National Projects
Innovative electric drive unit for commercial vehicles
Title:
Innovative electric drive unit for commercial vehicles
Programme name: LIDER
Project value: PLN 1,500,000.00
Contribution from national funds: PLN 1,500,000.00
Co-financing for Łukasiewicz – GIT: PLN 1,500,000.00
Project financed by the National Centre for Research and Development under the LIDER XI programme
Start: 01.01.2021 / End: 01.01.2024
Executive Agency: National Centre for Research and Development
Project Manager:
Bartłomiej Będkowski, BEng, PhD
Tel.: 32 258 20 41 ext. 42
E-mail: bartlomiej.bedkowski@git.lukasiewicz.gov.pl
Objective:
The aim of the project is to develop the structure and solve the construction and technological problems of traction drives excited by permanent magnets integrated with a mechanical transmission, intended for installation in electric wheels of commercial vehicles with increased demand for torque.
The achievement of the goal is planned by carrying out 6 tasks divided into 2 stages.
In stage 1, the aim of task 1 is to develop design assumptions that will allow the design of model drives for research. In this task, structural and technological analyses will be carried out using applicable methods using kinematic analyses, analytical and numerical calculations based on the finite element method. Test components of the drive system will also be made using 3D printing technology (FDM technology) in order to initially verify the correctness of the concepts planned for use in the model drive of the mechanical solutions of the transmission part.
As part of task 2, electromagnetic calculations will be performed using the peripheral method and the peripheral-field method to design the electromagnetic circuit, as well as analytical methods to design the mechanical part (transmission) of the drive system. The design calculations will take into account the construction guidelines developed as part of task 1. The electromagnetic circuit will be designed so that the drive achieves the highest possible parameters while obtaining high efficiency and low weight, while the mechanical part (transmission) so as to obtain the highest possible transmission with a compact structure. As part of the implementation of task 3, model electric drives intended for installation in the wheels of an electric vehicle will be made. The drives will be made in accordance with the developed documentation created in task 2. After the model drives are made, laboratory tests will be carried out, taking into account, among others, their operation at different loads and heating trials will be performed using thermal imaging cameras and temperature sensors located in the drives, as well as test procedures used in the Łukasiewicz-GIT laboratory. As part of the implementation of stage 2, the aim of task 4 is to develop documentation of the prototype drive, taking into account the conclusions drawn from the research carried out in task 3. The new drive will be equipped with the most efficient cooling system, while its design will be optimised in terms of weight, strength, efficiency, and operating parameters. The result of the task will be the documentation of a traction drive prototype using the most advantageous solutions in terms of technology and expected parameters, selected during the implementation of previous tasks. As part of the implementation of task 5, a prototype of an electric drive will be physically made and laboratory tested using a test stand developed in stage 1, equipped with an inverter, gearboxes, control system, measuring instruments, system for supplying cooling substance to the engine, a heat exchanger and a mount made as part of the project. At the test stand, the prototype drive will be coupled to the loading machine. Laboratory tests analogous to those carried out in task 3 will be performed. The aim of task 6 is to analyse the results of laboratory tests of all model and prototype drives. The analysis will include a comparison of the results of computer simulations and the results of design calculations with the test results obtained in the laboratory. Guidelines and design solutions will be presented along with the developed technology for applications in drives intended for installation in electric vehicle wheels.
