SLIDE 1
Vehicle Electrification Lubrication Challenges
Edward P. Becker, P.E., Ph.D. Friction & Wear Solutions, LLC Brighton, MI frictionandwearsolutions@gmail.com www.frictionandwearsolutions.com
SLIDE 2 “Research engineers are now at work seeking new and satisfactory fuels which can be obtained, at a reasonable cost, to take the place of our rapidly decreasing supply of petroleum, from which gasoline is distilled.”
- -Wright, J. C. and F. C. Smith, Automotive
Construction and Operation, J. Wiley & Sons, Inc., New York, 1924
SLIDE 3
SLIDE 4
- CO2 Emissions
- Fuel Economy
- Active Safety
- Accident avoidance
- Driver independent braking,
steering and braking
- Passive Safety
- Occupant protection
- Exterior energy absorption
- Interior energy absorption
Industry Drivers
https://www.vox.com/cards/obama-climate-plan/what-are-u-s-fuel-efficiency- standards-for-cars-and-trucks http://www.climatechangeauthority.gov.au/reviews/light-vehicle-emissions-standards-australia/light-vehicle-emissions- standards%E2%80%94setting-right
CO2 Requirements – U.S. vs. Europe vs. Australia U.S. MPG Requirements
SLIDE 5 72 lotuscars.com/engineering
Three Phases of Powertrain Evolution
+2 to +3% FE increase +5% to +12% FE increase > +12% FE increase after 2025
Slide Courtesy Of Lotus Engineering
SLIDE 6
SLIDE 7 ICE Vs. EV Global Fleet Projections
and Europe will make up over 60%
market in 20401
vehicles (BEV) leave plug-in hybrid vehicles (PHEV) behind beginning in 20251
1. https://data.bloomberglp.com/bnef/sites/14/2017/07/BNEF_EVO_2017_Execut iveSummary.pdf
SLIDE 8
Tesla Roadster Charging
SLIDE 9
1914 Detroit Electric
SLIDE 10
Campbell House, Spokane, WA
SLIDE 11
SLIDE 12
Gasoline Engine
SLIDE 13
Diesel Engine
SLIDE 14
Electric Motor
SLIDE 15
Tesla Electric Motor (single speed gearbox)
SLIDE 16
SLIDE 17
SLIDE 18
Chevy Volt Electric Motor
SLIDE 19
Nissan Leaf Motor
SLIDE 20
Protean In-Wheel Motor
SLIDE 21 Batteries for EVs
- Lead-acid batteries were used for the earliest EVs
through the GM EV-1 (1999)
– Limited range – High cost – Long charging time
- Lithium-ion batteries are now used
– Higher cost – Better range – Faster charging
SLIDE 22
SLIDE 23
Fuel Cell (Schematic)
SLIDE 24
Equinox Fuel Cell Vehicle
SLIDE 25
H2 from water + Al alloy
SLIDE 26
SURUS (Silent Utility Rover Universal Superstructure)
SLIDE 27 Grease Requirements for Hybrid and Electric Vehicles
- Most greased structures remain the same
– Wheels – Closures – Sealed motors
- Accessories (power steering, AC) use greased, sealed for
life, electric motors
SLIDE 28 Lubrication Challenges for Hybrid Electric Vehicles
- Both an internal combustion engine and electric motors
provide propulsion
- Electric motors are typically lubricated by conventional
transmission fluid
- ICE requires engine oil, but the engine experiences many
more stop-start cycles and lower overall operating temperature than dedicated ICE vehicles
– Water and fuel dilution – Additive activation
SLIDE 29 Lubrication Challenges for Pure Electric Vehicles
- EVs with a gearbox use transmission fluid to lubricate the
motor bearings
– May be torque-limited due to gear wear
- In-Wheel electric motors typically used sealed roller
bearings
- Grease is added only at assembly
- Temperature range in excess of -40°C to +40°C
SLIDE 30 Future of Grease for Electric Vehicles
- Compatibility with new materials
– Copper wires and windings – Advanced polymers
- High and low temperatures
– Vehicles must operate at -40°C – Electric motors generate heat
- Permanent magnet motors are temperature limited
- Induction motors can experience temperature excursions
- Electric current and magnetic field compatible
- High speed and torque input to reduction gears
