Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.

Jaydip Das - Carpenter Technology Corporation

168 views

Published on

Jaydip Das's Talk at EV Momentum Berlin, 20 June 2018

Published in: Engineering
  • Be the first to comment

  • Be the first to like this

Jaydip Das - Carpenter Technology Corporation

  1. 1. When performance, range and efficiency matter Powder Dense Motor Solutions for Electric Vehicles
  2. 2. 2 Improved motor responses ▪ Faster response ▪ Greater force ▪ Lower loss Improving EV Performance via Better Alloys Soft magnetic alloy performance EV system level benefits Extended range Vehicle light-weighting Smaller battery packs Reduced charging times Lower total system costs Reduced form factor
  3. 3. 3 BH Curve Saturation Induction vs Core Loss Alloy performance comparison Motor Solutions: Carpenter Materials Outperform Other Alloys Saturation induction (T) CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of Carpenter Technology Corporation ▪ The highest induction alloy in the worldHiperco50A® ▪ High induction with higher thermal conductivityHiperco27® ▪ Alloy with a unique combination of high induction and low lossHypocore™
  4. 4. 4 Improved Permanent Magnet Motor Specs with Carpenter Alloys CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of Carpenter Technology Corporation DC bus voltage: 660V Max stator current (peak): 636A Comparison PM Motor Specs using Carpenter magnetic materials PM Motor Stator: Electrical steel Rotor: Electrical steel Stator: Hiperco50A Rotor: Electrical steel Stator: Hypocore Rotor: Electrical steel Peak Power (kW) 220 220 220 Max. speed (rpm) 10000 10000 10000 Max. torque (Nm) 488 546 (+12%) 497 (+2%) Peak efficiency (%) 95.5 97.8 (+2.3%) 97.5 (+2%) Continuous peak power (kW) 116 150 (+30%) 150 (+30%) Continuous max. torque (Nm) 335 368 (+10%) 349 (+4%) Motor weight (kg) 40 40 40 ▪ High power density ▪ High torque density ▪ Higher efficiency ▪ Increased motor life Key motor benefits Equipmake Ltd. APM 200
  5. 5. 5 Carpenter Materials Help to Improve Motor Power Density Flux distribution, electrical steel Flux distribution Hiperco50A 1.87-2.0T 1.75-1.87T 1.87-2.0T 2.25-2.37T 2.12-2.25T 2.25-2.37T Torque vs. speed Power vs. speed CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of Carpenter Technology Corporation Hiperco50A 0.15mm Hypocore 0.125mm Electrical steel 0.35mm 10% higher @Hiperco50ATransient Continuous 30% higher power density
  6. 6. 6 Carpenter Alloys Help to Save Power CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of Carpenter Technology Corporation 8-10% current saving for Hiperco50A 26% lower total loss for Hiperco50A Stator winding temperatures1 low speed (0rpm) Motor runs at lower temperatures Stator winding temperatures1 high speed (15,000rpm) Motors using CRS materials can offer significant power saving 0 1000 2000 3000 4000 5000 6000 M19 0.35mm Hiperco50A 0.15mm Totalloss(W) Rotor Stator Copper 6000 rpm Max current 20C lower temperature 15-60C lower temperature 74% vs. M19 Losses:
  7. 7. 7 Segmented stator stack Hiperco50A stator stack >97% stacking factor BEV Motor Prototyping Using Hiperco50A CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of Carpenter Technology Corporation Example prototype motor using Hiperco50 alloy. Wire wound segmented stack More assembly pics More assembly pics
  8. 8. 8 Coil wound segment Segmented stator design PM Motor Racing/High performance Motors CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of Carpenter Technology Corporation DC bus voltage: 595V Max stator current (peak): 85A Stator: Commodity steel Rotor: Commodity steel Stator: Hiperco50A Rotor: Commodity steel Peak Power (kW) 38 38 Max. speed (rpm) 20000 20000 Max. torque (Nm) 23.4 28.1 (+20%) Acceleration 0-62mph (s) 2 1.8 (+10%) Continuous power (kW) @10,000rpm 9.7 11.5 (+19%) Continuous torque (Nm) @10,000rpm 9 11 (+22%) Motor weight (kg) 3.3 3.35 Comparison PM Motor Specs using Carpenter magnetic materials ▪ High power density ▪ High torque density ▪ Higher efficiency Key motor benefits: Source: Stuttgart Green Team
  9. 9. 9 Motor Design Optimization can Improve Benefits CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of Carpenter Technology Corporation Torque vs. speed Hiperco50A motor efficiency map Higher torque from higher flux density Flux distribution, electrical steel Flux distribution Hiperco50A 23.4Nm 28.1Nm 1.89T 2.31T 0 10 20 30 40 0 10 20 30 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 M(Nm) N (min-1) Hiperco50A Electrical steel P(kW)
  10. 10. 10 CRS Materials Open up Options for EV/Motor Designers CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of Carpenter Technology Corporation CRS materials offer high power, energy efficient, durable motors BEV benefits ▪ Power Savings ▪ Cost saving ▪ Space saving ▪ Improved range ▪ Improved acceleration ▪ Durable motor ▪ Payload improvement ▪ Reduced charging time Motor benefits Higher torque 10-22% for Hiperco 50A 8-13% Hiperco 27 3-6% for Hypocore Improved efficiency 1-2% higher efficiency Lower Fe & Cu loss Improved motor life Less heat generation Motor design freedom Smaller motor Electrical Steel Hypocore Hiperco50A Electrical Steel Hypocore Hiperco50A Current Design Modeled Modeled Current Design Modeled Modeled nge (miles) 84 90 101 210 225 252 x torque (N m) 280 297 342 430 456 525 0 Mph (Sec) 9.9 9.3 8.1 5.5 5.4 4.5 p speed (mph) 93 93 93 130 130 130 tery pack (kWh) 24 24 24 60 60 60 tery weight (kg) 300 300 300 540 540 540 hicle weight (kg) 1,500 1,500 1,500 2,090 2,090 2,090 100 mile range passenger EV 200 mile range passenger EV Electrical Steel Hypocore Hiperco50A Electrical Steel Hy Current Design Modeled Modeled Current Design M Range (miles) 84 90 101 210 Max torque (N m) 280 297 342 430 0-60 Mph (Sec) 9.9 9.3 8.1 5.5 Top speed (mph) 93 93 93 130 Battery pack (kWh) 24 24 24 60 Battery weight (kg) 300 300 300 540 Vehicle weight (kg) 1,500 1,500 1,500 2,090 2 100 mile range passenger EV 200 mile range passen ~20% improvement Motor cost increase Battery cost savings Net cost savings Hiperco50A PM* Motor * PM motor (rotor + stator) 1 Based upon reference designs from Electric Bus Manufacturers. Hiperco® cost savings are significant 2 Modeling based upon $250kWh battery cost and current alloy prices. 13,600 20,000 10,000 0 -10,000 30,000 3,400 Hiperco50A PM* Motor Hiperco® cost savings are significant 24,600 100 mile range1 250 mile range1 350 mile range1

×