美国车桥AAM：高功率密度电驱动单元（EDU）-2026-01-技术资料

⑧

HighPowerDensityEDUwitha30kRPMMotorandHighlyIntegratedRingInverter

DavidCrecelius

AAM

AdvancedTechnologyDevelopmentCenterDetroit,Michigan

CTISymposiumUSA13-14May2025,DavidCrecelius,AAM

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AUTOMOTTVE·PROPULSION·SYSTEMS

BRINGINGTHEFUTURE

FRSTER

TopicsOverview

AAMOverview

Trends&BarrierstoHighSpeed

EDUDesign

ComponentFabrication&Build

MotorTesting&Results

SummaryComments

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CTISymposiumUSA13-14May2025,DavidCracelius,AAM

BRINGINGTHEFUTURE

AAMisaLeadingGlobalDrivelineSupplierFRSTER

Globalleaderindesign,engineeringandmanufacturingofautomotivepropulsionsystemsandtechnologiestosupportelectric,hybridandICEvehicles

$6.1B2024Sales

16Countries

Over75Locations

2024SalesByBusinessUnit

2024SalesByCustomer

2024SalesByGeography

SohAnerdea3%

11EngineeringandTechCenters

hcudestenpovary/contractandJVAssociaes

CTISymposiumUSA13-14May2025,DavidCracelius,AAM

3

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TrendsinElectricPropulsion

IncreasingMotorSpeedsandSystemIntegration

BRINGINGTHEFUTURE

FRSTER

30,0oPra

IncreasingRotorSpeeds

28,000RPM

26,000RPM

24,000RPM

22,000RPM

20,000RPM

18.00RPRM16.0PR

1.0oBPpw200oPea

10,000RPM

8,000RPM

00RPy

OEM5

5000RPM

OEM1

11,400RPMAAM

3.000RPM

1,163PM

OEM4

10,500FPM

OEM3

8,800RPM

SlancaioneMotor,

GeatboxInverter

inbgraledSatorand

Rotsr

CTISymposiumUSA13-14May2025.DavidCrecelius,AAM

AAMGen5

30,000RPM

AAM

6,000RPM

OEM6

16000RPM

SharedinwarterStructuralHousing

OEMB

20,000RPM

OEM715.500PPM16,000RPM

SharodGarandMobrCooling

AAMMGen4

24,000RPM

0EM7

20,000RPM

Supliar216,000RPM

CurentGenerationNextGeneralticn

rveraInegaled

InsideEDUHosng

AAMGen524,000RPM

MarketSpeedRange

IncreasingLevelofIntegration

InverterInegrahedat

MoorEndCol

IneterOICooing

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BRINGINGTHEFUTURE

BenefitsofHigh-SpeedMotors

FRSTER

■POWER=TORQUExSPEED

-Higherspeedenableslowertorqueforthesamepower

-Lowertorqueenablesaphysicallysmallermotor

·Lessactivematerial

·Lessmass

·Lesspackagespace

·Lesscost

AAM'sHigh-SpeedMotorReducesEDUsize,mass,andcost

MotorAssemblyComparison

Samepower,smallermotor,lesscost

CTISymposiumUSA13-14May2025,DavidCracelius,AAMctisymposium⁸

BRINGINGTHEFUTURE

BarrierstoHigh-SpeedMotorsFRSTER

BarriertoHigh-SpeedMotor

AAMSolution

Bearingife

Duallayshatgeardesignbalancesrotorshatbeaningloads

RotorBursting

Reducemotordiametetomaintaintipspeedwithinvalidatedlimits

InverterSwitchingLosses

Use4-polemotor(versus6-poleor8-pole)&SiCMOSFETs

ShatSealing

Integratemotorandgearboxtousesameoil;nohigh-speedshaftseal

GearPitchLineVelocity

Reducedmotorshaftgearpitchlinediameter

Cooling

Oicolinginstatorlaminationstackwithproprietaryoilpathdesign

CTISymposiumUSA13-14May2025,DavidCrecelius,AAM

HighlyIntegratedEDU-Sameoilusedforcoolingandlubrication

InnovativeDualLayshaft

Arrangement

RotorTipSpeed@Vmax

SiCRingInverter

SmallDiameterRotor

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M

RE

R

otorBarriers-HeavyRareEarth(HRE)Materials

AM

BRINGINGTHEFUTU

FRSTE

HREFreeMotorBarier

AAMSolution

MagnetCost&VolatilityforIPM

High-speed30kRPMinductionmotorwithcopperrotorbars(NoHREMaterials)

ReducedPerformance(vsIPM)

Improveeficiencywithinsulatedcopperrotorbars

Improvepowerdensityandcostbyrotatingathighspeeds

Improvemotorthermalperformancebyencapsulatingstatorwindings

Designmotor&invertertorunathighervoltages

pieie

High-SpeedMotorDesign

CTISymposiumUSA13-14May2025,DavidCrecelius,AAM

UninsulatedBar

InsulatedCopperRotorBars(AcrylicBasedPolyamide)

EncapsulatedStatorWindings

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AUTOMOTIVE·PRBOPULSION-SYSTEMS

AAM30kRPMHigh-SpeedEDUFRSTER

■224kWInductionMotorw/CopperRotor

■MaxOperatingSpeed:30kRPM

■DualLayshaft23:1GearReduction

■SiCRingInverter@650Vdc

■DielectricOilCooling:Motor,Inv,GearBox

■Motor&InverterVolume:9.07Liters

■PowerDensity:24.7kW/L(Motor+Inv)

-TeslaModel3PowerDensity:10.02kW/L

■HeavyRareEarth(HRE)MineralFreeMotor

■ProjectpartiallyfundedbyDepartmentofEnergy(DOE)cooperativeagreement

CTISymposiumUSA13-14May2025,DavidCracelius,AAM

ctisymposium⁸

BRINGINGTHEFUTURE

InductionMotorDesignSpecificationFRSTER

■UtilizedTeslaModel3assimulationplatform

■Constructedhigh-speedmotorspecsbasedonvehicleperformance(Front&Rear)

■DevelopedarrayofEMmotordesignsandselectedoptimal

Parameter

Units

SpecificationFrontMotor

SpecificationRearMotor

SelectedEM

Design

PeakTorque(motor)

Nm

144

192

199

PeakPower(motor)

kW

180

160

225

MaxMotorSpeed

RPM

30,000

30,000

30,000

GearReductionRatio

22.93

22.93

22.93

vmaxPower

KW

108

96

132

PeakTorqueatAxle

Nm

3302

4403

4563

PeakPhaseCurrent

Arms

350

DClinkVoltage

V

650

650

650

PowerDensity(motoronly)

kW/L

67.3

MotorStackLength

mm

152

MotorDiameter

mm

153

153

153

TurnsPerCoil

5

ParallelConnections

·

4

LaminationPower

Steel(kW)

M518M5203MI5211M15196

MI5224M5185MI5185M15173M15188M1518M5185M1515

M1597M5112

M15155

Sub-setofEM

Torque

(Nm)

260

239

196

196

199

143

149

144

205

130

130

117

136

136

175

StackLengh (m)

7

7

7

7

6

55

5.75

6

6

5

5

45

4

4

7

EndTumsmm

3030二30

30

30

30

30

30

30

30

30

30

30

30

30二

ToraueDensity(Metor)(nmu

63316055L.71517159814619464043286161453953944456656654617

Designs

Tota

Motor

volume

(L)

3.83.8二3.8

3.8

3.3

3.1

3.2

3.3

3.3

2.9

2.9

2.6

24

2.43.8二

Power

Denny

(Motor)Kw)

4881

53.5556□5171

67.32597657.615199565064.6064.600

70.28041□466

40的

SelectedDesign

Designwithhigherpowerdensitybutdidnotmeettorquerequirements

CTISymposiumUSA13-14May2025,DavidCracelius,AAM

ctisymposium⁸

BRINGINGTHEFUTURE

FRSTER

High-SpeedMotorEMDesign

MotorCadEMDesignSimulation

5h酬bm

mc

B4

8poodppm)

Spoedipm)

PeakTorque=199Nm

PeakEff=95.4%

PeakPower=225KW

CTISymposiumUSA13-14May2025,DavidCracelius,AAMctisymposium⁸10

Cross-SectionofMotorOnly&FullEDU

MotorOnlyDesign

PhaseLead

High-SpeedRotorConnections

DummyHousing

BRINGINGTHEFUTURE

FRSTER

FullEDUDesign

DCLinkCap

MOSFETs

Ringlnverter

RotorShaftInsert

EncapsulatedStatorGearbox

OilPump

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Cooling

CTISymposiumUSA13-14May2025,DavidCracelius,AAM

BRINGINGTHEFUTURE

FRSTER

StatorDesignandEncapsulation

EncapsulatedStatorDesign

·Overmoldedendturnswithintegratedfinsforimprovedconvectioncooling

·Phaseterminalsencapsulated

·Moldedsealingsurfacesonendturnsforoilflow

·Injectionovermoldedencapsulation

Overmksedonmtumwindings

154mmbondedstaorlanirabionstack

Mokdaed-inseaingsurfaoforMOSFET

oclingcavityInegratedoioinsktsinaminabionstack

Integaedfnsforimprowedoonwechonccingfhomolmeda

Oatirizadnspargandrafsrhighohmemandachuning

Crmoasdwedphasetemiealwmknurl

CTISymposiumUSA13-14May2025,DavidCracelius,AAM

EncapsulatedStatorHardware

12

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FRSTER

High-SpeedRotorDesign&Build

UninsulaedBar

CopperInductionRotor

InsulatedBar

Shaft

Endring

RotorLaminations

Copperbar

RotorShaftwithCoolingInsert

RotorCoreAssembledRotor

OilFlow

OilCooledRotorShaftwicoolingheatsinkinsert

LaserWeldedRotorAssembly

CTISymposiumUSA13-14May2025,DavidCrecelius,AAM

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BRINGINGTHEFUTURE

RingInverterAssembly

FRSTER

GateDriverPCB

InverterDesign&Components

·DCLinkVoltage:650Vdc

·MaxPhaseCurrent:350Arms

·PowerDevice:SiC1200V,TO-247(x24)

·PeakOutputPower:280KVA

·Invertervolume:1.415liters(IncludingCap)

LaminatedBusBar

CurrentSensorCore

Adaptor(3-DPrinted)

MOSFET+CopperSinteredHeatSinkAssembly

CTISymposiumUSA13-14May2025,DavidCracelius,AAM

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BRINGINGTHEFUTURE

SinteredMOSFETHeatsinkAssembliesFRSTER

SinteredHeatsinkAssemblies

■Developedprocessforsilversintering&coppersinteringofTO-247MOSFETtocopperheatsink

■FEAthermalanalysistoconfirmthermalperformanceofheatsinkdesign

·Thermaltestingofsilver&coppersinteredMOSFETassemblies

Performanceofsinteredjointsuperiortosoldering

■Built55coppersinteredassembliesforinverterbuild

HeatSinkDesign

AttachmentMethod

Solder(Baseline)

SilverSintered

CopperSintered

Rth

(CM)

.88.77.76

Coppersintered

heatsinktoTO-247

55coppersinteredassemblies

Flow(/min)

12

12

12

15

CTISymposiumUSA13-14May2025,DavidCracelius,AAMctisymposium"

BRINGINGTHEFUTURE

DualLayshaftHigh-SpeedGearboxFRSTER

DualLayshaftArchitecture

CompoundHelicalGear

RingGear

·Overallratio23:1

·Compoundhelicalgearsloadshareloadfromrotorshaft

·180°piniongearlocationcancelsaxialloadonrotorshaft

·Ringgearcombinesloadfromdualhelicalgears

·Reducedaxialloadonrotorgearenableslow-costhigh-speedbearingCTISymposiumUSA13-14May2025,DavidCracelius,AAM

GearboxAssembly

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EDUAssemblyFRSTER

FullIEDUbuildwithhigh-speedmotor,ringinverter,andduallayshaftgearreduction

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CTISymposiumUSA13-14May2025,DavidCracelius,AAMAUTOMOTIVE·PROPULSION-SYSTEMS17

BRINGINGTHEFUTURE

MotorOnlyTestingFRSTER

·Motoronlyunitassembledandsetuponhigh-speeddynofortesting

·Completedtestingaccordingtoestablishedtestplan

■Testedmotorto30kRPMunderno-loadconditionandto15kRPMloadedduetodynolimitation

·MotordrivenbySemikronSKAlinverter

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CTISymposiumUSA13-14May2025,DavidCrecelius,AAM18

BRINGINGTHEFUTURE

MotorOnlyTestResultsFASTER

Torque(Nm)

Torque:200.6

Nm

Peak

MotorperformancealignswellwithMotorCadsimulation

·

■

PeakPower:223.4

kW

Efficiency=95.35%

Motor

Peak

·

MotorTorque-SpeedCurves

·MesounedTorgem

●MotocCadTorgce(um

160.0

140.0

120.0

80.0

60.0

40.0

20.0

0.0

200040006000120001400016000

18

7M

700010

ctisymposiumu

800010000MotorSpeed(BPM)

PeakTorqueMeasuredvs.MotorCadSmulation

24306m00120001400

toeMmandel+leael

PowerMeasuredv.MotorCadsimalation

Motor

CTISymposiumUSA13-14May2025.DavidCracelius,AAMALTOMOTIVE·pROPULSION·5YSTEMS

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BRINGINGTHEFUTURE

MotorEfficiencyTestResultsFRSTER

TorqueRequest(%(

RotorSpeed(RPM)

1000

4000

7000

10000

11000

12000

13000

14000

15000

100

55.42

82.63

88.60

91.22

95

91.11

89

58.34

84.15

89.63

92.06

91.97

90.87

79

60.81

85.45

90.65

92.67

92.72

91.80

90.23

74

91.61

89.95

72

92.37

68

63.64

86.76

91.58

93.24

93.86

92.48

91.27

89.46

64

93.53

92.00

90.95

60

93.39

57

67.25

88.35

92.45

93.79

94.28

94.07

92.87

91.58

52

93.80

92.55

46

70.39

89.79

93.20

94.56

94.65

94.70

93.91

93.75

43

94.76

35

73.92

91.20

93.77

94.97

95.19

95.22

95.04

95.01

94.28

31

94.94

24

78.98

92.70

94.64

95.19

95.01

95.14

95.02

95.35

94.71

14

81.36

93.53

94.71

94.57

94.65

94.52

94.39

94.25

94.03

4

87.20

93.53

93.05

91.90

92.27

91.57

90.90

89.40

89.25

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CTISymposiumUSA13-14May2025.DavidCracelius,AAM20

BRINGINGTHEFUTURE

FullEDUDynoTesting

FRSTER

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CTISymposiumUSA13-14May2025,DavidCracelius,AAM

BRINGINGTHEFUTURE

DOEEDUPeakTestResultsFRSTER

■MotorSpeed:0-30kRPM

■PeakAxleTorque:4265Nm

■PeakPower:194kW

■PeakSystemEfficiency=91.4%

-Motor+gearbox+inverter

EDUAxleTorqueOutputRotorSpead(RPM)

000

4000

7000

10000

12000

14000

16000

18000

2000

22000

24000

26000

2800030000

100

4265

4212

4180

4154

80

3515

75

3246

3190

3153

3176

70

2890

60

2849

2776□

50

2191

2142

2106

2104

2434

45

2058

40

1758

1721

1883

1752

1718

30

1353

1245

1340

1343

25

1121

1071

1042

1029

1114

1013

20

828

827

867

798

852

836

841

883

858736

16

661650

15

605

607

637

12

476470

10

463

428

406

392

389

379

403

381

391

379

380

398

8

292291

5

157

159

162

162

4

114114

CTISymposiumUSA13-14May2025,DavidCracelius,AAMctisymposium⁸22

EDUAxleOutputPowerMap

%)st(Re

RotorSpeed(RPM)

BRINGINGTHEFUTUREFRSTER

1000

4000

7000

10000

12000

14000

16000

18000

20