Transcript Slide 1

HEV Motor
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
Overview
2
Engine
Clutch
Engine
HSG
Wheel
Motor
A/T
Wheel
Battery
HSG
Theta Ⅱ
Hybrid Engine
Drive Motor
Hybrid
6 Speed A/T
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
3
Specifications
Item
Drive Motor
HSG
16 / 24 Slots
6 / 36 Slots
Max
[email protected]~6krpm (5s)
[email protected]~12krpm (5s)
Continuous
[email protected]~4krpm (40min)
[email protected]~12krpm (40min)
Max RPM
6300rpm
15750rpm
Max Torque
205Nm(@245A)
43.2Nm(@125A)
Max Output
95% ↑
95% ↑
Core (Stator)
Split Core/0.35t/Sheet Type
Unibody Core/0.35t/Sheet Type
Permanent Magnet
High Energy Rare-earth Type
High Energy Rare-earth Type
Position Sensor
Resolver
Resolver
High Voltage
Connector
100A Connector Type
40A Connector Type
Sensor Connector
8P Integrated Type (position and
temperature sensors)
10P Integrated Type (position and
temperature sensors)
Number of Mag. Polarity/Core
Output
Output
Spec.
Category
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
4
Composition of Drive Motor
Stator Ass’y
Drive Motor Ass’y
Rotator
Stator
Resolver
Transaxle
· matching engine/transaxle
· motor cooling function (oil cooling type)
· power cable connection
· terminal
Engine
ROTOR Ass’y
generate/deliver power
PM (16 polarities)
rotor core
PM (ND series)
(16 polarities,
IPM)
high voltage terminal
(connector type)
stator
(concentrat
ed winding)
resolver
(position sensor)
- detects magnet
position
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
5
HSG Configuration
HSG Ass’y
Stator Ass’y
· Emergency power generation
· HSG cooling
· Power cable terminal
Resolver
Stator
Rotor Ass’y
· Engine start
· PM
· Rotating magnetic field
PM (ND series)
Housing
bearing
pulley
bearing
rotor
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
6
Motor Operating Principle
0˚
Magnetic Torque
N
S
S
N
Permanent Magnet
※PMSM : Permanent Magnet Synchronous Motor
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
7
Motor Operating Principle
Inverter
(MCU)
3 Phase
Current
Inverter
HSG
Motor Drive
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
8
Role of the Drive Motor
Electric Motor
Power Source for HEV
 Starting and low-speed/cruising: motor power only
 Acceleration: supplement engine power
 Deceleration and braking: store electric energy
 Elec. Mode: electric motor only
 Hybrid Mode: engine + motor
 Regenerative Brake mode:
stores electric energy
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
9
Role of HSG
 Engine Start Control: Starts the engine when HEV mode is engaged.
 Engine Speed Control: Raises the engine RPM to equal the motor speed
when the engine clutch is activated.
 Soft Landing Control: Minimizes engine vibration when the engine is turned off.
 Alternator: Starts the engine when the SOC is low and charges the high voltage battery.
Engine + Electric motor
② Instantly raise
speed to equal
① motor
motor speed
speed
① Minimize engine
vibration when turning
OFF the engine
① Start the engine and
recharge the high voltage
battery when the SOC is low
High Speed Accelerating
③ engage when both
speeds are equal
Engine Start Control
Engine Speed Control
Soft Landing Control
Alternator Control
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
10
Temperature Sensor’s Role
Drive Motor
Temp Sensor
HSG
PIN NO
1
2
3
4
5
6
7
8
PIN ASSIGN
REZ +
REZ S1
REZ S2
TEMP
REZ ㅡ
REZ S3
REZ S4
TEMP GND
PIN NO
1
2
3
4
5
6
7
8
9
10
온도 센서
PIN ASSIGN
REZ +
REZ S1
REZ S2
TEMP
SHIELD
REZ ㅡ
REZ S3
REZ S4
TEMP GND
SHIELD
1 2 3 4
5 6 7 8
Temp.
sensor
Pin 4-8
126.8
㏀±5%
@20℃
Temp.sensor
Pin 4~9
143~71 ㏀
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
11
Resolver’s (Position Sensor) Role
Drive Motor
Position sensor
(Resolver)
PIN NO
1
2
3
4
5
6
7
8
HSG
PIN ASSIGN
REZ +
REZ S1
REZ S2
TEMP
REZ ㅡ
REZ S3
REZ S4
TEMP GND
Position sensor
(Resolver)
PIN NO
1
2
3
4
5
6
7
8
9
10
PIN ASSIGN
REZ +
REZ S1
REZ S2
TEMP
SHIELD
REZ ㅡ
REZ S3
REZ S4
TEMP GND
SHIELD
1 2 3 4
5 6 7 8
Position
Sensor
(resolver)
Pin 1-5
11.7 Ω±10%
Pin 2-6
32 Ω±10%
Pin 3-7
27 Ω±10%
@20~30℃
Position
Sensor
(resolver)
Pin 1~6
14.2~17.4 Ω
Pin 2~7
26.1~32 Ω
Pin 3~8
26.1~32 Ω
@20~30℃
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
12
Resolver’s (Position Sensor) Waveform
↓ HSG ON
↑ IG ON
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
13
Motor Cooling
ATF Oil Cooling Type
ATF is filled in the lower section of
the motor up to the oil level
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
14
HSG Cooling
Cooling System Configuration
R
A
D
I
A
T
O
R
EWP
Reservoir
Tank
HPCU
▶Elec.
W/Pump
HSG is cooled via water cooling of EWP System
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
15
Precautions when replacing motor
Drive Motor
HSG
When the IPM is removed, it may affect your mobile phone, credit cards, or other
magnetic devices. Therefore, when conducting motor maintenance, make sure you
remove mobile phone and credit cards from your possession before you start the
task
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
16
Inspecting Drive Motor
PIN NO
1
2
3
4
5
6
7
8
PIN ASSIGN
REZ +
REZ S1
REZ S2
TEMP
REZ ㅡ
REZ S3
REZ S4
TEMP GND
1 2 3 4
5 6 7 8
Test item
Test part
spec
note
U-V
Power
(Line-Line)
Average±5%
mΩ
@10Arms
@20~30℃
Pin 4-8
126.8 ㏀±5%
@20℃
Pin 1-5
11.7 Ω±10%
Pin 2-6
32 Ω±10%
Pin 3-7
27 Ω±10%
V-W
W-U
Resistance
Temp.
sensor
Position
Sensor
(resolver)
U, V, W
W
V
U
Insulation
Cover
(ground)
@20~30℃
10 ㏁↑
@DC500V, 1min
5 mA↓
@AC1500V, 1min
Resolver
10 ㏁↑
Temp.
sensor
10 ㏁↑
@DC500V, 1min
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
17
Inspecting HSG
② Sensor connector
1
W
V
U
2
1
Test item
① High
Voltage
connector
Test part
Power
(LineLine)
2
PIN NO
1
2
3
4
5
6
7
8
9
10
PIN ASSIGN
REZ +
REZ S1
REZ S2
TEMP
SHIELD
REZ ㅡ
REZ S3
REZ S4
TEMP GND
SHIELD
Resistance
Temp.
sensor
Position
Sensor
(resolver)
Insulation
Housing
/Cover
(ground)
spec
note
U-V
V-W
95~106 mΩ
@10Arms
@20~30℃
W-U
Pin 4~9
143~71 ㏀
U-V-W
1 ㏁↑
Pin 1~6
14.2~17.4 Ω
Pin 2~7
26.1~32 Ω
Pin 3~8
26.1~32 Ω
@20~30℃
U-V-W
@20~30℃
10 ㏁↑
@DC500V,1min
5 mA↓
@AC1500V,1min
Resolver
1 ㏁↑
Temp.sensor
1 ㏁↑
@20~30℃
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
HEV Motor
18
Resolver Calibration
 Conduct Calibration after replacing;
- Drive Motor
- HSG
- MCU
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.