Electric powertrain, custom-made for China
The powertrain system is highly scalable and covers the power range from 60kW to 120kW, making it a perfect fit for a broad range of vehicle types including plug-in-hybrids (PHEVs) to battery electric vehicles. Depending on the application scenario, the drivetrain is available in two engine variants – with an asynchronous motor (ASM) or a permanent magnet synchronous motor (PSM). The drivetrain will be shown at the upcoming IAA automotive show in Frankfurt (September 17 to 27).
The basic concept has been developed at Continental’s Berlin and Nuremberg (where also the company’s electric vehicles business unit is headquartered). For the development the engineers were inspired by many details of other concepts. By integrating transmission and power electronics many components such as connectors, cables and cooling water supply became redundant, resulting in significant cost reductions and at the same time 15% lower weight. The specific customer applications will be designed at Continental’s local subsidiary in China where the new powertrain will also be manufactured.
In PHEVs and EVs three-phase motors prevail. In these motors, the electric current flows through the stator winding and creates a magnetic rotating field which in turn causes the rotor inside the motor to move. With respect to this type of motor, experts discriminate between asynchronous motors (ASM) and two different types of synchronous motors: the permanent magnet synchronous machine (PSM) with magnets attached to the rotor and externally excited synchronous machines (SM), on which the rotor carries electromagnets in the form of excitation winding that is not magnetized until a flow of current is applied.
Which technology is used depends on the application. For example, an asynchronous machine generally serves as a simple belt-driven starter generator. However, if the installation space is particularly restricted and high performance is required, the permanent-magnet synchronous machine is the favorite. In the case of the direct-drive motor, all three technologies can in principle be used and make the most of their advantages. For example, the asynchronous machine is suited primarily to smaller electric vehicles due to its simple design. The compact and powerful permanent-magnet synchronous machine is preferred for use in sports and large electric vehicles, as well as in plug-in hybrids. Alternatively, the particularly energy-efficient synchronous machine technology is a good solution for this vehicle segment. It enables control of the rotor magnetization, which can minimize energy losses. "With the new, compact electric drive, we now have innovative solutions in our portfolio for all three motor technologies and can offer competitive tailor-made electrification for every vehicle type and every market," explains Bernd Mahr, Head of the Hybrid Electric Vehicle (HEV) Business Unit, which is part of the Continental Powertrain Division. According to the expert, customers can assemble the best technology and output in accordance with the modular principle. The modular structure of the machine means that only the rotor and length vary depending on requirements.
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