EV & HEV Drive System Technology Expo 2014

NIDEC, MITSUBA & Meiwa show switched reluctance motor; Nippon Chemi-Con exhibits capacitors

2014/02/13

Summary

Automotive World 2014
Opening ceremony of Automotive World 2014

 The 5th EV Japan (EV & HEV Drive System Technology Expo) was held at Tokyo Big Sight on January 15th to 17th, 2014 as part of Automotive World 2014. This report summarizes the 5th EV Japan.

 NIDEC, MITSUBA, and Meiwa exhibited SR motors that do not use a permanent magnet, attracting attention to their technologies for in-vehicles products. In particular, NIDEC displayed an EV drive system, a starter and generator, an electric assist turbocharger, and an electric supercharger that use an SR motor.

 Yaskawa Electric presented lightweight and compact EV motor and inverter. MEIDENSHA exhibited a module that integrates a motor and an inverter. Nichicon displayed a compact DC-DC converter with battery charger, which it supplies to Mitsubishi i-MiEV.

 Nippon Chemi-Con exhibited electric double layer capacitor/module that it supplies to Mazda and Honda. The company also unveiled a next-generation capacity that it will ship samples soon.

 At other exhibition floors, although models including Honda Accord plug-in hybrid were exhibited, no special booth was set as the one that had featured EVs in the previous year. We will report the outlines of the Automotive Weight Reduction Expo that was also held at Automotive World 2014 in February.


Related Reports:
EV & HEV Drive System Technology Expo 2013
Automotive Weight Reduction Expo 2013 (Report 1)
Automotive Weight Reduction Expo 2013 (Report 2)


 



SR Motor: NIDEC, MITSUBA, and Meiwa

NIDEC exhibits traction machine and starter and generator that uses an SR motor

SR motor Traction Machine  NIDEC is currently developing SR (Switched Reluctance) drive motor for EVs, which uses a steel rotor instead of a permanent magnet, and its inverter. Since no permanent magnet is used, it is enabled to have a robust and simple structure and to cut costs. Also, no demagnetization occurs, which leads to excellent performance in high temperature driving conditions.
SR motor starter/generator  NIDEC and its UK partner, Controlled Power Technologies (CPT), exhibited a 48V SR motor starter and generator. As a starter, it can provide 4kW or higher output power and as a generator, 10 kW or higher. The spokesperson says that it will launch the product around 2016. It is also currently developing an electric super charger and electric assist turbocharger that uses an SR motor.

 (Note) The rotor of the SR Motor does not have a permanent magnet or a coil, but is made of ferromagnetic steel (which is a material that has magnetic polarity temporarily when placed in a magnetic field). It is attracted by the magnetic field of the stator to rotate.

NIDEC's SR motor Traction Machine NIDEC's  inverter for SR motor
NIDEC's SR motor Traction Machine NIDEC's inverter for SR motor
NIDEC & CPT's SR motor starter/generator NIDEC & CPT's  electric assist turbocharger that uses an SR motor.
NIDEC & CPT's SR motor starter and generator NIDEC & CPT's electric assist turbocharger that uses an SR motor.
NIDEC & CPT's electric supercharger that uses an SR motor
NIDEC & CPT's electric supercharger that uses an SR motor

Specifications of traction machine that uses an SR motor

SR motor@150V Inverter
Output Rated 19kW(Maximum 44kW) Dimension W 395×L 330×H 100 mm
Maximum torque 86Nm Mass 13.0kg
Maximum speed 11000rpm
Cooling Water and 60% Ethylene glycol
Operating temperature -40°C ~ 105°C
Dimension φ177mm×L234mm
Mass 26.5kg

 

MITSUBA exhibits SR motor for racing karts

MITSUBA exhibited an SR motor that it developed for racing karts and a kart with the SR motor installed. The number of power elements in the driver (IC that rotates the motor) is reduced from 12 to 8, which cuts cost. In addition to karts, the company also proposes the SR motor to be used on an electric assist turbocharger, a starter, and a generator.
MITUSBA SR motor @48V Driver
Maximum Output 4.3kW/5000rpm Dimension 301×173×137 mm
Maximum torque 14Nm/1000rpm Mass 7kg
Dimension φ174mm×L158mm
Mass 11kg
MITSUBA's SR motor and a driver
MITSUBA's SR motor and a driver (located behind the seat) on a racing kart.

 

Meiwa exhibits SR motor for compact EVs

Meiwa exhibited an SR motor for compact EVs. The volume of the motor is reduced to two thirds (of the company's previous product) by forced air-cooling with a built-in fan. The company aims to sell the product to EV venture companies rather than major companies. It plans to launch a three-wheeled scooter with an SR motor in 2014.
Meiwa SR motor@96V Meiwa SR motor
Output Rated 3.5kW(Maximum 7.2kW)
Maximum torque 60Nm
Maximum speed 7500rpm

 

 



EV-related system: Yaskawa Electric, MEIDENSHA, Nichicon, and DANA

 

Yaskawa Electric makes a motor/inverter for EVs smaller and lighter

YMEV 35kW motor Yaskawa Electric has made  the 35kW motor smaller and lighter, which is used in its YMEV drive motor series for mini vehicles and small cars. The motor is about 30% smaller than the previous model (also made shorter from 266 mm to 215 mm in overall length). The use of square wire and the optimization of the magnet arrangement have increased torque density.
Yaskawa Electric will be able to supply samples in December 2014. If it receives orders, it can begin production in mid 2015. The company says that a 50kW motor is also available.
Inverter The company has made a 120kW inverter for EVs smaller into the same size as an 80kW inverter, which reduces the installation area by 24%. It has standardized parts and revamped internal structure/cooling structure.
The smaller Yaskawa Electric 35kW motor The smaller Yaskawa Electric 120kW inverter
The smaller Yaskawa Electric 35kW motor The smaller Yaskawa Electric 120kW inverter (under which is a picture of the current inverter)

 

Motor (35kW) Inverter (120kW)
Maximum torque 130Nm DC Bus voltage range DC240V-DC400V
Maximum speed 10,000 min-1 Maximum current 440Arms
Maximum Output 35kW Mass 約10.5kg
Mass 30kg Dimension 295mm×272mm×163mm
Dimension φ230mm×215mm

 

MEIDENSHA exhibits a drive unit currently under development for EVs

Integrated module for motor and inverter MEIDENSHA is currently developing an integrated module for drive motor and inverter. The integrated motor and inverter module eliminates cables. The company aims to make the product smaller, reduce costs, minimize dead space when the product is installed on vehicles, and cut radiation noise.
Inverter that drives a 100kW motor This product is an inverter that drives a motor. The company has made the inverter smaller with enhanced 14.5kW/L output power density. The power cable, control connector, and cooling water are unidirectionally located, which enhances mountability. The operating voltage is DC240V-400V. The external dimensions of a sample product is Width: 298×Depth: 230×Height: 154 mm.
Integrated unit for 100kw motor and gear MEIDENSHA exhibited a compact and light-weight drive unit for EVs, which integrates a drive motor and a reducer, for two consecutive years. The maximum output is increased from about 55kW to 100kW. The integrated drive unit reduces the weight of joint parts. The lubricant of the reducer is used to cool the motor, which eliminates an oil pump, resulting in weight reduction.
Integrated motor and inverter module Integrated motor/inverter module
Output Maximum 60kW
Motor torque Maximum 160Nm
Motor maximum speed 12,000rpm
Dimension W 330×L 300×H 305 mm

 

MEIDENSHA's inverter that drives a 100kW motor MEIDENSHA's integrated 100kw motor/gear unit
MEIDENSHA:'s inverter that drives a 100kW motor MEIDENSHA:'s integrated 100kw motor/gear unit
A cut-away model of Mitsubishi Outlander PHEV
A cutaway model of Mitsubishi Outlander PHEV is also exhibited. It comes with MEIDENSHA's motor and inverter for EVs/HEVs

 

Nichicon exhibits two DC-DC converters of unequal size with battery charger

DC-DC converter with battery charger for EVs Nichicon exhibited a DC-DC converter with battery charger for EVs. This converter is 20% smaller than the conventional product, although it maintains the same specifications. This is achieved through improving parts,layout, and the exhaust heat system. This DC-DC converter is used in Mitsubishi Motors' ongoing models of i-MiEV and Minicab MiEV.
DC-DC converter with battery charger for ultra-compact EVs Nichicon has developed a DC-DC converter with battery charger for an ultra-compact mobility that the Japanese government is considering. This converter uses an air cooling system and is applicable to either a lithium-ion battery or a lead-acid battery. The volume is 2.3 liters and the weight is 3.3 kg. Nichicon says that it will produce the product if there is demand.
DC-DC converter with battery charger for EVs DC-DC converter with battery charger for ultra-compact EVs
DC-DC converter with battery charger for EVs DC-DC converter with battery charger for ultra-compact EVs

 

DANA reducer for EVs

A reducer with a reduction ratio of 10.86 for EVs. The maximum torque is 300Nm. It is for midsize EVs including minivans.

DANA reducer for EVs

 

 



Nippon Chemi-Con exhibits capacitors

 Nippon Chemi-Con announced that it would execute a capital increase through a public offering in December 2013 to raise up to JPY7.2 billion. With the capital to be raised, the company will invest JPY1.09 billion in the expansion of cell production facilities for an automotive electric double layer capacitor, the DLCAP (scheduled to be completed in March 2016), JPY1.12 billion in the expansion of production facilities for DLCAP modules (to be completed in March 2017), and JPY4.69 billion in production facilities for nano-hybrid capacitors (to be completed in March 2017).

 

DLCAP, electric double layer capacitor for vehicles Nippon Chemi-Con exhibited an electric double layer capacitor that is supplied to Mazda and Honda. The company supplies the capacitor to Mazda's i-ELOOP regenerative braking system that is used in Mazda AXELA, ATENZA, and CX-5 that is made in China. It supplies the capacitor for Honda's start/stop system that is used in Honda Fit with a 1.3-liter gasoline engine. The capacitors are derivative products of the DXE series, which is a general purpose product. Nippon Chemi-Con also develops a product that enhances heat resistance from 70 degrees C to 85 degrees C.
Next-generation capacitor currently being developed Nano-hybrid capacitor The nano-hybrid capacitor is a hybrid capacitor that uses lithium titanate (nc-Li4Ti5O12)/carbon nano fiber complex as an anode. The new capacitor has achieved about three times (30WhL-1 class) the energy density and about the same output performance (6kWL-1 class) of the conventional activated carbon capacitor. Nippon Chemi-Con plans to build new facilities for nano-hybrid capacitors to be completed in March 2017.
Carbon nanotube capacitor The carbon nanotube capacitor is an electric double layer capacitor that uses single-layer carbon nanotubes for cathode and anode. The product uses electrodes that do not use binder/adhesive, which contributes to the improvement of life performance of the capacitor. The capacitor has doubled the energy density (W/L) from that of the conventional capacitor.
Electric double layer capacitor/module that is supplied to Mazda Electric double layer capacitor/module that is supplied to Honda
Electric double layer capacitor module that is supplied to Mazda Electric double layer capacitor module that is supplied to Honda
Nano-hybrid capacitor Carbon nanotube capacitor
Nano-hybrid capacitor Carbon nanotube capacitor

 

 



Main vehicles exhibited: Honda Accord plug-in hybrid and others

Honda Accord plug-in hybrid and external power supply system

Honda Accord Plug-in Hybrid Honda exhibited a plug-in hybrid version of the Accord high-end sedan. The company initially started marketing it in North America in January 2013. It began a limited lease sales of the model to Japanese corporations in June 2013 and to the general public in December. Honda plans a limited lease sale of 170 units for corporations and 400 units for individual customers. The company says that this release is limited because its production capacity for lithium-ion batteries has limitations.
The model comes with Honda's 2-motor hybrid system, SPORT HYBRID i-MMD. It can run up to 37.6 km in an EV mode. The PHV combined fuel economy is 70.4 km/L (JC08 mode). The model for corporations is equipped with a external charge function, while the model for individual customers is not.
Inverter box for external power supply The inverter box runs off an AC100V power from the vehicle's lithium-ion battery to supply the power externally. The Accord PHV is capable of supplying power with a rated output of 3kVA for up to 27 hours. The inverter box weighing about 27 kg can be housed in the trunk of a vehicle.
Honda Accord Plug-in Hybrid Inverter box for external power supply
Honda Accord Plug-in Hybrid Inverter box for external power supply

 

PUES EV:OMV-01

The OMV-01 is two-seater ultra-compact commercial EV (length: 2550 mm). The model is a remodeled version of France-based MEGA's EV to meet Japanese safety standards. The lead-acid battery is also replaced with a lithium-ion battery (capacity: 2.2kWh or 4.4kWh). The cruising range is 35 km (measured by PUES with a model having a capacity of 4.4kWh when the air-conditioner is used). PUES plans to start marketing the model for corporations after the Japanese government announces the specifications for a new vehicle category. PUES revamps MEGA's EVs at its affiliate in Okinawa, Japan.

Okayama Vehicle Engineering Center for the next EV: OVEC-ONE

OVEC-ONE is a convert EV that Okayama Vehicle Engineering Center for the next EV developed on a trial basis with 16 participating companies. The model is based on the Mitsubishi GALANT FORTIS, having the same vehicle frame structure and position of the suspension. It is equipped with a lithium-ion battery (capacity: 32kWh) and an outer rotor in-wheel motor (maximum output: 45 kW, maximum torque: 450Nm) is built in the four wheels. OVEC-ONE weighs 1650 kg, which is 300 kg heavier than the base model.
PUES EV:OMV-01 Okayama Vehicle Engineering Center for the next EV: OVEC-ONE
PUES EV:OMV-01 Okayama Vehicle Engineering Center for the next EV: OVEC-ONE

 

<Automotive Industry Portal MarkLines>