Copyright 2013
  • 16. Response to Representative Unit Excitations • Focus on peaks of interest All Results (linear scale) Input Shaft (RPM) 3.0E-02 Torque ripple at low speed 2.5E-02 1st mesh TE at 8000 RPM Velocity (m/s) 2.0E-02 Structure-Torque Ripple Structure-1st TE Structure-2nd TE 1.5E-02 Structure-Unbalance Structure-0 Lobe_36Cycles Structure-6 Lobes_12Cycles 1.0E-02 Structure-6 Lobes_24Cycles Structure-6 Lobes_48Cycles 5.0E-03 0 lobe at 13000 RPM 1.0E-09 0 4000 8000 12000 16000 Slide 16 20000 24000 CONFIDENTIAL © Copyright 2013
  • 17. Understanding the peaks 0 Lobe at 13000 RPM • Noise radiation through motor end plate, matching with test experience o Design Action: • Use understanding of vibration to design rib patterns to reduce response Slide 17 CONFIDENTIAL © Copyright 2013
  • 18. Simulation of Driveability Key Activities • Dynamic model created for the driveline from concept model, automatically exported to Modellica and ADAMS using Dynamic FUSION • Driveline shuffle behaviour predicted and checked against torque ripple signal • Results matched with test and simulation data for other drivelines Outcome • Potential problems identified at early stages • Limits on torque ripple set early in motor design phase • Can investigate effect of mount stiffness on driveability Slide 18 CONFIDENTIAL © Copyright 2013
  • 19. Advanced Wind Turbine Drivetrains Funding body: UK Government Regional Growth Fund. Project partners: Romax Technology (technical lead), University of Sheffield Electrical Machines and Drives Group. Duration: 2 years (2012-2014). Aim: To develop a toolset for optimisation of electro-mechanical wind turbine drivetrains. Romax responsibilities: • Dynamic driveline modelling and analysis, • Lifetime cost of energy modelling, • Gear impact durability analysis. Slide 19 CONFIDENTIAL © Copyright 2013 Distribution Allowed
  • 20. Drivetrain concept optimisation tool Calculate & filter 1000’s of potential drivetrain designs in seconds Generator Rotor shaft assembly Modify components, achieve system level result! Gearbox Optimised drivetrain design Power electronics Slide 20 CONFIDENTIAL © Copyright 2013
  • 21. Method for the Rapid Design of ProtoDrive Efficient Hybrid Vehicle Drivelines Funding body: Technology Strategy Board UK Project partners: Romax , CMCL, UoS Duration: 2 years (2013-2015). Aim: To develop a process for the rapid concept design of hybrid electric vehicle systems. The process will enable the designer to rapidly perform highly productive investigations at the initial concept design stage of the driveline Romax responsibilities: • Leading the project and taking it to market • To develop tool to simulate and model gearbox concept designs and to create efficiency maps • To integrate the gearbox concept design with engine concept design and power electronics, motor and battery. Slide 21 CONFIDENTIAL © Copyright 2013 Distribution Allowed
  • 22. Summary • Romax continues to invest in innovative technical methods • “R&D” is not Blue Sky but is application-specific and ready for implementation • Aim is to lead to innovations in Simulation Technology that can move swiftly into software product, complete with: o Suitable case study o Validation o User experience Slide 22 CONFIDENTIAL © Copyright 2013

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