Electric propulsion: steering towards efficiency1 June 2021 • 14:00-14:45 BST

#marinepropulsion

Marine Propulsion Webinar Week

Part of

1-4 June 2021

Presentation documents:Page 2: Dr Christoph Priestner, AVL ListPage 12: Philipp Fedorov, Danfoss Editron

Christoph Priestner

AVL List GmbH (Headquarters) Confidential

Marine Propulsion Webinar Week

Electric propulsion: steering towards efficiency

June 2021

Electric Drive Development

Christoph Priestner | DAD | 28 September 2020 |/ 2Confidential

ChallengeSOLVING THE TRADE-OFF

Performance

Noise

Vibrations

Weight

PackeageRobustness

Efficiency

Christoph Priestner | DAD | 28 September 2020 |/ 3Confidential

The AVL Solution

▪ Accurate prediction from sub-system to system level using simulation in early stage

Virtual Development HW-Phase / Calibration

Christoph Priestner | DAD | 28 September 2020 |/ 4Confidential

AVL multi-disciplinary approachDetailed expandable platform

REAL INVERTER

BATTERY

HV AUXILIARIES

Thermal losses:• EM• Switches• Diodes

EM

CONTROL

Mechanical output:• Speed• Torque• Rotor Position

Real time capable inverter optimization including• EM characterization• Control circuit development• Tuning for stability, overshoot, rise time and settling time• Co-simulation and circuit adjustment

Christoph Priestner | DAD | 28 September 2020 |/ 5Confidential

• Model quality

• System sensitivity

• Global optimization: performance, efficiency, losses, torque ripple, NVH...

• Variation definition

• Creation of DoE

• Parametrization of geometry and non-dimensional parameters

Electromagnetic simulationE-machine optimization, Design of Experiments

Setup of EMAG simulation

Design of Experiment

Modeling of system behaviour

Optimization

/ Robustness

E-MACHINE OPTIMIZATION PROCESS

Christoph Priestner | DAD | 28 September 2020 |/ 6Confidential

• Model generation with

o Maximum accuracy (based on L vs. dL/dt)

o Harmonic space resolutiono Non-linearityo Temperature effects

• Thermal, NVH… can be exported in parallel for holistic simulation

• Direct integration in most SiL/MiL

• FPGA code generation for most HiL systems

• Map generation with AVL

in-house scripting

• NVH and loss evaluation

• Assess and optimize winding AC resistance

• Account for 3D effects

• Fast and reliable evaluation of different e-motor topologies suited to fulfill customer requirements

Electromagnetic simulationXiL integration of E-machine

EM concept generation

FEM simulationRT capable

model generation

SiL/MiL/HiLintegration

E-MACHINE DEVELOPMENT FOR XIL ENVIRONMENT

VOLTAGE CURRENT TORQUE

Christoph Priestner | DAD | 28 September 2020 |/ 7Confidential

NVHDoE control optimization for NVH & Efficiency based on electromagnetic simulation

Electromagnetic simulation

Stator forces

DoE generation for control maps

Control map optimization

Implementation to e-Drive

testbed

FROM SIMULATION TO TESTBED VALIDATION

Optimal efficiencyOptimal NVH

-7.5 dB

Combined mapoptimal efficiency + optimal NVH

Christoph Priestner | DAD | 28 September 2020 |/ 8Confidential

Efficiency and NVH OptimizationMethod validation in testbed

• Example:• +4% cycle efficiency increase• EM efficiency is lower• This makes the optimization complex and requires system focus.

EM efficiency INV efficiency System efficiency

• Further optimization of e-drive system by control only, with given hardware on testbed

Christoph Priestner | DAD | 28 September 2020 |/ 9Confidential

KEY TAKE AWAYS

Trade-Off: Power & Efficiency, Cost, Weight, Packaging, Noise, Vibrations

E-Drive system focus

Calibration & Control Optimization

www.avl.com

Confidential

Thank you

State-of-the-art DC system for Electric Hybrid marine applications

Philipp Fedorov, 06/01/2021

Danfoss Editron

2 | Classified as Business

27,491Employees

WORLDWIDE SALESin more than 100 countries

71 PRODUCTION SITES in 21 countries and R&D SITES in 23 countries

Key facts 2020

Net sales, EURbn

5.8

USA, CHINAAND GERMANYTop three markets

PRIVATELY HELDOwnership

NORDBORG,DENMARKHeadquarters

3 | Classified as Business

Global trends driving electrification:CLIMATE CHANGE

• Demand for lower carbon emissions

• Regulation to cut particulate pollution

• Diesel bans in big cities

• Ongoing expansion of electrification market

• Falling costs of electrification

• Increasing demand for energy efficiency

4 | Classified as Business

SOFTWARE

Offering:

EDITRON SYSTEMSFull electric and hybrid systems

ELECTRIC MACHINES

ELECTRIC CONVERTERS

EDITRON SUB SYSTEMS

SYSTEM BENEFITS:

• Lower fuel/energy consumption

• Reduced CO2 and small particle emissions

• Space and weight savings

• Allows integration into various different systems

5 | Classified as Business

Electric machines

THE HIGHEST EFFICIENCY ON THE MARKET

• Synchronous reluctance assisted permanent magnet (SRPM) and permanent magnet (PM) maximum torque from any speed, even from standstill

• Liquid-cooled

• Designed to work in harsh operating environments

• Available both as generators and motors

High efficiency:

→ less batteriesor less fuel

EM-PMI300…PMI1520Power up to 6 MW

• SRPM machines up to 1 MW

• Marine PM machines up to 6 MW

• Enclosure class: IP65 (IP67 option for EM-PMI375 motors)

EM-PMEPower up to 75 kW

• SRPM machines up to 75 kW

• Short axial length to fit tight places

• Enclosure class: up to IP65

EM-PMI250...PMI318BPower up to 180 kW

• PM machines up to 90 kW, high speed (7000-10000 rpm)

• Peak power up to 250 kW

• Enclosure class: IP67

Note: No third-party components or technology

6 | Classified as Business

EC-C1200-450Electric Converters

• Danfoss Editron product

• Robust design with IP67 enclosure

• High mechanical vibration (10 G) and shock (50 G) tolerance

• Compact and light weight design (15kg)

• Liquid cooled

• Max. 350Aac per unit (~300kW@500Vac)

• Same unit can be used for:

• Motor inverter

• Generator converter

• Active front end unit

• DC/DC converter

• Microgrid unit

(300kW)

482mm

7 | Classified as Business

Danfoss Editron Marine systemDC-Grid power plant and propulsion system

• Distributed design allows flexible installation

• More even weight distribution

• No need for large electrical rooms

• Less power conversions in hybrid systems

• Modular system for different vessel sizes and types

• Variable speed gensets for optimal efficiency

• System design and SRPM machines ensure high system efficiency

• High redundancy for demanding applications

8 | Classified as Business

Danfoss Editron system examples 300 kW power unit, 15 kg

Voltage boost for batteries

9 | Classified as Business

Want to learn more?eClaculator

• eCalculator | Electrificationstory Tools

https://tools.electrificationstory.com/ecalculator

• Web based tool to support you designing EDITRON Marine system for your needs

• Features e.g.:

• Automatic inverter selection

• Automatic machine selection

• Single-line design

• Provides list of equipment for the system

• Battery estimations based on route information

• Save your project ideas

• And much more…

Where to find us?