magneti marelli e il recupero di energia in “f1”. quali
Transcription
magneti marelli e il recupero di energia in “f1”. quali
MAGNETI MARELLI E IL RECUPERO DI ENERGIA IN “F1”. QUALI INSEGNAMENTI PER L’ AUTO DI TUTTI I GIORNI ? Milano, 6/05/2009 Magneti Marelli Motorsport Confidential 2 Company overview Magneti Marelli is an international group leader in developing and manufacturing high-tech automotive systems and components. With 67 Production Sites (80 production units), 10 R&D Centers and 28 Application Centers in 18 countries and a workforce of ~33,000 people, Magneti Marelli is a world class global automotive supplier. POWERTRAIN AUTOMOTIVE LIGHTING MOTORSPORT SUSPENSION SYSTEMS ELECTRONIC SYSTEMS (Suspension Systems, Cofap Shock Absorbers, Dynamic Systems) AFTERMARKET PARTS & SERVICES EXHAUST SYSTEMS Magneti Marelli Motorsport Confidential PLASTIC COMPONENTS AND MODULES 3 Magneti Marelli Group Facts Worldwide presence Argentina Brazil China Sales 2008 5.4 billion € Employees ~ 33,000 Czech Republic France Germany India R&D (of sales) 5.0 % Investments (of sales) 6.3 % Production sites 67 R&D Centers 10 Application Centers 28 Italy Japan Malaysia Mexico Poland Russia Slovak Republic South Africa Act. 2008 Spain Turkey USA Production plant Application Center Magneti Marelli Motorsport Confidential R&D Center 4 K E R S inetic nergy ecovery ystem Magneti Marelli Motorsport Confidential 5 IL REGOLAMENTO Extract from 2009 F1 technical regulations: …“1.20 Kinetic Energy Recovery System (KERS): a system that is designed to recover kinetic energy from the car during braking, store that energy and make it available to propel the car”… …”5.2.3 The maximum power, in or out, of any KERS must not exceed 60 kW. Energy released from the KERS may not exceed 400 kJ in any one lap. Measurements will be taken at the connection to the rear wheel drive train.”… Magneti Marelli Motorsport Confidential 6 KERS block diagram DRIVER Braking system (car kinetic energy available) Boost request (car kinetic energy released) Motor-generator STORAGE system Energy Recovery KERS Control Unit Energy Release Magneti Marelli Motorsport Confidential 7 KERS System: Motogenerator Mission Time history 3: 4 regeneration phases (each 2 sec. long, 60 kW charge power, initial speed 19000 rpm, final speed 13000 rpm, speed gradient -3000rpm/s); 2 boost phases (6.5 sec. long, 60 kW discharge power, initial speed 15500 rpm, final speed 19000 rpm, speed gradient 500 rpm/s) with 3 sec. interval; 4 regeneration phases (each 2 sec. long, 60 kW charge power, initial speed 19000 rpm, final speed 13000 rpm, speed gradient -3000rpm/s); Total duration 100 sec. Magneti Marelli Motorsport Confidential 8 KERS : I componenti del sistema MGU (Motor Generator Unit) KCU (KERS Control Unit) BPU (Battery Pack Unit) Weight, volume, efficiency, power density, high cooling temperature (100° C) Magneti Marelli Motorsport Confidential 9 KCU Pre-Driver Module • Control Board Module In house tecnology, for design and production • Logic Core, Safety, diagnosys • In house tecnology, for design and production POWER Module DC-BUS FILTER Module • High current / high voltage capacitor • 600V/600A Hybrid Semiconductor Module • Codesign with best in class suppliers • Codesign with best in class components and modules suppliers • Possible assembly in MM in future (White Rooms) Current Sense Module • In house tecnology, for design and production Magneti Marelli Motorsport Confidential 10 KCU - dimentions Weight : < 4 kg Magneti Marelli Motorsport Confidential 11 MGU Motor/generator Motor/generator caracteristics caracteristics :: RPM RPM max max Max. power Max. power Max. Max. voltage voltage Max. current Max. current Cooling Cooling Weight Weight Magnets Magnets Wiring Wiring Magneti Marelli Motorsport Confidential :: :: :: 40.000 40.000 rpm rpm 60 Kw 60 Kw 480 480 VV :: :: 550 550 AA (rms) (rms) up to 120 up to 120 °C °C :: :: 5,3 5,3 Kg Kg Samario/cobalto Samario/cobalto :: Bar Bar technology technology 12 MGU Tecnology Magneti Marelli Motorsport Confidential Volume - 40% Length - 32% Weight - 25% 13 MGU: Design Magnetic ,thermal and mechanics 3d calculation with resonances frequency analysis are performed for ensuring maximum performances and reliability level Magneti Marelli Motorsport Confidential 14 MGU: Thermal dynamic Design On of the key design criteria is the thermal behaviour control under the mission profile. The thermal working condition must be stable and inside the safe technologies limit also in the worst cases of mission profile and coolant temperature. The Motogenerator is designed to work with coolant fluid temperature until 140 ° so avoiding the needing of a Separate dedicated cooling circuit Magneti Marelli Motorsport Confidential 15 MGU Magneti Marelli Motorsport Confidential 16 MGU Construction - Stator Stator cutting Conductors mounting Magneti Marelli Motorsport Confidential Conductors cutting Conductors welding 17 MGU Construction - Rotor Rotor machining Magnets glueing Rotor final assembly Magneti Marelli Motorsport Confidential 18 MGU Construction - Casing Inner shell Ball bearings Magneti Marelli Motorsport Confidential Outer shell Assembling particulars 19 BPU charg e One pulse UCAP Power [ kW] SMES single charg e Two consecutive pulses charg 120 e 90 Li Ion Kinetic 60 NiMH Na/NiCl2 0 0 Magneti Marelli Motorsport Confidential 300 180 360 Energy [kJ] 600 900 SAFETY Magneti Marelli Motorsport Confidential 21 Magneti Marelli Motorsport Confidential 22 • Messa a punto della tecnologia di realizzazione dei moduli di potenza realizzati direttamente sul supporto dissipante. • Sviluppo in codesign con fornitore selezionato dei condensatori per alte correnti ed alte tensioni. • Messa a punto delle tecnologie per la realizzazione degli avvolgimenti statorici “bar based”. • Messa a punto dei modelli di calcolo per il dimensionamento elettrico e termico dei motogeneratori, dato il profilo di missione. • Messa a punto in codesign di materiali innovativi per resistenza all’ isolamento e alla temperatura. • Approfondimenti delle problematiche di safety indotte dalla presenza di alta tensione ed alte concentrazioni di energia. • Consolidata cooperazione con centri di ricerca e Università. Magneti Marelli Motorsport Confidential START&STOP Vehicle traction / stability control with two independent emotors Interdivisional MM project Foreseen on test bench by end 2009 Included in the INDUSTRIA 2015 FGA proposal Two kers motors Two rotors single stator multiphase CO2 Reduction COSA, IN SINTESI, MAGNETI MARELLI STA ACQUISENDO DALL’ ESPERIENZA F1 DA METTERE A DISPOSIZIONE PER L’ EVOLUZIONE DELL’ AUTOMOBILE DI TUTTI I GIORNI ? 23 GLI ACCORDI INTERNAZIONALI 29th April 2009 Milan, Italy and Silverstone, UK For Immediate Release Magneti Marelli and Flybrid Systems to collaborate on KERS energy storage for Motorsport Italian Motorsport electronics specialist Magneti Marelli and British high-speed flywheel specialists Flybrid Systems today announce the collaboration to develop a new energy storage solution for the Kinetic Energy Recovery System (KERS). The new product will deliver a high power electrical storage system for hybrid racing cars capable of deep depths of discharge with no performance degradation and a long service life. The new product named Flywheel Capacitor consists of a high-speed carbon fibre flywheel incorporating Flybrid® technology connected to a high-speed electric motor generator using technology from Magneti Marelli, all managed by Magneti Marelli’s control electronics. The device works by applying to the electric motor generator the recovered electrical energy captured from the vehicle during braking events. The energy is stored into the Flywheel Capacitor by speeding up the flywheel. During the acceleration events of the vehicle, the energy stored into the flywheel capacitor is returned to the vehicle by transforming the kinetic energy of the flywheel into electrical energy via the motor generator. The Flywheel capacitor will not use chemical battery based energy storage systems. The first Flywheel Capacitor to be developed will have a specification of 60 kW power and 600 kJ total storage capacity but the specification can be readily adapted to any vehicle requirements. Both partners will draw upon extensive experience with their own KERS products to deliver a working prototype in the next few months. The electric motor and flywheel will rotate at up to 60,000 RPM and the flywheel will sit inside an evacuated chamber that includes special containment features to ensure complete safety. A small electric pump will occasionally top up the vacuum so that no regular maintenance is required. State of the art magnetic design of the motor generator and high efficiency electronics are expected to deliver round trip storage efficiencies approaching 80%. The device has a low cooling requirement and contains no flammable materials. The complete flywheel capacitor including the associated electronics is expected to weigh just 20 kg. Magneti Marelli Motorsport Confidential Many thanks for your attention Magneti Marelli Motorsport Confidential