汽车前沿技术 | 采埃孚开发出紧凑型“三合一”电驱动装置High Revolution Drive

据报道，采埃孚（ZF）开发出了一款名为“高转速驱动系统”（High Revolution Drive）的紧凑型“三合一”电驱动装置。其转速最高可达 30,000 rpm，在输出相同功率的同时，体积更小、重量更轻。得益于此，电机本身可以做得更小、更轻，且对磁性材料的需求也随之降低。通过高传动比的两级减速器，该系统能够为车轮提供所需的扭矩。这一全新的驱动概念基于现有的 SELECT 平台打造，使汽车制造商能够以更低的开发成本，更迅速地将其应用于新车型之中。

High Revolution Drive 的电机转速远高于传统系统。要实现这一目标，需要整个系统协同运作。采埃孚电驱动事业部负责人 Thomas Meiser 表示：“High Revolution Drive 充分发挥了采埃孚在系统集成方面的专业优势。我们并非孤立地优化各个零部件，而是对电机、电力电子设备和变速器进行系统化的协同调配。”

其原理很简单：在功率输出相同的情况下，更高的转速意味着所需的电机扭矩更小。由于扭矩与转子体积密切相关，因此电机可以设计得更小、更轻。为了将这种高转速转化为可用的扭矩，系统配备了一套速比约为 18:1 的两级直齿轮变速器，确保所需的扭矩能够传递至车轮。文中展示的版本可实现 200 kW 的峰值功率输出，以及 3,500 Nm 的峰值轮端扭矩。

高速与低噪

转速越高，噪声和振动就越难控制。凭借在齿轮和传动系统领域数十年的经验， ZF 成功应对了这一挑战。采埃孚通过对各部件进行协同设计来解决这些难题。Meiser 表示：“从项目伊始，高稳健性以及低噪声与低振动水平就被列为严格的开发目标。为实现这一目标，我们将电机、齿轮机构、轴承以及齿形几何结构视为一个整体系统进行考量。对于目前所展示的配置而言，30,000 rpm 是兼顾经济性与技术性能的最佳转速点。”

降低磁体质量、重量及安装空间需求

与同类转速为 18,000 rpm 的 SELECT 驱动系统相比，High Revolution Drive 的体积缩小了近 25%，重量也减轻了近 25%。所需磁体质量减少了 50%，这不仅降低了成本，还减少了对关键供应链的依赖。即便在高转速和大传动比工况下，该系统的效率仍能达到近 93%，与同类 SELECT 系统相当。

重量的减轻还有助于提升电动汽车的续航里程。该系统主要面向大批量乘用车市场，驱动输出功率约为 150 至 200 kW。其架构具备可扩展性，既能适配不同的功率等级，也支持 400 伏和 800 伏电压系统。

SELECT：基于成熟平台的新型驱动概念

这一方案遵循了采埃孚的平台战略：High Revolution Drive 被设计为模块化“SELECT”平台的一种变体，并采用了现有技术。这不仅使产品成本保持在可控范围内，还为汽车制造商在驱动系统的生产方式上提供了灵活性。采埃孚的 Meiser 表示：“借助 SELECT 平台，我们无需为每一款新的驱动变体从零开始研发。我们利用模块化系统，能够根据不同客户的需求，量身定制全新的驱动概念。”

目前，采埃孚已与多家汽车制造商展开洽谈，并计划在 2030 年前实现量产。

ZF has unveiled the High Revolution Drive, a compact three-in-one electric drive motor that spins at up to 30,000rpm and is smaller and lighter than conventional drives with reduced magnet requirements while delivering the same power.

A high-ratio two-stage transmission delivers the required torque at the wheel. The new drive concept builds on the existing Select e-drive platform, so auto makers can bring it into new vehicles faster and at lower development cost.

Higher speeds, less space

The motor speed of the High Revolution Drive is significantly higher than that of conventional systems. Making that work requires the whole system to work together. “Rather than optimizing individual components in isolation, we systematically coordinate the electric motor, power electronics and transmission,” said Thomas Meiser, head of the E-Mobility business unit at ZF.

At the same power output, higher rotational speed reduces motor torque, enabling a smaller, lighter motor. A two-stage spur gear transmission with an approximately 18:1 ratio transfers torque to the wheels.

High speed, low noise

Higher speeds make noise and vibration harder to control. ZF addresses these challenges through the coordinated design of the components. “Robustness and low noise and vibration levels were stringent development targets from the outset,” said Meiser. “To achieve this, we considered the electric motor, gearing, bearings and tooth geometry as an integrated system. For the configuration presented, 30,000rpm is the economic and technical sweet spot.”

Reduced magnet mass, weight and installation space

The High Revolution Drive is nearly 25% smaller and nearly 25% lighter than a comparable Select drive running at 18,000rpm. The required magnet mass is reduced by 50%, which lowers costs and reduces dependence on critical supply chains. Even at high rotational speeds and with a high gear ratio, the system achieves an efficiency of nearly 93%, on par with the comparable Select system.

The lower weight also helps increase electric range. The focus is on the high-volume passenger car market, with drive outputs of approximately 150kW to 200kW. The architecture is scalable for different power ratings and for both 400V and 800V systems.

New drive concept on a proven platform

The High Revolution Drive has been designed as a variant of the modular Select platform and uses existing technologies. This keeps product costs predictable while giving auto makers flexibility in how the drive is produced, ZF said.

“With Select, we do not have to start from scratch for every new drive variant,” said Meiser. “We use our modular system to tailor new concepts to different customer requirements.”

ZF is already in talks with several auto makers and is targeting production by 2030.

作者：ZF

来源：https://press.zf.com