BorgWarner DrivetrainSystems eGearDrive高效电动车驱动桥
8 Dec, 2011
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PDF created with pdfFactory Pro trial version www.pdffactory.com BorgWarner Overview
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PDF created with pdfFactory Pro trial version www.pdffactory.com BorgWarner = Powertrain Innovation
Engine 72% / SALES Drivetrain 28% / SALES
Turbo Systems Morse TEC Drivetrain Systems ® • AWD Couplings • Wastegate • Engine Valve Timing Systems • DualTronic Systems for Dual Clutch Transmissions • Variable Turbine Geometry • Timing Chain • Transfer Cases (VTG) • Transmission Control Modules • eGearDrive® Electric • Variable Cam Timing and Solenoids • Regulated 2-stage ® Drive Transmissions • HY-VO Transmission Chain • High Pressure Transmission (R2S™) • eAWD Torque Vectoring Control and Actuation Systems BERU Systems • AWD Electronic Controls • One-way Clutches • Glow Plugs and Systems Integration Thermal Systems • Friction Plates • Thermal Management • Instant Start System Components and Systems • Pressure Sensor Glow Plugs • Visctronic® Systems • Spark Plugs Morse TEC Drivetrain • Fans/Fan Drives • Ignition leads, Ignition Cables Thermal Systems • Ignition Coils Systems Emissions Systems • Sensor Technology • Exhaust Gas Recirculation • PTC Cabin Heaters (EGR) Valves • Tire Pressure Emissions • EGR Coolers & EGR tubes Monitoring System Systems • Integrated EGR Modules • Secondary Air Systems Turbo • Actuators BERU Systems Systems
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PDF created with pdfFactory Pro trial version www.pdffactory.com Drivetrain Systems Global Footprint
Ketsch, Auburn Hills, MI Ochang, Germany Dalian, USA Arnstadt, S. Korea Bellwood, IL China USA Germany Frankfort, IL Eumsung, USA S. Korea Heidelberg, Germany Beijing, China
Shanghai, Addison, IL China USA Livonia, MI Longview, TX USA USA Tulle, Monaco Seneca, SC France Tokyo, Juarez, USA Fukuroi, Japan Mexico Japan Water Valley, MS USA Pune, India Sirsi, India
Manufacturing Plant Sales / Admin Headquarters Tech Center Americas Europe Asia 9 Locations 5 Locations 9 Locations 4
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100 ~100% Growth 11.6 90 350+% Growth 5.8 2-10% 80 2.1 9.0 6.7 70 1.2 0.9 17.7 22.2 60 4.7 10.1 75% Growth 25% Growth 50 8.0 4.0 1.4 2.0 12.6 40 0.9 30 45.8 47.0 M il l i on s o f T r a n m ss ons 20 36.0 10 0 2010E 2015E 2020E
Dual Clutch 6/7/8 Speed Step Automatics Full HEV/PHEV/EV 3/4/5 Speed Step Automatics Continuously Variable Automated Manuals Manual Trans 6
Source: CSM, BorgWarner forecasts (July 2010)
PDF created with pdfFactory Pro trial version www.pdffactory.com BorgWarner = Dual Clutch Technology
§ Global DCT volume of nearly 6 million units by 2015 § BW DualTronicTM content in > 80% of global market by volume § Programs with VW/Audi, Ford/Getrag, BMW/Getrag, SAIC, FAW, Nissan, and other Chinese and Japanese customers 7
Source: CSM, JD Power, BorgWarner forecasts (July 2010)
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Increasing Electrification Internal Combustion Engine (ICE) Electric Motor Electric Motor + Electrification + ICE Only
Hybrid Electric Plugg--In Electric “HEV”
Stop/Starrtt HEV Mild HEV Full HEV RangPeH EEVxtender PEV Parallel Parallel/Series Series HEV Electric Vehicle
§ Engine Stop-Start Stop/Start HEV + Mild HEV + § Electric motor as § Electric motor as § Regen braking § Electric only driving primary drive primary drive § Power boosting mode § ICE driven § Range limited to § Some with plug-in generator as battery capacity capability range extender
Smart Hyundai Sonata Hybrid Prius GM Chevy Volt CODA Sedan Ford Transit Connect % of Total LV % of Total LV % of Total LV % of Total LV 2015 ~19% 2015 <1% 2015 ~2.5% 2015 ~1% 2020 ~25-35% 2020 ~2-4% 2020 ~4-10% 2020 ~2-10% 8 Source: BW & CSM (July 2010)
PDF created with pdfFactory Pro trial version www.pdffactory.com BorgWarner = Hybrid & Electric Vehicles
BorgWarner is developing advanced powertrain products for HEVs vehicles driving efficient use of electrical energy
Driving the Engine Turbochargers Electronic Coolant HY-VO® Chain Driven Valve Alternator/Starter Module
Driving the Wheels DualTronic™ DCT eAssist Disconnect eGearDrive® Clutch Transmissions*
Driving the Accessories Air Heater Water Heater Hybrid Coolant H y brid Fan Pump Drive 9 *Single and Multiple Speed
PDF created with pdfFactory Pro trial version www.pdffactory.com Key Factors for Electric Drive Transmissions
§ Highest efficiencies will be critical to maximizing driving range (impacts battery range and cost) § Higher input speeds § High sensitivity to Noise, Vibration, and Harshness (NVH) § Less gear ratios § High duty cycle of forward and reverse torques (regenerative braking) § Light weight and compact designs
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PDF created with pdfFactory Pro trial version www.pdffactory.com eGearDrive® Product Range
Speeds / Vehicle Input Available Reduction Center Max Input Model Driveline Segment Torque Park or Ratio Distance Speed Family Architecture Focus Rating Disconnect Range 31-03 Transverse Drive Mechanical or (primary & secondary) 200 Nm electric park lock B/C+ Single Continuous 210 mm 14,000 Rpm Electric driveline Segment (300 Nm peak) 6.5 to 9 disconnect
SOP 2010 32-01 Longitudinal Drive
Light Duty Single 200 Nm Commercial Mechanical or 2 to 3 95 mm 10,000 Rpm Continuous
G e a r box Fleet electric park lock Truck/Van (300 Nm peak) Prototype 34-01 Longitudinal Drive
Medium Duty 400 Nm Multi-speed Mechanical or
G ea r box Commercial 110 mm 10,000 Rpm Continuous 3-speeds electric park lock Fleet Truck/Van (650 Nm peak)
In Development
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PDF created with pdfFactory Pro trial version www.pdffactory.com BorgWarner 31-03 Single Speed eGearDrive
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PDF created with pdfFactory Pro trial version www.pdffactory.com 31-03 eGearDrive®
Electric Drive Transaxle Technical Features • Mass: 28Kg* • Speeds: Single • Available reduction ratios: 6.54, 7.17, 8.00, 8.28, 8.76, 9.07 • Efficiency: >97% • Rated input torque: ~200 Nm continuous** (300 Nm peak**) • Max input speed: ~14,000 rpm • Center distance: 210 mm • Lubrication: Splash • Park lock system § Electronic shift-by-wire park lock system (ePark) § ECU integral to actuator (CAN capable) • E-machine interface: Adaptable flange • Status: SOP Q3 2010 (CODA Sedan – lead program) *Core unit without motor adapter and without ePark **Nominal rating – dependent on reduction ratio 13
PDF created with pdfFactory Pro trial version www.pdffactory.com Announced eGearDrive® Programs
Application Left View Right View 31-03 CODA Sedan (2010 SOP)
31-03 Ford Transit Connect (2011 SOP)
31-01 Tesla Roadster (In production since 2008)
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PDF created with pdfFactory Pro trial version www.pdffactory.com Automotive X-Prize Finalists: Aptera 2e and ZAP Alias
Aptera 2e (179 MPGe) ZAP Jonway Alias (124 MPGe)
Remy Motor
BorgWarner 31-03 eGearDrive UQM Motor Transmission 15
PDF created with pdfFactory Pro trial version www.pdffactory.com 31-03 eGearDrive® Competitive Attributes
§ Adaptable Design § Adjustable to any electric motor interface § Accommodates different vehicle packaging (10 to 90 drop angle) § Wide range of reduction ratios (6.54, 7.17, 8.00, 8.28, 8.76, 9.07) § Efficiency and Noise § High efficiency helical geartrain – all ball-bearing construction Adaptable e-machine Wide range of gear interface § Pumpless lubrication (no oil pump) reduction ratios Electric park lock § World class noise levels § ePark System § Electronic shift-by-wire park lock
§ CAN enabled for ease of vehicle integration High efficiency low noise gear train (no oil pump) 16
PDF created with pdfFactory Pro trial version www.pdffactory.com 31-03 eGearDrive® Competitive Attributes
§ Adaptable Design
§ Efficiency & Noise
§ ePark System
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PDF created with pdfFactory Pro trial version www.pdffactory.com Adaptable Design – Gear Ratios
250
200 Gear Ratios 150
10.0 100
9.1 P o w e r ( k W) 50 9.0 8.8 8.3 0 8.0 0 2000 6000 10000 8.0 14000 Speed (rpm) 7.2 7.0 6.5 Input
R e d u c t io n a 6.0 from motor 5.0 A - D A - E B - D C - D B - E C - E Gear Combinations
Output Output to left to right wheel wheel
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PDF created with pdfFactory Pro trial version www.pdffactory.com Adaptable Design – Motor Interface and Orientation
§ Flexible Drop Angle § Fill & drain options
§ Universal mount bosses 10º to 90º § Positive vent position
§ Adaptable e-Machine Interface § Unique motor flange adapter design § Various input shaft connection options 19
PDF created with pdfFactory Pro trial version www.pdffactory.com 31-03 eGearDrive® Competitive Attributes
§ Adaptable Design
§ Efficiency & Noise
§ ePark System
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PDF created with pdfFactory Pro trial version www.pdffactory.com Efficiency -Gear Design
§ Helical Gears § Low Noise Transmission § Total Contact Ratio >4 on first mesh for reduced high speed mesh whine § Modified Tooth forms § Fatigue Performance § Ground AGMA class 10 § Surface finish for high speed rolling § High Speed Performance § Surface finish for reduced flash temperature
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PDF created with pdfFactory Pro trial version www.pdffactory.com Efficiency – Deep Groove Ball Bearings
§ Offset architecture to accommodate deep groove ball bearings § Ball bearings are larger but….. § No system preload (as in tapered rollers) § Lower parasitic losses § Lower running temperature
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PDF created with pdfFactory Pro trial version www.pdffactory.com Efficiency – Pumpless Lubrication
§ Pumpless Design § Utilizes the natural pumping action of gears to lubricate bearings and seals § Oil gallery and fluid level to accomplish distribution goals § Supports multiple drop angles
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PDF created with pdfFactory Pro trial version www.pdffactory.com Efficiency – 31-03 eGearDrive®
Efficiency = Driving Range 31-03 eGearDrive Efficiency
98.0
96.0 § Efficiency 94.0 92.0 § Peak ~ 97% Eff 90.0 84.0-86.0 86.0-88.0 § Normal Operating 88.0 Condition ~ 96% 88.0-90.0 90.0-92.0 86.0 92.0-94.0 94.0-96.0 96.0-98.0 84.0 225 500 125 2 0 00
3 5 00 Torque (Nm) 5000
6 500 25 8 0 00
Speed (RPM) 9500 110 00
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PDF created with pdfFactory Pro trial version www.pdffactory.com Noise Quality
Tesla 31-01 vs. Gear Drive Transfer Case System Acoustic Response Tesla – BLACK Premium Vehicle Powertrain -RED
Premium Vehicle Overall Tesla Overall Noise Noise
Premium Vehicle Gear Tesla Gear Noise Noise
§ Drivers have a noise expectation § Modern vehicles have very good noise quality § Electric vehicles need to have equivalent or better noise quality
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PDF created with pdfFactory Pro trial version www.pdffactory.com 31-03 eGearDrive® Competitive Attributes
§ Adaptable Design
§ Efficiency & Noise
§ ePark System
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PDF created with pdfFactory Pro trial version www.pdffactory.com ePark Advantage
Mechanical Systems ePark § High mass Versus § Shift-by-wire park lock § High build variation § Integral ECU § High complexity § CAN enabled § Easily adaptable
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PDF created with pdfFactory Pro trial version www.pdffactory.com BorgWarner 34-01 Multi-Speed eGearDrive
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PDF created with pdfFactory Pro trial version www.pdffactory.com eGearDrive® Core Product Range
Speeds / Vehicle Input Available Reduction Center Max Input Model Driveline Segment Torque Park or Ratio Distance Speed Family Architecture Focus Rating Disconnect Range 31-03 Transverse Drive Mechanical or (primary & secondary) 200 Nm electric park lock B/C+ Single Continuous 210 mm 14,000 Rpm Electric driveline Segment (300 Nm peak) 6.5 to 9 disconnect
SOP 2010 32-01 Longitudinal Drive
Light Duty Single 200 Nm Commercial Mechanical or 2 to 3 95 mm 10,000 Rpm Continuous
G e a r box Fleet electric park lock Truck/Van (300 Nm peak) Prototype 34-01 Longitudinal Drive
Medium Duty 400 Nm Multi-speed Mechanical or
G ea r box Commercial 110 mm 10,000 Rpm Continuous 3-speeds electric park lock Fleet Truck/Van (650 Nm peak)
In Development
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PDF created with pdfFactory Pro trial version www.pdffactory.com 34-01 Features and Benefits
§ Three-speed geartrain § Improved vehicle gradeability while maintaining vehicle top speed target § Allows motor operation in most efficient speed range § Enhanced battery electric driving range § Reduced clutch shift energy requirements over two-speed § Efficient dual clutch power flow § No power required to hold transmission in 1st or 3rd gear § Fully automatic power shifts (without torque interruptions) § High pressure hydraulic actuation system § High-efficiency pump-on-demand system § Electronic park lock § Electronic shift-by-wire park lock § CAN enabled for ease of vehicle integration
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PDF created with pdfFactory Pro trial version www.pdffactory.com 34-01 eGearDrive™
Electric Longitudinal Drive Technical Features (Initial Concept) Ge a r box • Mass: 68.5 Kg • Speeds: Three • Available ratios: 1st: 3.125; 2nd: 1.726; 3rd: 1.0 • Rated input torque: ~400 Nm continuous (650 Nm peak*) • Max input speed: ~10,000 rpm • Gear center distance: 110 mm • Output/Input orientation: Inline • Shift system: Dual clutch with on-demand high pressure hydraulics • Lubrication: Splash • Efficiency: TBA • Park lock system § Electronic shift-by-wire park lock system (ePark) • E-machine interface: Adaptable flange • Status: In development *Torque capacity dependent on duty cycle and life requirements 31
PDF created with pdfFactory Pro trial version www.pdffactory.com What eGearDrive® Systems Provide
§ Over one hundred years of geartrain system design experience § Industry first high-speed high-range electric sports car transaxle application (Tesla Roadster) § Proven single-speed electric drive technology for fast to market low-risk implementation now! § Adaptable designs for rapid vehicle integration § Highest efficiency for extended driving range § High reliability and best in class NVH § Mechanical and electronic park lock systems § Shift system technology for multi-speed requirements
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And growing…… 33
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better fuel economy reduced emissions great performance
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