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