EV & HEV Drive System Technology Expo 2015

Meidensha's integrated motor and gear units; Nippon Chemi-Con's capacitors

2015/02/24

Summary

Venue of Automotive World 2015
Venue of Automotive World 2015

  The sixth EV & HEV Drive System Technology Expo (EV Japan 2015) was held at the Tokyo Big Site in January 2015 as part of the Automotive World 2015. This report summarizes exhibitions at the Expo.

 Meidensha exhibited an improved drive unit that integrates a motor and gears as well as a module that integrates a motor and an inverter. Shindengen Electric Manufacturing showcased a direct current to direct current (DC-DC) converter and an in-vehicle battery charger, , which the company supplies to Honda. Nichicon exhibited a downsized charger-integrated DC-DC converter, which the company supplies to Mitsubishi i-MiEV. Sinfonia Technology and Sumitomo Shoji Machinex each displayed a motor for ultra-compact electric vehicles (EVs).

 Nippon Chemi-Con exhibited an electric double-layer capacitor/module, which is supplied to Mazda and Honda, for the second straight year. The company also displayed next-generation capacitors.

Nidec and Yaskawa Electric, which exhibited their products until last year, presented no products at the Expo this year. The Automotive Weight Reduction Expo and other Expos held in conjunction with the Automotive World 2015 will be featured in the upcoming reports.


Related Reports:

Automotive World 2015 reports
European OEMs and suppliers plan to launch 48V hybrid systems after 2016 (Feb. 2015)
Advanced Driver Assistance Systems (ADAS) by Bosch, Denso and Renesas (Feb. 2015)


Automotive World 2014 reports
EV & HEV Drive System Technology Expo 2014 (Feb. 2014)
Automotive Weight Reduction Expo 2014 (Part 1) (Feb. 2014)
Automotive Weight Reduction Expo 2014 (Part 2) (Mar. 2014)



Technologies for HVs and EVs: Meidensha, Shindengen and Nichicon

Meidensha exhibits drive unit currently under development for EVs

Integrated unit for motor and gears

Meidensha Corporation is currently developing a drive unit, which integrates a motor and reduction gears. Although the integrated configuration reduces flexibility at installation, the company will decrease the number of parts to cut costs. The drive motor is being jointly developed with Univance Corporation.
Lubricant for the gears is used to cool the motor. An electric oil pump is also used to enhance cooling at low rotational speeds. Three models with a maximum output of 50 kW to 150 kW will be available. Customers' demands are greater for a higher output model.
Maximum output 50kW 85kW 150kW
Maximum motor torque 180Nm 200Nm 300Nm
Maximum motor speed 9,000rpm 13,000rpm 13,000rpm
Gear ratio Approx. 6 Approx. 9 Approx. 9

Integrated unit for motor and gears

Integrated module for motor and inverter

A silicon carbide (SiC) module with high efficiency and superior heat resistance is used to integrate the motor and the inverter. This results in an integrated cooling system, leading to downsizing. This configuration also eliminates the need for cables, reducing radiated noise. The company aims to commercialize the integrated module by 2020. The SiC module is expensive; therefore, reducing the cost will be a challenge to commercialize the module.
Output Maximum 60kW Integrated module for motor and inverter
Motor torque Maximum 160Nm
Maximum motor speed 12,000rpm
Dimensions Width: 330 × Length: 325 × Height: 305 mm

 

Shindengen Electric Manufacturing exhibits DC-DC converter, in-vehicle battery charger, etc. for Honda HVs

DC-DC converter for HVs This DC-DC converter is used in the Honda Accord hybrid vehicle (HV) and plug-in hybrid vehicle (PHV). The DC-DC converter converts the voltage of electric power that is supplied from the battery, and then supplies electric power with the converted voltage to the headlights, audio system, and other electric auto parts. The input voltage is 180 to 310 V. The output voltage is 10.5 to14.5 V
In-vehicle battery charger for EVs This in-vehicle battery charger is used in the Honda Fit EV for the North American market. The output power is 6.6 kW and the power density is 815 W/L. The size of the in-vehicle battery charger is the same as an ordinary 3 kW battery charger. The in-vehicle battery charger is, however, capable of outputting an electric power that is more than twice that of an ordinary 3 kW battery charger. The in-vehicle battery charger is cooled by a water-cooling system but it can also be cooled by a forced air-cooling system.
ECU for rear-wheel steering This ECU is used in the Precision All-Wheel Steer system, which offers all-wheel steering for the new Acura TLX released in 2014.
DC-DC converter for Honda Accord HV In-vehicle battery charger for Honda Fit EV
DC-DC converter for Honda Accord HV (Dimensions: Width: 167 x Height: 74 x Diameter: 200 mm; weight: 2.0 kg) In-vehicle battery charger for Honda Fit EV (Weight: 9.9 kg)
ECU for rear-wheel steering
ECU for rear-wheel steering (Dimensions: Width: 216 x Height: 34 x Diameter 127 mm; weight: 810 g)

 

Nichicon exhibits charger-integrated DC-DC converter

Nichicon exhibited a charger-integrated DC-DC converter for EVs. This converter is 20% smaller than the conventional converter but it maintains the same specifications. This was achieved by improving the parts layout and the exhaust heat system. The maximum output power is 2.8 kW. This converter uses a water-cooling system. This DC-DC converter is used in Mitsubishi Motors' ongoing i-MiEV and Minicab MiEV models.
Tommykaira ZZ Tommykaira ZZ
Tommykaira ZZ sports EV produced by start-up company, GLM Co., Ltd., is showcased at Nichicon booth. It comes with Nichicon's charger-integrated DC-DC converter.
Nichicon's charger-integrated DC-DC for EVs
Nichicon's charger-integrated DC-DC for EVs

 

 



Technologies for ultra-compact EVs: Sinfonia, Sumitomo Shoji Machinex and others

Sinfonia Technology exhibits in-wheel motor and inverter for ultra-compact EVs

In-wheel motor This in-wheel motor with an IPX7 waterproof rating was jointly developed by Sinfonia Technology Co., Ltd. and FOMM Corporation. The in-wheel motor adopts a direct-drive system, which drives without a reducer, and offers highly-efficienct driving of motors The maximum output is 5 kW and the maximum torque is 280 Nm. The new motor is used in FOMM's ultra-compact EV concept, the FOMM Concept One (described later).
Inverter This inverter with an IPX7 waterproof rating contributes to space saving because a single inverter can control two axes. This inverter adopts an air-cooling system, which is less costly, as the inverter is designed for ultra-compact EVs.
In-wheel motor Inverter
In-wheel motor (Diameter: 340 mm x Thickness:150 mm, excluding attachment and shaft) Inverter (Dimensions: 260 x 380 x 120 mm, excluding connectors)
In-wheel motors and inverter fitted to frame
In-wheel motors and inverter fitted to frame

 

TUV Rheinland Japan exhibits FOMM Concept One

TUV Rheinland Japan Ltd., a provider of testing and certification services, exhibited the FOMM Concept One ultra-compact EV concept, which is under evaluation by the company. The FOMM Concept One measures 2,495 mm in length and seats four passengers. The concept model features a floating function, which enables the EV to move on the surface of water in case of emergency. FOMM plans to produce the Concept One in Thailand. In December 2014, FOMM and a Thai company signed a memorandum of understanding to form a capital alliance.

FOMM Concept One

 

Sumitomo Shoji Machinex exhibits inverter integrated SR motor

SiC-inverter integrated 20 kW air-cooled SR motor This product is a combination of a switched reluctance (SR) motor without a permanent magnet and an inverter with a SiC power semiconductor in one. Sumitomo Shoji Machinex Co., Ltd. intends to offer the product to automakers and Tier 1 suppliers. The company will mass-produce it if there are demands. The product has a maximum torque of 50 Nm at 3,000 rpm.
The inverter integrated with the motor adopts an air-cooling system. The company also offers a water-cooled inverter as the following product.
Compact in-vehicle water-cooled inverter with high output power The water-cooled inverter offered by the company has a continuous output of 75 kVA and a maximum output of 100 kVA. This inverter can be customized for a SR motor.
SiC-inverter integrated 20 kW air-cooled SR motor Prototype car
SiC-inverter integrated 20 kW air-cooled SR motor (Black portion on right side is the inverter) Prototype car with four wheels each fitted with SiC-inverter integration type 20kW air-cooled SR motor
Compact in-vehicle water-cooled inverter with high output power
Compact in-vehicle water-cooled inverter with high output power

 

Nichicon exhibits charger-integrated DC-DC converter for ultra-compact EVs

Nichicon has developed a charger-integrated DC-DC converter for an ultra-compact mobility project that the Japanese government is considering to initiate. This converter uses an air-cooling system and can be mated to either a lithium-ion battery or a lead-acid battery. The output power is 800 W, the volume is 2.3 liters, and the weight is 3.3 kg. Nichicon says that it will produce the product if there are demands. The size is 235 mm in width, 60mm in diameter, and 160 mm in height

Compact in-vehicle water-cooled inverter

 

 



Nippon Chemi-Con exhibits capacitors

DLCAP, electric double-layer capacitor for vehicles Nippon Chemi-Con exhibited an electric double-layer capacitor that is supplied to Mazda and Honda. The capacitor is used in Mazda's i-ELOOP regenerative braking system that is equipped in the Mazda Demio (diesel model), AXELA, ATENZA, and CX-5 (China model). The capacitor is also used in Honda's start/stop system that is equipped in the Honda Fit (1.3-liter gasoline engine model). Nippon Chemi-Con is receiving many requests to have the voltage increased from the current 2.5 V to 3.0 V. There are still some challenges in reducing the price of the capacitor.
Next-generation capacitor currently being developed Nano-hybrid capacitor The nano-hybrid capacitor is a hybrid capacitor that uses lithium titanate (Li4Ti5O12)/carbon nano fiber complex as an anode. The new capacitor has achieved about three times (30 Wh/L class) the energy density and about the same output performance (6 kW/L class) to that of a conventional activated carbon capacitor. The nano-hybrid capacitor features high efficiency, which allows the capacitor to be made smaller in size than that of an electric double-layer capacitor. In December 2013, Nippon Chemi-Con announced its plan to build new production facilities for nano-hybrid capacitors by March 2017.
Carbon nanotube capacitor The carbon nanotube capacitor is an electric double-layer capacitor that uses single-layer carbon nanotubes for cathodes and anodes. The product uses electrodes that do not use binders or adhesives. This contributes to the improvement of life performance of the capacitor. The energy density (W/L) of the capacitor has been doubled to that of a conventional capacitor. The rated voltage is 3.0 V. The capacitance is rated at 800 mF. Commercialization of the product will take some time because carbon nanotubes are costly.
DLCAP Nano-hybrid capacitor
DLCAP, electric double layer capacitor for vehicles Nano-hybrid capacitor
Carbon nanotube capacitor
Carbon nanotube capacitor (Dimensions: 20 × 20 × 1.5 mm)

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