Introduction of 125kW 3 in 1

electric drive assembly

2020/10/20
Catalogue

Part 1 Introduction of 125kW 3 in 1 electric drive assembly

l 1.1 Product description
l 1.2 Product main parameters
l 1.3 Product interface introduction

Part 2 125kW electric drive assembly-motor solution introduction

Part 3 125kW electric drive assembly-controller solution introduction

Part 4 125kW electric drive assembly-reducer introduction

1.1 Brief introduction of 125kW 3 in 1 product

Characteristic EPT2-125

Power（kW） 125

Main parameters Peak wheel speed（rpm） 1317

Peak wheel torque（Nm） 2550

Integrated motor, controller, reducer, 2 high-voltage branch
Integrated configuration
lines
Weight（kg） 83.5kg
472mm 485mm

325.3mm
Dimensions (length * width * height mm)
1.2 125kW 3 in 1 product parameters
parameters EPT2-125
operating voltage range（V） 240-460
Full power voltage（V） 330~450
Peak power(kW） 125
Rated power(kW) 60
Motor peak torque(Nm) 280
Motor rated torque(Nm) 125
Motor rated speed(rpm) 12000
Gearbox ratio 9.11
Peak wheel speed(rpm) 1317
Peak wheel torque(Nm) 2550
Rated wheel torque(Nm) 1138
Maximum system efficiency >91%
type of cooling water-cooling
operating temperature range(℃) -40~85
level of protection IP67
1.3 Product interface introduction

Low pressure High pressure

connector Molex connector
477259010 HVC2PG80FS250

Respirator
Ground point

water inletΦ20
water outletΦ20
1.3 Product interface introduction
Low-pressure box
High-voltage box cover: cover: double-lip
Double lip rubber seal rubber sealing ring
Flat seal Flat seal

Three-phase interface:
Water pipe connection: Double lip rubber seal
Rubber pipe joint Flat seal
radial seal

Junction box cover:

Double lip rubber seal
End face of reducer:
Flat seal
Sealant plane seal

Rear cover:
pipe connector: Sealant plane seal
Interference cold
pressing, pipe thread
sealant
1.3 Product interface introduction
p Controller support description
Connection description:
4 lock points to lock the motor
casing;
1 lock point to support the
controller
The lock point reserves a
φ45 circumferential space
for the suspension
structure design and
process operation space;
Note: M10 corresponds to
a sleeve tool diameter of
24mm

Support
controller

Description:
Lock 3 bolts of the motor, passing through
the bracket and the flange surface of the
motor, there is a risk of bolt loosening;

Locking Countermeasures: Apply thread fastening

glue to bolt threads to improve fastening
motor
strength.
1.3 Product interface introduction
p Controller support strength simulation
material parameter：
yield strength elasticity modulus
name of parts material densityg.cm-3 Poisson's ratio μ
σb/MPa E/Gpa
box
box cover ADC12 2.7 0.33 154 69
bracket
boundary conditions：
Random vibration PSD: According to GB/T 18488 and ISO19453
frequencyHz PSD （m/s2）2/Hz
X direction Y direction Zdirection
10 10 10 10
100 10 10 10
300 0.51 0.51 0.51
500 1 1 1
Acceleration root mean square value 6.1m/s2 2000 1 1 1
1.3 Product interface introduction
p Controller support strength simulation
analysis result：

Conclusion: The maximum stress of the bracket is 49.5MPa, which occurs under Z-direction vibration. The
bracket material is ADC12, its yield strength is 154MPa, and the safety factor is 3.1, which can meet the
strength requirements.
Catalogue

Part 1 Introduction of 125kW 3 in 1 electric drive assembly

Part 2 125kW electric drive assembly-motor solution introduction

l 2.1 General layout of the motor

l 2.2 Basic electromagnetic parameters
l 2.3 Motor performance
l 2.4 Motor temperature rise
l 2.5 Motor and system efficiency

Part 3 125kW electric drive assembly-controller solution introduction

Part 4 125kW electric drive assembly-reducer introduction

2.1 General layout of the motor
I. Envelope size (length×width×height): 279mm×370.8mm×321mm;
II. Combination of motor and gearbox: the motor shell can be mechanically connected with the half shell
of the gearbox;
370.8mm
279mm

321mm
2.1 General layout of the motor

1 2 3 4 5 6 7

1. Junction box cover

2. Resolver
3. Rear cover
4. Floating end bearing
5. Stator assembly
6. Rotor assembly
7. Fixed end bearing
2.2 Basic electromagnetic parameters
Mechanical parameters
Outer diameter Φ210mm
Core length 140mm

Stator axial length 210

212mm
（Includes coil end）

Effective weight 30.5kg 212

Electrical parameters

Maximum line BEMF 477Vpk@12krpm@20℃ DC bus voltage 360VDC

Maximum phase current 439Arms Peak power 125kW

Peak torque 280N·m Torque density 9.18N·m/kg
Peak speed 12000r/min Power density 4.1kW/kg
 2.3 Motor performance

1 No-load simulation

cNo-load back EMF Cogging torque

No-load line back EMF: 477V@12000rpm Cogging torque: ±0.34Nm

 2.3 Motor performance

2 Load simulation

rated torque Peak torque

Rated torque: 127Nm@213.6Arms Peak torque: 280Nm@438.5Arms

Torque ripple: 3.05% Torque ripple: 2.91%
 2.3 Motor performance

3 External characteristics under different voltages

125kW Torque curve 125kW power curve

Simulation conditions: maximum phase current Simulation conditions: maximum phase current
438.5Arms, magnetic steel 100℃ 438.5Arms, magnetic steel 100℃
2.4 Motor temperature rise

4 Motor temperature rise simulation

Rated temperature Peak temperature rise Temperature rise in front

rise working condition

Motor winding temperature 143℃ Motor winding temperature103℃@30S Motor winding temperature135℃@30S
(60℃, 8L/Min) （60℃ ，8L/Min） （60℃ ，8L/Min）
 2.5 Motor efficiency

5 Efficiency simulation

125kW
Simulation conditions: phase current 439Arms, voltage 330V,
fsw=10KHz

p Motor efficiency>80% area accounts for 94.38% p Motor system efficiency>80% area accounts for
p Motor efficiency>85% area accounts for 91.77% 87.95%
p Motor system efficiency>85% area accounts for
Catalogue

Part 1 Introduction of 125kW 3 in 1 electric drive assembly

Part 2 125kW electric drive assembly-motor solution introduction

Part 3 125kW electric drive assembly-controller solution introduction

l 3.1 The overall design of the controller

l 3.2 Selection of key components
l 3.3 Software design

Part 4 125kW electric drive assembly-reducer introduction

3.1 Controller overall design
I. Envelope size (length×width×height): 353mm×326mm×104mm;
II. Combination of controller and motor: controller and motor high-voltage copper bar
connection;
104mm

353mm
326mm
3.1 Controller overall design

Layout explosion diagram High

高压箱盖 pressure box cover

Low
低压箱盖pressure box cover

Drive control
驱动控制板 board IGBT
current
电流传感器 sensor
Insurance
保险
Waterway
水道底板floor Insurance
保险支座 support

三相支座
Three-phase bearing Bus support
母线支座

Low voltage plug-in

低压插件 Film
薄膜电容 capacitor

box Cable
电缆端盖 end cap
High
高压分线 voltage branch line
external
cable
3.1 The overal l desi gn of the control l er
pE l e c t r i c a l a r c h i t e c t u r e

Electrical block diagram Functional safety diagnosis

• Torque
扭矩监控 monitoring·
Three-phase current
• 三相电流校验
calibration
• 旋变故障监测
Resolver fault
• monitoring
母线电压监控
Bus voltage monitoring
3.2 Key component selection

p Power module
I. Select automotive-grade 750V/820 power module to meet the reliability requirements of the vehicle;
II. Rohm automotive-grade isolation driver chip is selected to realize protection functions such as driving undervoltage, IGBT short circuit,
and over temperature;

Power Cycles>100k
2.3 Controller program introduction
p IGBT loss and temperature rise calculation

750A/820A module loss

125kW
Calculation output power IGBT loss per bridge cDiode loss per bridge
Total loss（w）
conditions （kw） arm（w） arm（w） Simulation conditions: phase current 440Arms, voltage
Peak 125 3218 460 74
450V, fsw=10KHz
rated 60 1580 218 44

IGBT loss calculation

140

120 129

100
100
80

60

40

20

0 p Control efficiency>90%, area accounts for

Rated temperature
额定温升
rise peak 峰值温升
temperature rise
90.26%
IGBT junction temperature estimation Controller efficiency simulation
3.2 Selection of key components
p DC filter capacitor
I. Choose 450V/500uF film capacitors to meet the requirements of ripple voltage, current and life;

II. The laminated busbar design minimizes stray inductance and improves the EMC performance of the system;

III. Built-in Y capacitor design improves integration and reduces cost.

ESL simulation: 13.5nH

Peak ripple voltage -Vpp=15V

Life prediction curve

Temperature rise simulation: 93.4℃ Peak ripple current-Irms=308A

3.2 Selection of key components

p DC filter inductor
I. The use of nanocrystalline ribbon winding technology has the characteristics of high magnetic permeability and high saturation magnetic

induction;

II. Compact structure design, high space utilization, convenient installation and good vibration resistance.

Inductance characteristics Similar product test photos

DC terminal filter inductance

CE-voltage test RE-0.15~30MHz test

3.2 Selection of key components

p current sensor

Integrated current sensor

⊕ Open loop gain HALL principle

⊕ Linearity: 1%
⊕ Response time: <7us
⊕ Full range accuracy: <3.5%FS

Full range sampling accuracy

3.3 software design
p Software Architecture

Applicati
on layer

Bottom
layer
 3.3 software design
p Software function layering
Ø Motor control algorithm: torque control, speed control, etc.;
软件功能实现 Ø Active damping, rapid discharge and other control strategies.
Function software

Ø Torque monitoring function ensures that the system can quickly enter a safe state under extreme
abnormalities;
Ø Real-time monitoring of overvoltage faults and timely activation of active short circuit protection

Software 软件功能监控 controller hardware safety;

function Function monitor Ø Current, temperature, resolver and other sensor fault monitoring and protection;
Ø Other complete protection functions such as over current, over temperature, over speed, etc. ensure that
the system can enter a safe state when the system fails.

Ø Memory monitoring ECC and CRC, CPU lock step control;

MCU底层安全监控 Ø Clock monitoring, stack protection, etc.;

MCU monitor Ø Power monitoring, watchdog monitoring, etc.
3.3 software design
p Random frequency conversion technology
I. Reduce IGBT switching frequency, start at 2KHz frequency, reduce IGBT switching loss;

II. Below the frequency of 10KHz, random frequency conversion control is carried out in sections according to the speed to improve the vehicle

NVH;

III. The total loss of the 2kHz frequency controller is 35% lower than that of the 10kHz frequency controller;

10kHz frequency 2kHz frequency

3.3 software design
p Active short circuit technology
3.3 software design
p Torque monitoring

I. Estimate the motor output torque based on the motor input power, copper loss, and iron loss;
II. Considering the influence factors of resolver zero offset and motor temperature on output torque, the torque estimation
error is less than 5%.

Torque estimation method Torque estimation accuracy verification

3.3 software design

p Software reliability verification

{ Development and testing process management based on V model;

{ Complete design process review;
{ 100% software code coverage automatic test based on TESSY integrated environment, condition
combination coverage MCC, correction condition/judgment coverage MC/DC, branch coverage;
{ System testing and evaluation combining real bench environment and HIL.
Catalogue

Part 1 Introduction of 125kW 3 in 1 electric drive assembly

Part 2 125kW electric drive assembly-motor solution introduction

Part 3 125kW electric drive assembly-controller solution introduction

Part 4 1125kW electric drive assembly-reducer introduction

4.1 Reducer introduction

ü Type: Single gear two-stage reducer

ü Manufacturer: Qingshan
ü Overall speed ratio: 9.114
ü Maximum input speed: 12000rpm
oil filler hole
ü Maximum input torque: 350Nm
ü Input and output center distance: 210mm
ü Parking P gear: optional
ü Working temperature: -40℃~120 ℃

Oil drain