Hyundai Product and Technology FairSolutions for HEV - MotorsHyundai / Kia R&D Center - June 27 th, 2006
Raimund PillathStefan SeifertJohnny YeoSteven SW Lee
Group EA 3 / 4 / 5"Environment –
Alternate Energy / Power"
2Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Electrical Insulation Systems ( EIS )• Wire Enamels (WE)
• Impregnating Resins (IR)
• Core Sheet Varnishes (CSV)
Where are we locatedOur headquarters for business responsibility and R & D are located in Germany and in Austria
EIS belongs to BU: DuPontDuPont Performance Performance CoatingsCoatings
3Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - MotorsDuPont - Five Growth Platforms
DuPont Safety &
Protection
DuPont Electronic &
Communication Technologies
DuPont Coatings & Color
Technologies
DuPont Performance
Materials
DuPont Agriculture &
Nutrition
Market Leadership
Large Opportunities Strong
Capabilities
4Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Wuppertal
Nanjing
Brazil
Canada
Mexico
Austria
DPC Production CenterLicencees
Tollmanufacturer
NagoyaShanghai
Locations Electrical Insulation Systems ( EIS )
DuPont’s Electrical Insulation Systems are available everywhere in the world.We can supply globally and offer local service.
Headquarters and R & D Centers
Service and application labs in China (Shanghai), Mexicoand Japan (Nagoya) (DKK Automotive Center)
Jiangyin
5Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Paint and Exterior
DuPont AutomotiveThis is how you know us …today
6Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Materials for Chassis and Structural
DuPont AutomotiveThis is how you know us …today
7Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Materials for Under Hood Components
Electrical Insulation Systems for Electrical Motors• Wire Enamels• Impregnating Resins• Core Sheet Varnishes
DuPont AutomotiveThis is how our customers know us …today
8Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Battery - Ni-Me-H system- Li-Ion system- Ultra-Capacitors
Inverter / Converter- DC-AC Inverter- DC-DC Converter
Electric Motor- Engine Starter - Drive to Wheel- Charge to Battery
Generator
ECU - Electronic Control Unit
for each system
Hybrid Electric Vehicle: Unique Systems
9Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Battery• Ionic liquids, electrolyte, binder• Membranes• Housing: Engineering Polymers
Inverter / Converter• Engineering Polymers
for housings, electrical transformer, new cooling system
• Electronic Materials
Generator & Electric Motor• Magnet Wires (Wire Enamels)• Impregnating materials• Insulation materials• High temp. eng. Polymers
Electronic Control Unit• Housing: Eng. Polymers• Polymeric film for Insulation• FCM, MCM
Opportunities for Material Solutions from DuPont
Solutions for HEV - Motors
10Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - MotorsSolutions for HEV - Motors
DuPontDuPont Materials in a MotorMaterials in a Motor
Vespel®
Delrin® (POM) Zytel® (PA)
Crastin® (PBT)
Zenite®
Teonex® (PEN)
Teflon®
Crastin®
Nomex®
Kapton® (CR) Vespel® (PI)
Voltron®
Wire Enamel
Voltatex®
Core Sheet Varnish
Impregnating Resin
11Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - MotorsSolutions for HEV - Motors
Purpose of Wire Enamels• Primary Insulation of Round or Rectangular
Copper or Aluminum Wires
12Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
0,4 0,3 *)
> 1000> 900 *)
297
55 *)120
54 *)2 1 *)
0,0
100,0
200,0
300,0
400,0
500,0
600,0
700,0
800,0
900,0
1000,0
1100,0
Lifetime of different Magnet Wires under Inverter DutyLi
fetim
e [h
]
Standard, PEI+ AI Voltron™ Coating 1 Coating 2 Coating 3*) magnet wire with 10% pre- stretching ; coatings 1, 2 and 3 are pigmented insulation films
• VoltronTM E 3597 is a new generation of magnet wireinsulation that solves the problem of premature failures of inverter fed motors
Value for Hyundai Motor Company⇒ VoltronTM magnet wires for HEV - MotorsValue for Hyundai Motor Company⇒ VoltronTM magnet wires for HEV - Motors
13Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
-1500
-1000
-500
0
500
1000
1500
-0,002 -0,0015 -0,001 -0,0005 0 0,0005 0,001 0,0015 0,002
Time [s]
Volta
ge [V
]
Voltage at the motor
Corona inception at +/- 850 V
Voltage vs. Time at the Input of an Inverter Driven Electrical Motor
14Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Benefits when using VoltronTM magnet wire• outstanding corona resistance
• prevent premature failures caused by partial discharges
• very high V-t Lifetime (more than 1000 hrs @ 2,4 kV)
• superior thermal properties under the influence of ATF – oil
• good flexibility
• high increase of film hardness
• use of nanotechnology ( no classical fillers )
15Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Purpose of Impregnating Resins• Mechanical Strengthening of the Winding
• Additional Electrical Insulation
• Protection against Chemical and Mechanical Attack
• Improved Heat Transfer
16Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Graph shows excellent emission behavior compared to conventional styrene-based products
0
200
400
600
800
1000
1200
0 20 40 60 80 100 120 140 160 180Curing Time (min)
Emis
sion
s (p
pm -
calc
ulat
ed a
s C
H 4)
UP-Impregnating Resinstyrene-basedE 4011, LP1006 lowemission
Comparison of Emissions 1K-Impregnating Resins: styrene-based / low emission systems
Value for Hyundai Motor Company⇒ low emission 1K-Impregnating Resins
E 4011 UV & LP 1006 UV
Value for Hyundai Motor Company⇒ low emission 1K-Impregnating Resins
E 4011 UV & LP 1006 UV
17Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Aging Performance: comparison between conventional systems & new developed products shows excellent Bond Strength
M agne t Wire : Impreg. R e s in: Standard: IEC 61033
100 windings/ 0,315mm/twisted 720° Curing conditions date: 17.03.2006
Conditions for impre g.: Twisted Coil 10 min horizontal dipping - 10 min horizontal draining - Curing 4h in horizontal position at 150°C
Twiste d Coil:
Decrease of Bond Strength on Twisted Coils at 155°C after Aging at 260°CS H Therm 210 Grd 1 se e lege nd
4h 150°C
30
50
70
90
110
130
150
170
190
210
230
250
270
290
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70Aging Time (days)
Bon
d St
reng
th (N
)
conventional Styrene-based Impregnating Resin
E 4011
LP 1006
18Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
What‘s so special about Electrical-UV ?
Value for Hyundai Motor Company⇒ Herberts® Electrical / UV - ProcessValue for Hyundai Motor Company⇒ Herberts® Electrical / UV - Process
State of The Art Impregnating Technology
• most environmental-friendly impregnating-technology
• amount of resin usage and impreg-nating quality can be controlledexactly from average to maximum
• draining losses and evaporationlosses are minimized
• combined with low emission productsand high pre-heat temperaturesemissions from 1-3 % only are possible
19Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Value for Hyundai Motor Company⇒ Herberts® Electrical / UV - Process
(for Impregnation of Stators)
Value for Hyundai Motor Company⇒ Herberts® Electrical / UV - Process
(for Impregnation of Stators)
0
20
40
60
80
100
Cos
ts (%
)
Plant Energy ProcessingTime
Cleaning ReductionVOC
Typical Dip & Bake Process Electrical / UV Process
20Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Purpose & Users of Core Sheet Varnishes• Purpose:
electrical insulation of each metal sheet to another for construction of magnetizable cores in electrical machines
• Users:Producers of electrical steel and big-sized generators,worldwide
• VOLTATEX®:DuPont brand name for the family of highly sophisticated core sheet varnishes
21Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Value for Hyundai Motor Company⇒ VOLTATEX® E 1175W:Value for Hyundai Motor Company⇒ VOLTATEX® E 1175W:
Properties5 excellent 0 not applicable
DuPont has developed the self-bonding varnish VOLTATEX® E 1175W, a waterborne system with excellent insulation and processing characteristics.These advantages make VOLTATEX® E 1175W the ideal insulation system for high performance applications, e.g. advanced HEV- Motors.
012345
Insulation
Punching
Overcoatability
Corrosion
Pressure StabilityBurnoff repair
Annealing
Welding
Bonding
22Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Benefits when using Core Sheet VarnishVoltatex® E 1175W• Functional self-bonding varnish to hold a stack of electrical steel
sheets together and form a solid core
• Exact stack dimensions and flexibility in design
• homogeneous core stacking and no interlaminar cross-circuit in the stack
• No squeezing effect
• Excellent surface insulation
• High bond strength
• Waterborne system, environment-friendly, innovative varnish systems
23Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
• VOLTATEX® E 1120:the innovative Titanate based C5 insulation system with high heatresistance as an environmental-friendly alternative to delicate chromiumbased varnishes (complies with the stringent RoHS standards)
• VOLTATEX® E 1175W:self-bonding varnish system based on epoxy resins allowing a very efficient fixing technology for core sheet stacks
• VOLTATEX® E 1151:pigmented and filled core sheet varnishes engineered especially for the advanced generator industry
• VOLTATEX® E 1153:unfilled systems with excellent punching performance and outstanding resistance against mechanical and chemical influences
=> all VOLTATEX® systems are waterborne systems
Product Range VOLTATEX®: The Family of Core Sheet Varnishes
24Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
From Electrical Steel To Electrical Machinesyellow Requirements of Core Sheet Varnishes
Electrical Steel
Application
Compound Technologies
Punching
Annealing
Electrical Machines
GeneratorMotor Transformer
CorrosionInsulation
Al die castingStacking Welding Bonding
25Hyundai Techology Fair - DuPont Performance Coatings, ACS, SC, Electrical Insulation Systems, Raimund Pillath, June 27-2006
Solutions for HEV - Motors
Impregnating Materials Wire Enamels Core Sheet Varnishes
DuPont Performance Coatings Electrical Insulation Systems