New technologies in seven areas of new energy vehicles: low fuel consumption and small size and light weight

At the "People and Car Technology Show 2014" (Pacific Yokohama International Convention and Exhibition Center) held on May 21-23, 2014, the latest technologies developed to win in the fierce global competition gathered together to acquire technology in the automotive industry. Close attention of personnel. At the show, technologies such as low fuel consumption, small size and light weight, cost reduction, autonomous driving, new materials, new joining technologies, and new development tools have emerged. This article introduces these new technologies to you in conjunction with the pictures.

Low fuel consumption: Toyota's SiC power semiconductor, want to increase fuel efficiency by 10%

At this exhibition, the most influential visitors were the silicon carbide (SiC) power semiconductors exhibited by Toyota. The power semiconductor is the core component of the power control unit (PCU), and the PCU functions to control the current of the drive motor of a hybrid vehicle (HEV) or the like. The use of SiC to make power semiconductors can reduce power loss, greatly reduce the size of the PCU and greatly improve fuel efficiency. Toyota has produced two types of SiC power semiconductors, which are transistors that control current switching and diodes that control current flow (rectifying).

The left is the transistor and the right is the diode. Manufactured on Toyota's own production line.

SiC power semiconductors are jointly developed by Toyota Motor, Denso, and Toyota Central Research Institute. Toyota has set up a SiC-specific cleaning workshop in the company. In addition to the wafers coming from the outside, the rest is basically done by Toyota.

The use of SiC power semiconductors maintains the same performance, reducing the size of the PCU to around 1/5.

The goal of the development is to replace the current Si (silicon) power semiconductors, increase fuel efficiency by 10%, and reduce the size of the PCU to 1/5. We will strive to put PCU equipped with SiC semiconductor into practical use around 2020. Regarding the cost issue, Toyota's commentator said, "The cost of SiC power semiconductors is high, but we pay more attention to the advantages of reducing fuel consumption, so we use it and hope to cut costs elsewhere."

Low fuel consumption: Mitsubishi Electric exhibited the industry's smallest EV drive system with SiC power semiconductors

Mitsubishi Electric has developed the "EVMotorDrive System", a pure electric vehicle (EV) drive system that uses SiC power semiconductors to reduce the size. The power module of the inverter uses a SiC power semiconductor. Compared to existing systems using Si power semiconductors, the volume is reduced by half.

In addition to reducing losses, SiC power semiconductors also contribute to miniaturization of inverters because SiC power semiconductors can reduce the size of capacitors and coils in circuits compared to Si power semiconductors. The Si transistor cannot be powered down immediately after being turned off, and will continue to be energized (tail current) for a period of time, but there is no tail current in the SiC transistor. Since there is no tail current, the SiC transistor can achieve about 10 times higher frequency driving (high speed switching) than Si. After the high frequency drive is realized, the power stored in the switch of one cycle can be reduced, and the size of the capacitor can also be reduced.

The industry's smallest EV drive system.

The inverter is embedded inside the casing of the motor for integration. This not only simplifies wiring and wiring, but also simplifies water-cooled piping by combining the motor and the inverter's cooler.

The goal of Mitsubishi Electric is to put this drive system into practical use in 2023. It is hoped that the mass production effect generated by the popularity of SiC power semiconductors, coupled with miniaturization and integration, will gradually reduce costs.

Small and lightweight: 40% lighter than glass, Toyota automatic loom achieves roof resinization

Resin the car roof as a whole - Toyota's automatic loom exhibits a multi-functional resin that has evolved from the Toyota Prius polycarbonate (PC) two-color molded roof, integrating solar cells, cameras and many other devices. The roof." The device integrated with the roof includes a camera (front view camera and rear view camera), an antenna (shark fin antenna), a brake light (high brake light), and a solar battery. When the solar cell is embedded, the weight of the new resin roof can be reduced by 40% compared to the use of glass cover. Further, the resin has a high degree of freedom in shape, and it is possible to easily realize a shape in which the glass is difficult to manufacture. Since there is no dividing line (joining surface of the part), the resin also has the advantage of good appearance quality.

Small and lightweight: use bamboo fiber to make the back seat backboard, 10% lighter than using wood

Compared with wood panels, the backboard made of bamboo fiberboard is stronger and lighter in weight.

NHK Spring has developed bamboo fiberboard for automotive interior materials. The rear seat back panel was made using bamboo fiber made in Thailand. The weight can be reduced by 10% compared to current products using wood panels.

The reason why bamboo is considered is that bamboo is a natural resource and grows faster than trees, and it is expected to achieve stable procurement. It takes nearly 60 years for trees to grow from planting to harvesting, and bamboo takes only about 3 years. Moreover, the yield of bamboo-made materials is higher than that of cannabis. "Cannabis only uses the epidermis, and bamboo can be used except for the leaves."

The manufacturing method uses papermaking, which is the same as manufacturing and paper. The green bamboo was pulverized into a fiber having a width of 0.2 mm and a length of about 50 to 60 mm, and dried at a temperature of 120 ° C for 2 hours to obtain a bamboo fiber material. The material was subjected to papermaking, that is, mixed with water and polypropylene as a binder (having a particle diameter of about 200 μm), poured onto a metal mesh to form a sheet having a thickness of 5 to 10 mm. The sheet is then heated at a temperature of 130 to 160 ° C for about 1 minute to be stamped when the sheet becomes soft when heated.

Small and lightweight: Dacheng PLAS displays structural materials that can float on the water surface, using a three-layer composite structure

A three-layer structure is formed of aluminum, polypropylene (PP), and aluminum.

Dacheng PLAS manufactures the seat frame from the material “MetalSand” with aluminum/polypropylene (PP)/aluminum structure and displays it in water. The frame can be floated on the water surface, showing its light weight. In fact, the company exhibited this material in 2013, but this time it has a clear purpose, the company has a more detailed introduction to the relevant technology.

MetalSand is sealed with a thickness of 4.0 mm between two aluminum plates of 0.25 mm thickness. Polypropylene is foamed using a "MuCell" process that is blown into supercritical nitrogen. MuCell is a patented process of Nippon Steel Works. MetalSand has a bending strength equivalent to a 1.6 mm thick steel plate (SPCC), but the weight is reduced from 108 g to 31 g, which is reduced by about 70%. This is due to the fact that the polypropylene layer keeps the two aluminum plates at a certain distance, and the stress applied to each aluminum plate is transformed into an axial force of stretching and compression without causing bending. In addition to a simple structural material such as a seat frame or a floor, it can also be used as a structural material and a heat insulating material.

Used for Suzuki "HUSTLER". The wall thickness is reduced to 1.5 mm, which reduces the weight. PA66 with 34% glass fiber added was used.

Small and lightweight: German Mahler introduces a cylinder head cover for light vehicles, reducing weight by reducing the wall thickness to 1.5mm

Mahle, Germany, exhibited a cylinder head cover for Suzuki light-duty vehicles that reduced the weight by reducing the wall thickness to 1.5 mm. The cover was injection molded, and the resin used was added with 34% glass fiber in polyamide (PA) 66. Suzuki has adopted this cover on the engine "R06A" of the light vehicle "HUSTLER" (listed in January 2014). In the past, the cylinder head cover had a wall thickness of 2 mm, and by reducing the thickness, the weight was reduced by 20%. In order to avoid under-filling and insufficient strength, reinforcing ribs are provided on the side from the valve to the other side.

Small and lightweight: Toyota Textile develops a new separator that shrinks to 1/4

The function of the separator is to remove the lubricating oil droplets when recovering the leaking gas (unburned mixed gas that leaks into the crankcase). Toyota Textile uses a new method of “inertial impact” that reduces the size of the separator to about a quarter of the past. In this way, the nozzle and the nonwoven fabric are provided on the way of the flow path, and the leaking gas which is accelerated by the nozzle is brought into contact with the nonwoven fabric. The oil droplets will drip down after infiltrating into the nonwoven fabric. In the past, the way to remove oil droplets was to allow the leaking gas to pass through the labyrinth of the flow path and separate it by the weight of the oil droplets.

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