Brose Fahrzeugteile GmbH and Co. KG

Würzburg, Germany

Brose Fahrzeugteile GmbH and Co. KG

Würzburg, Germany
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Holland-Moritz S.,University of Kassel | Somonov V.,Saint Petersburg State University | Volkers S.,University of Kassel | Geyer M.,Brose Fahrzeugteile GmbH and Co KG | Bohm S.,University of Kassel
Welding and Cutting | Year: 2014

This work is devoted to the research of hot spots generated by induction heating in order to prevent hot cracks during laser welding of aluminium samples. Plates were used which were made from aluminium alloys AA6082T6 and AA5754H22 with a thickness of 2 mm. The article shows the results of numerical modeling of temperature fields and stress fields formed during the process of induction heating. The results of experimental validation of the simulation are also demonstrated.

Carraro E.,University of Padua | Bianchi N.,University of Padua | Zhang S.,Brose Fahrzeugteile GmbH and Co. KG | Koch M.,Brose Fahrzeugteile GmbH and Co. KG
2015 IEEE Energy Conversion Congress and Exposition, ECCE 2015 | Year: 2015

Fractional Slot Concentrated Winding (FSCW) Interior Permanent Magnet (IPM) synchronous motors are nowadays an attractive solution in automotive applications due to their important advantages in terms of high performance and manufacturing simplicity. Among the different topologies, the spoke type is an effective configuration when high torque density is required. On the other hand, the motor performance are heavily related to the selected slot-pole combination. This is a critical issue when there are high constraints in terms of torque quality, flux weakening performance and noise/vibration/harshness. This paper deals with the design and analysis of FSCW IPM spoke type motors, comparing eight optimal slot-pole combinations. Two different low cost PM typologies are considered. Design and optimization procedures, based upon a finite element analysis, are presented. The torque density, torque quality, electromechanical performance and deformation of the machines are compared, highlighting the advantages and the differences among the solutions. © 2015 IEEE.

Rusu T.,Technical University of Cluj Napoca | Pop A.-C.,Brose Fahrzeugteile GmbHandCo. KG | Szabo L.,Technical University of Cluj Napoca | Martis C.,Technical University of Cluj Napoca
2015 13th International Conference on Engineering of Modern Electric Systems, EMES 2015 | Year: 2015

The paper presents the analysis of losses of a three-phase, high speed 12/8 switched reluctance motor (SRM), intended to be used in automotive applications. The objective is to investigate by comparison the iron losses considering different types of short pitch winding arrangements, as well as different core laminations, and how much these affect the performance of a SRM having the same structure and working under the same conditions. The flux paths and static characteristics of several configurations are analyzed by means of 2D finite-element method (FEM). The effect of different lamination materials on the iron core losses are also studied. Dynamic simulation results were used to evaluate the performance of different SRM variants. © 2015 IEEE.

Carraro E.,University of Padua | Bianchi N.,University of Padua | Zhang S.,Brose Fahrzeugteile GmbH and Co. KG | Koch M.,Brose Fahrzeugteile GmbH and Co. KG
2014 IEEE Energy Conversion Congress and Exposition, ECCE 2014 | Year: 2014

The combination of the spoke type interior permanent magnet synchronous motor together with the NdFeB is an effective solution when high torque density is required. On the other hand, in the last years, the instability and the high price of the rare earth make the magnet minimization and the optimization of the motor design critical and mandatory. This paper deals with the design criteria of a spoke type, fractional slot concentrated winding, interior permanent magnet motor, especially as regards the minimization of the magnet volume, maximization of the airgap flux density and optimization of the split ratio. An analytical procedure is presented and validated by means of finite element analysis. At last, the advantages and the differences among the solutions are highlighted. © 2014 IEEE.

Ombach G.,Brose Fahrzeugteile GmbH and Co. KG
COMPEL - The International Journal for Computation and Mathematics in Electrical and Electronic Engineering | Year: 2011

Purpose - In the last few years, the understanding of environmental problems has grown. Car producers - original equipment manufacturers - are aiming to reduce fuel consumption and pollution. In order to fulfil these aims, new technologies have been launched. Many hydraulics systems have been removed and replaced with electric ones, e.g. power steering, water and oil pump, etc. In this paper, an electromechanical subsystem used in an automotive application is analyzed. The subsystem is composed of interior permanent synchronous magnet motor and electronic control unit. The range of mechanical output power for studied system is up to 1 kW. The aim of this paper is to compare electromechanical systems working with different on-board voltage levels in order to find the optimum balance between motors' and electronics' efficiency. This will help to decrease the total system's weight, the consequence of which will decrease fuel consumption and reduce CO2 emissions. Design/methodology/approach - During the analysis, the reduced order modelling (ROM) techniques has been applied. First, with utilization of finite-elemente-methode the basic motor's parameter like: synchronous inductance and flux per pole as a function of the direct-axis current and also the quadrature-axis current are calculated. In the second step, these parameters are used in the system simulation. During this simulation, the maximum torque per ampere control strategy together with ROM techniques was used. Findings - As a result, the performance of the system for different voltage levels has been obtained. Additionally, the important factors for an electromechanical system, such as maximum power density, sizing and cost of the total electromechanical system, have been compared. Practical implications - The performed comparison shows that the cost optimized system should work with the higher voltage, where the electric motor size is reduced ca. 25 per cent. This result is also valid for different electromechanical systems in an automotive area, e.g. automated manual transmission, engine cooling and electric compressor. Originality/value - It is the first paper, where electric power steering system design for different on-board voltage levels has been systematically analyzed and compared. Results from this paper can be also applied to different electromechanical systems mounted in hybrid or electric cars. © Emerald Group Publishing Limited.

Chlebosz W.,Brose Fahrzeugteile GmbH and Co. KG | Ombach G.,Brose Fahrzeugteile GmbH and Co. KG | Junak J.,Brose Fahrzeugteile GmbH and Co. KG
19th International Conference on Electrical Machines, ICEM 2010 | Year: 2010

This paper presents the comparison and optimization of a drive system used in an electric bike with outer and inner rotor permanent magnet brushless motor based on theoretical and experimental analysis of e-bike drive. The analyzed e-bike was equipped with the permanent magnet brushless synchronous motor with mechanical output power in range of 250W. The electric motor together with a planetary gear was mounted in a hub of 26 inch bike wheel. This kind of e-bike can reach maximum speed up to 25km/h. The aim of this paper is to investigate drive system used in the commercial e-bike with outer rotor, and theoretical analysis this same system combined with permanent magnet brushless motor with inner rotor. As a result of work the optimized motor topology with inner rotor is presented. ©2010 IEEE.

Junak J.,Brose Fahrzeugteile GmbH and Co. KG | Ombach G.,Brose Fahrzeugteile GmbH and Co. KG
19th International Conference on Electrical Machines, ICEM 2010 | Year: 2010

The paper deals with an analysis of permanent magnet brushless motors with interior pocket magnets (IPM) designed for automotive applications. The presented motors are used in automated manual transmission (AMT) and twin-clutch systems. The AMT systems allow fuel consumption and CO2 emission to be reduced in the vehicle. In the paper are described two versions of the motor design - with 8 pole rotor and with 10 pole rotor. Optimization of both IPM rotor shapes in case of sinusoidal or block current supply is delivered. The stators of both versions are wounded with needle winding technique which is very robust but ensures relatively low copper fill factors in slots. The described motors are designed for mass production and tolerance analysis hat influence of their output performance. The results of the robust analysis are also included in the paper. ©2010 IEEE.

Sawczuk G.,Brose Fahrzeugteile GmbH and Co. KG | Junak J.,Brose Fahrzeugteile GmbH and Co. KG
2013 International Conference on Electrical Machines and Systems, ICEMS 2013 | Year: 2013

The paper deals with the two-dimensional finite element analysis (FEA) for the irreversible demagnetization characteristics of a rare-earth permanent magnet in the permanent magnet synchronous motor (PMSM). The motor is designed for electric power steering (EPS) of automotive application. The irreversible demagnetization has been carried out for high temperatures due to an external magnetic field during the specified test procedure for EPS. At first, the magnetization model using a special magnetizing fixture is employed to analyze the proper distribution and radial orientation of the magnetization vectors in the radial anisotropic ring magnet. The nonlinear demagnetizing curves for permanent magnet as well as the influence of temperature on the demagnetization have been taken into account. Also the nonlinear BH characteristic of the magnetic iron core is considered. The described coupled field analysis has been performed using the commercial finite element software ANSYS MuItiphysics. Finally, the obtained simulation results with good accuracy have been verified by comparing with performed measurements. © 2013 IEEE.

Junak J.,Brose Fahrzeugteile GmbH and Co. KG
2015 International Conference on Sustainable Mobility Applications, Renewables and Technology, SMART 2015 | Year: 2015

The paper reviews new drivetrain concepts including plug-in full hybrid, mild hybrid designed for 48 V and zero emission vehicles like battery electric vehicle. The presented drivetrain concepts should lead to reduction of CO2 emission what is one of the most important goals of future transportation. Comparison between parallel and series hybrid drivetrain is specially delivered. The series hybrid drivetrain could be efficient alternative to parallel one. Such drivetrain concept, where electric drivetrain can be separated from power unit, can be adapted for fuel cell vehicle or battery electric vehicle. Mild hybrid solutions for 48V due to optimised costs should have more importance in the near future. © 2015 IEEE.

Bucker R.,Brose Fahrzeugteile GmbH and Co. KG
SAE Technical Papers | Year: 2015

Future doors require light weight, cost efficient and acoustic optimized solutions. Current steel doors offer only a small range of possibilities in these areas. With the use of aluminum doors the weight will be reduced but production complexity and costs will be increased. A modular door approach supports all of these future demands. Door modules have set milestones for door concepts in the past. Due to technological progress, door modules are more relevant in the current scenario. The use of reinforced plastics allows a high degree of design freedom with high integration of features.[2] In addition to weight reduction of up to 1.5kg per door the complete production process comes leaner with a higher grade of quality. The acoustic performance of a door system can be adjusted for noise reduction and improvement of the sound quality of speakers as illustrated. Functional integration is the key driver of weight and cost reduction Copyright © 2015 SAE International and Copyright © SAEINDIA.

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