보안과제 ( ) 일반과제 ( o ) EO120017 한국생산기술연구원연구운영비지원 경량소재, 전동력응용및생산공정융합기술개발 Development of Merged Technology of Light-weight material, Electro-mechanical application, and Manufacturing process 한국생산기술연구원 한국생산기술연구원
연구보고서, Development of Merged Technology of Light-weight material, Electro-mechanical application, and Manufacturing process
() 1., Development of Merged Technology of Light-weight material, Electro-mechanical application, and Manufacturing process ) 1~9 ([ 3] P. 61~) / ) /
2. / - - -. - (1.1kW/kg) - - (FVM) CAE - (Al Mg ). - 1.1kW/kg 21kW - DSP 20kW~30kW - -, - 185.7W/m K Al - 2,500Hv AIP
3. R5220121003A, R52201210072, R5220121013F PCT/KR2012/006295, PZT OCT - : 13/504,706 US, - : PCT/KR2012/ 004697, 4. - - CO2 - - Eco-Vehicle /,, -, 5. - 5 -
1 1 2 3 2 1 2 3 1 1. 2. 3. 2 1. 2. - 3
1 1 1.,, OA,,,,. - 1 -
2.,,,,,,,., EU,. (HEV, EV, PHEV) - 2 -
,. 2003 CARB, CO 2 ( 2009 140g/km) Tier-Ⅱ, LEV-Ⅱ, EURO-Ⅳ EURO-Ⅴ, 2007, FMVSS,,. 2003 11.06%, 9.77% 2004 22 8.04%.,,,. 1 40, 1 80., EV( ), FCEV( ). - 3 -
3..,.,,,,,,,,,.,, Line Start Permanent Magnet Motor(LSPM Motor), Brushless DC Motor(BLDC Motor), Synchronous Reluctance Motor(SynRM), Free Style Motor,,. - 4 -
VVVF(Variable Voltage Variable Frequency). GaN Si 30%. 4,500 4,400 4,300 비용 [$] 4,200 4,100 4,000 3,900 3,800 Sillcon GaN 4. (SiC) (GaN) 10% 4% 10% km 10kg CO 2.,. - 5 -
CO 2 - -, - / - -,, -,, -,, (234W/m K),. Al-Si-Cu (96W/m K, 41%),.,. - 6 -
, - -. 5. - -,, - 2-2000,, - 7 -
Toyota, Aisin, Honda John Deere(), CNH(), AGCO () / 100~250kW Trans-axle (HMT),, / 100kW (HMT) 3 Trans-axle(HMT),, & Power shuttle/shift,, - 62kW 1 95kg 2 65kg 3 55kg 4 50kg.,,. 60kw ( ) (Kw/kg) 1.1 1.2, (), - 8 -
. 5. 6. - 9 -
(,,, 50kW ) - :,, 7. () - ( ) :, 8. ( ) - ABB ( ) : IMO().,. 60 120kW, PMSM. - 10 -
적용된선박추진체단면도 9. (ABB) - LS (IT ) :, 40~120kW. 적용된 IT 농기계 구동모터 10. (LS ) 1 2, 3. -, ISG 50%, 20%, 20% -, 15% - Rotor,, - 11 -
, 2005 600V/5A (SiC) 2007 1200V/8A SiC. RF SiC MOSFET KEC 600V/20A SiC MOSFET. SiC,, SiC. 2008 900V, 0.85m Ω m 2 SiC, 20%. 2009 2 3 thinkq! SiC.. 11. Infineon SiC SiC 3kV (SBD, Schottky Barrier Diode) 3.3kV. 3kV SiC-SBD - 12 -
30%. 12. SiC-SBD 3kV 2009 SiC, SiC 2.5, 20% 20kW Si 90%. SiC MOSFET SiC SBD 13. SiC SiC 1.2kV 230A 280kVA. SiC SiC. 14. - 13 -
SiC Si IGBT 1/7., 4. SiC "Full SiC" ( 1200V / 100A)., SiC 1,200V 200A SiC-MOSFET SiC-SBD 6, Si 2 2015 EV. GaN GaN IC., 900V 800. 2011 70kW. 50%. SiC, 15.,, - 14 -
,,,,,, (weight reduction), Al, Mg Ti, Al Mg,, / /, - - / / - 15 -
3 - Eco-Vehicle /,, -, - - - - - 80% (2030 )) -, - - - - 16 -
2 1 1.1kW/kg - 95% - 5kW/L (FVM) CAE (Al Mg ) Arc Ion Plating -, - 2,500Hv 시작품적용대상 : Eco-vehicle 구동기당해연도는전기차용구동기로제작 적용기술대상 : 고출력밀도달성을위한기술적용 당해연도시작품집중분야 : ( 통합진행 : 인버터 + 모터 + 열해석 ) 차년에적용될소재원천기술확보 : 고방열소재기술 - 17 -
목표항목 주요성능 1. 열전도도율 ( 순금속대비 ) 2. 출력밀도 단위 전체항목에서차지하는비중 세계최고수준 보유국 보유기업 연구개발전국내수준 개발목표치 성능수준성능수준당해연도 % 20 80 ( 일 /DAIKI) 50 75 kw/k g 평가방법 ASTM E-1461 30 0.8 0.5 1.1 KS C 4214 3. 전동기효율 % 15 90 88 90 KS C 4214 4. 인버터효율 % 20 97 ( 일 / 미쓰비시 ) 95 95 KS C 4214 5. 코팅경도 Hv 15 2,700 ( 일본 / 히타치 ) - 2,500 경도시험 KS 2-1.1kW/kg - - (FVM) CAE - (Al Mg ) - 1.1kW/kg 21kW - DSP 20kW~30kW - -, - 185.7W/m K Al - 2,500Hv AIP - 18 -
3 1 + + +,., S/W balancing.,,,.,,,. 3 CAE. 3 DB,., - 19 -
,. AIP., Bias power Arc power,. - 20 -
개발목표 경량소재및전동력응용구동모듈요소기술개발 계획및자료수집 표면처리공정조건제어 합금설계 고출력구동전동기설계 전력변환기효율향상기술 차년도 년 열전도율 냉각해석및설계적용 물성평가 전동력응용구동모듈성능평가 1 차년도결과보고서 차년도계획수립 - 21 -
경량소재, 전동력응용및생산공정융합기술연구책임자 : 김명복 ( 선임연구원 ) 핵심기술 I 소재및표면처리기술개발 시스템사양 소재원천기술 핵심기술 II 전동력응용구동모듈개발 요소기술 1 경량고방열합금기술 요소기술 2 기능성표면처리기술 요소기술 3 고효율전동기기술 요소기술 4 고효율인버터기술 조재익, 손현택김철우 강창석, 최세원김영찬 이성호, 차현록이규석, 임대영 김명복, 최인철곽봉우 - 고열전도도합금개발 - 주조성평가및결함제어기술개발 - 기계적성질평가 기술협의 - 코팅공정조건도출 - 코팅층물성평가 - 고출력고속구동모듈설계 - 구동모듈모델링 /Grid 생성 - 구동모듈냉각해석결과분석및성능평가 기술협의 - 고효율전력변환기설계기술 - 수요전력별최적설계기술 - 열해석시스템구축 융합기술협의 - 22 -
2 1 2 3 4 5 6 7 8 9 10 11 12 1 100% 2 100% 3 1 100% 4 100% 5 100% 6 power 100% 7, Grid 100% 8 DB 100% 9 100% 10 1 100% 11 100% 12, 100% 13 100% 14 1 100% 15 100% 16 100% - 23 -
1) - 20kW 7kg.. 1. ( ) ( ) 4.9A/mm2 7A/mm2 180Φ 170Φ 90mm 45mm 17.4kg 9.5kg 17.5kW 20.7kW 16. Winding Fill factor 20%.. - 24 -
17. 12500rpm 6000rpm 45mm. rpm. 18. 33%, 35%. - 25 -
19. 2. V 310-6 - 9 mm 45 rpm 12,500-4.5Φ*1Reel*9Tc Throw - 1-1 Φ 170 Air gap mm 0.7 kw 21 % 91 N.m 16 (rms) A 67.8 A/mm 2 4.26 V(peak) 155-26 -
20,, 21. 1.1kW/kg ( 21kW, 19kg) 22. - 27 -
23. PSIM - DSP - LPF ADC filter - Resolver - IPMSM MTPA(Maximum Torque per Ampere) * w r * I m * i qd * V dq w r * di d i qd i abc d dt q r ) - 28 -
)PSIM ) PSIM 24. PMSM PSIM - : 1kW - : 50VDC ~ 450VDC - : 150MHz DSP (TI TMS320F28335) 25. 1-1200V, 100A IGBT - : 20kW~30kW - 29 -
26. 1 27. - 3D - - 30 -
28. 3D - - - ANSYS v14 29. - ( 20 ), 150-31 -
- 7.9W/m 2-17 340W/m 2 ( ) 30. - : - 21 - : 750, Mold 200, : SF 6, CO 2 x = 1, 2, 3, 4wt%) 2Ca (x = 2, 3, 5wt%) Ca (x = 3, 6, 9wt%) 2Ca (x = 2, 4, 6wt%) 1Sn-1Ag-xLi (x = 0, 11wt%) 3Zn-1Sn-0.4Mn-xCa (x = 0.4, 0.8, 1.2) -3Zn-1Sn-0.4Mn-0.4Zr 0.4Ag, 0.2Ca-0.6Zr-xLi ((x = 0, 11wt%) 2t Φ12.7 31. - Ca, Sn, Zn Ag - Al Li - Mg-Sn-Ca : 135.7W/mK ( 84.8%, AZ91 Mg 289% ) - 32 -
175 Mg-xCa(x=1, 2, 3, 4) Mg-xSn-2Ca(x=2, 3, 5) 200 175 Mg-xAl-2Ca(x=3, 6, 9) Thermal Conductivity, W/mk Thermal Conductivity 150 125 100 75 50 25 0 0 50 100 150 200 250 300 200 175 150 125 100 75 50 25 Pure Mg Temperature Mg-xZn-2Ca(x=2, 4, 6) Mg-1Ca Mg-2Ca Mg-3Ca Mg-4Ca Mg-2Zn-2Ca Mg-4Zn-2Ca Mg-6Zn-2Ca Thermal Conductivity Thermal Conductivity 175 150 125 100 75 50 25 0 0 50 100 150 200 250 300 150 125 100 75 50 25 Temperature Mg-2Sn-2Ca Mg-3Sn-2Ca Mg-5Sn-2Ca Mg-3Zn-1Sn-1Ag-xLi(x=0, 11) LZSM11310-1Ag ZTSM310-1Ag Thermal Conductivity Thermal Conductivity 150 125 100 75 50 25 0 0 50 100 150 200 250 300 Temperature Mg-3Al-2Ca Mg-6Al-2Ca Mg-9Al-2Ca Mg-6Zn-0.4Ag-0.2Ca-0.6Zr-xLi(x=0, 11) 175 150 125 100 75 50 25 Mg-6Zn-0.4Ag-0.2Ca-0.6Zr-11Li Mg-6Zn-0.4Ag-0.2Ca-0.6Zr 0 0 50 100 150 200 250 300 Temperature 0 0 50 100 150 200 250 300 Temperature 0 0 50 100 150 200 250 300 Temperature 32., - - 33. Ca SEM - 33 -
34. Al Al - (Cu, Fe, Mg, Mn, Si), Mn -, Mn Cp (J/g/K) 0.90 0.89 0.88 0.87 0.86 Cu Fe Mg Mn Si 0.85 0.0 0.5 1.0 1.5 2.0 2.5 Content (wt%) Thermal Diffusivity (mm 2 /s) 120 100 80 60 40 Cu Fe Mg Mn Si 20 0.0 0.5 1.0 1.5 2.0 2.5 Content (wt%) Thermal Conductivity (W/mk) 270 240 210 180 150 120 90 Cu Fe Mg Mn Si 60 0.0 0.5 1.0 1.5 2.0 2.5 Content (wt%) ( ) Cp ( ) ( ) 35. Si, Cu, Mg, Fe, Mn - Mn, Mg 2.5±0.2wt%. -, 225.3W/m K 80%, 185.7W/m K. - 34 -
(wt.%) Alloy Si Fe Cu Mg Mn Al 1 0.02 0.11 0.011 0.00051 0.0005 Rem. 2 0.98 0.39 1.123 0.011 0.0025 Rem. 3 1.48 0.62 0.593 0.008 0.0033 Rem. 4 1.68 0.39 0.244 0.005 0.0027 Rem. 5 1.96 0.62 0.004 0.010 0.0022 Rem. Thermal Diffusivity(mm 2 /s) 270 100 2.80 1.1 2.78 240 90 2.76 1.0 210 2.74 2.72 180 80 2.70 0.9 2.68 150 70 2.66 Diffusivity 2.64 0.8 120 Density Cp 2.62 60 2.60 0.7 90 No. 1 No. 2 No. 3 No. 4 No. 5 Density (g/cm 3 ) Spec. Heat (J/g/K) Thermal Conductivity(W/(mk) 225.3 181.6 185.7 185.7 172.7 No. 1 No. 2 No. 3 No. 4 No. 5 ( ), Cp ( ) 36. (fluidity) - Si 1.0 2.0wt%, Cu. - Si 1.5~2.0wt% ALDC12 58%. - (58MPa) 2.5, (24.7%) 85%. 1000 800 805.6 Flow Length(mm) 600 400 200 324.3 405.2 466.2 466.7 0 No. 2 No. 3 No. 4 No. 5 ALDC12 ( ) ( ) 37. AIP TiAlN TiAl N 2, AIP - 35 -
AIP Targets TiAl Reactive gas N2 Substrate SKD61 Base pressure 8 10-5Torr Working pressure 35mTorr Deposition temperature 450 Substrate bias voltage -60V Flow rate of gas 1sccm FE-SEM, EDX ( ), TiAlN ( ) ( ) 38. TiAIN SEM TiAlN EDX Element At% N 50.61 Al 23.68 Ti 25.70, 2,500Hv - 36 -
39. TiAIN - 37 -
2) 12 12 12 열전도도율 84.8% (Mg) ( 순금속대비 80% 75% 80.0% (Al) ) - - 출력밀도 0.8kW/kg 1.1kW/kg 1.1kW/kg - - 전동기효율 90% 90% 91% 인버터효율 97% 95% 96% - - 코팅경도 2,700Hv 2,500Hv 2,800Hv - 3) 20kW ( 30% ) (/ ) SCI SCI 3 3 (10/) / 3/0 / / / / / / / 3/0 / / / / 4) 1. ( ) 75% 100% 2. 1.1kW/kg 100% 3. 90% 100% 4. 95% 100% 5. 2,500Hv 100% - 38 -
3 1) /,,,,,, HEV, EV, 40. - 39 -
2) - - CO2 - - 80% (2030 )) -, - - - - Eco-Vehicle /,, -, - - - -, - 40 -
- - - 3 - - / - - - - (,, ) 경량구동모듈? 요소기술확보 [1 단계 ]? 공정최적화? 핵심원천기술확보 [2 단계 ]? 상용화기술? 기술이전 [3 단계 ]? 친환경자동차산업? 가전산업? 레저선박산업? 신재생에너지산업 전동력응용 경량소재생산기반 핵심원천특허확보고효율전동력응용시스템기술경량구동모듈소재기술경량구동모듈생산기반기술 경량 구동모듈 요소특허 융합특허 41. - 41 -