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11 e Mobility and Electrification 1619520407722
11 e Mobility and Electrification 1619520407722
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Vehicle Electrification
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▪ Shifting clutches are eliminated ▪ Motor and gears may be housed together, so
transmission fluid may cool and insulates the
▪ Transmission fluid used to cool and insulate the motor, while protecting the gears
motor, and protect the gears
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Basic
Schematic
Approx. Energy
+2% to 4% +8% to 11% +20% to 35% +30% to 50% +50% to 60% +60% to 70% +70% to 80%
Efficiency
Engine can shut-off when stopped
Engine assisted by motor for extra torque and can shut-off when coasting with motor restart.
Energy Braking energy recovered
Saving Operations Motor can propel vehicle with engine off
Plug-in recharge
Motor only propulsion [no engine]
Motor Before Engine [P0] Before [P2] or After Before & After [P2],[P3],
n/a [P4] on Axle[s]
Placement or After [P1] [P3] Transmission Trans.[P13 or P23] [P13] or [P23]
Transmission Standard Modified Electronically Variable Modified AT, CVT or Reduction Gear Box
Type MT, AT, CVT or DCT AT, CVT or DCT [EVT] DCT; or EVT [RED]
Transmission ATF, CVTF, DCTF ATF, CVTF, DCTF ATF, CVTF ATF, CVTF
ATF GEAR OIL or ATF
Fluid or MTF or MTF or DCTF or DCTF
Motor Contact n/a no typical yes typical possible, with motor cooling
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FULL HYBRID FULL HYBRID FULL HYBRID FULL HYBRID FULL HYBRID
Motor drives vehicle Engine drives vehicle. Engine and Motor both provide Engine off. Engine and Motor off.
Engine is on standby KEY Motor regenerates braking energy Battery provides energy to run
DIFFERENCE Motor captures any extra engine power to drive the vehicle
power to charge battery to charge battery accessories, such as A/C
Electronically New designs to Engine operates Toyota Prius, Ford Fusion A separate generator captures any extra
Variable manage the in higher engine power to drive the motor and/or
[EVT] power split efficiency range charge the battery
between engine
and motor
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E-Fluid Formulation
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▪ Increasing installations RED Tesla Motors BEV (P4) 1.3 Tesla Model 3 ATF (Tesla High Perf.)
justify a bespoke fluid GM BEV (P4) 0.2 Chevy Bolt ATF (DEXRON® HP)
* Cumulative sales of all vehicle models through model year 2020
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E-fluid
Electrical properties
Aeration and oxidation Insulation
Smaller sump, fill for life
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Heat transfer
Cool the windings Heat Transfer Requirements
High temperature can lead to motor performance loss and demagnetization
▪ Winding heads and magnetic rotors may be subject to localized hot spots at peak loads
Direct oil cooling is more efficient and less complex than water cooling jackets
▪ Oil cooling can improve motor efficiency and enable smaller higher voltage motors
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Heat transfer
Cool the windings Fluid Heat Transfer Properties
FLUID PROPERTY MEASUREMENT IMPACT ON HEAT TRANSFER
Dynamic
Molecular resistance to flow Fluids with lower µ have molecules with less internal
Viscosity
[cP] resistance to flow to hot surfaces and away with the heat
(µ)
Molecular compactness
Density Fluids with higher ρ have more molecules per given volume
[kg/m3]
(ρ) that can conduct heat between each other
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Heat transfer
Cool the windings Measuring Heat Transfer Properties
ASTM D7896:
Standard test method for thermal
conductivity, thermal diffusivity and
volumetric heat capacity of engine
fluids
▪ Uses a transient hot wire liquid thermal
0.16 Grp V 2
conductivity method Thermal Conductivity
ASTM D7896 (W/m·K) Grp V 1
0.15
Grp IV
The thermal conductivity of Grp III+
0.14
transmission fluids is largely a function Grp III
of the base oil used 0.13
MTF
CVTF
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Heat transfer
Cool the windings Formulating for Heat Transfer
The Mouromtseff number [M0] is used to compare the heat transfer capability of turbulent fluids
▪ e-fluids are subject to turbulent flow
Lower viscosity oil – major low cost effect on M0 [balance vs. wear]
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Heat transfer
Cool the windings Novel Approaches for Heat Transfer
Provides high heat capacity, Improves thermal conductivity Uses latent heat of
thermal conductivity and and breakdown voltage vaporization for heat transfer
oxidative stability (potentially)
E.g. hydrofluororethers, used in
E.g. polyol esters, silicones, heat E.g. boron nitride, aluminum immersion cooling of batteries
transfer fluids and vegetable oils oxide, titanium oxide, iron oxide
nanoparticles
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Material compatibility
Copper, resin, plastic Material Compatibility Requirement
Motors introduce new materials to the transmission
▪ Copper wire and connections, along with insulating materials, plastics, sealants, etc.
Insulating
Resins Plastics
Plastics
material
Cu
Cu (wire,
(wire,
connector
connector
Sealant
Al (case)
Material compatibility
Copper, resin, plastic Formulating for Material Compatibility
Material compatibility must be
considered for additive selection, e.g. Copper Compatibility Current Fluid Improved E-Fluid
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Electrical properties
Insulation Electrical Property Requirement
Motors rely on insulating material to isolate high voltage components
▪ When oil cooled, the e-fluid’s resistance to current flow must be considered
1 cm EXAMPLE:
Consider a 1 cm2 conductor immersed in oil and separated from ground by 1 cm
• Oil with conductivity 1x10-9 S/cm at 100 °C would present 1 GΩ resistance
• If driven by 500 V, a 0.5 μA leakage current would occur
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Electrical properties
Insulation Fluid Volume Resistivity Properties
Relationship between molecular electronic properties and measured resistivity
Dipole Moment (Debye): Polar Surface Area (PSA): Band Gap (eV):
Measures the difference in Measures polarity based on Measures the energy required to
electrical charge between a the surface area (Å2) of move an electron from the valence
positive end and a negative oxygen and nitrogen atoms band to the conduction band in the
end of a molecule including attached hydrogen outermost orbit of a molecule
atoms
▪ Polar molecules, with
higher Debye are less ▪ Molecules with higher PSA ▪ Molecules with lower eV are less
resistive are less resistive resistive
▪ Detergents ▪ Different Friction Modifiers ▪ Example: Zinc phosphide
[eV ~ 1.5] < Zinc oxide [eV ~ 3.4]
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Electrical properties
Insulation Measuring Volume Resistivity
ASTM D1169 –
Covers the determination of
specific resistance (resistivity)
▪ Applied to new electrical insulating
liquids, as well as to liquids in service,
or subsequent to service, in electrical
apparatus.
VR decreases as molecular
polarity increases:
▪ Debye → VR
▪ PSA → VR
▪ eV → VR
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Electrical properties
Insulation Formulating for Volume Resistivity
Maximum e-fluid VR is dictated by base oil: Additives lower VR as:
▪ Higher quality reduces polarity and increases VR ▪ Molecular polarity increases
▪ Higher viscosity increases molecule size and VR ▪ Molecules are smaller
▪ Treat rate increases
Volume Resistivity: ASTM D1169 (Mohm-m)
Grp IV 4cSt
INCREANSING VR [log]
INCREANSING VR [log]
LARGER MOLECULES
Grp III 3cSt Group II
Oils
Grp II 6cSt Base
Viscosity Stock
Grp I 4cSt modifiers
Temperature (ᵒC)
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Electrical properties
Insulation Volume Resistivity of Aged Fluid
Oxidation lowers the volume resistivity of aged fluids
▪ OEMs have introduced oxidation tests to evaluate electrical properties…
▪ including ISOT and DKA, but these approaches may be too severe
▪ VR remains relatively unchanged after field aging in cooler hybrid transmissions
▪ Battery electric vehicles may have even lower overall sump temperature
INCREANSING VR
ATF
INCREANSING VR
VW Golf GTE
avg. sump temp ~53 °C
Indiana Stirring 96 hr max. sump temp ~88 °C
Oxidation Test
[ISOT] 150 hr INCREASING DISTANCE 100km
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Electrical properties
Insulation Volume Resistivity Considerations
VR What may define the upper and lower limits for volume resistivity?
SAFETY:
ISO6469-3 Part 3:
Protection of persons against electric hazards OTHER PARAMETERS TO CONSIDER:
▪ (DC) Isolation resistance minimum value 100 ▪ Electrical arcing with high VR?
ohm/volt (10mA)
▪ Potential current leakage with low VR?
▪ (AC) Isolation resistance minimum value 500
ohm/volt (2mA) ▪ Electrically induced corrosion with low VR?
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Formulation Map
Balance of transmission performance and
protection with electrical properties
New considerations are
Viscometrics needed for component
OIL / VISCOSITY MODIFIERS selection
e.g. antiwear and
Wear durability Heat transfer antioxidant
ANTIWEAR AGENTS THERMAL CONDUCTIVITY
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Electrification Outlook
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© 2021 Infineum International Limited. All rights reserved.
Performance you can rely on.
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1200
• Even with high FHEV and BEV growth, MHEV 300
100
Summary/ Recap
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Performance you can rely on.
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Performance you can rely on.
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