SAE 2012 Powertrain Electric Motors Symposium

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Apr 23, 2012 ... The Westin Book Cadillac. Detroit, Michigan ... Sun Wing Lui, PhD ..... Chunting ( Chris) Mi, University of Michigan-Dearborn (See page 21 for complete abstract & biography) ..... This compendium presents the most complete.
SAE 2012 Powertrain Electric Motors Symposium for Electric+Hybrid Vehicles Monday, April 23, 2012 The Westin Book Cadillac Detroit, Michigan USA In conjunction with the SAE 2012 World Congress

Event Guide Includes Final Program and Exhibit Directory

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2012

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ON-HIGHWAY • OFF-HIGHWAY • DEFENSE October 2-3, 2012 Donald E. Stephens Convention Center Rosemont, Illinois USA

Total Vehicle Integration:

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What’s inside

Symposium Overview General Information Floor Plan Technical Program Speaker Biographies & Abstracts Exhibitors Profiles Sponsors

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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SYMPOSIUM OVERVIEW

SAE International Board of Directors OFFICERS Frank O. Klegon 2012 President Richard E. Kleine, EdD 2011 President Donald G. Hillebrand, PhD 2013 President Nominee Gregory E. Saunders Vice President – Aerospace Mircea Gradu, PhD Vice President – Automotive Bharat Vedak Vice President – Commercial Vehicle Ronald G. Rath Treasurer Robert Ireland Assistant Treasurer David L. Schutt, PhD Chief Executive Officer Gregory L. Bradley Secretary

Meet and mingle with technology leaders by attending the Electric Motors event. Unlike other events, this Symposium puts great emphasis on the electric motor, and will give a comprehensive overview on the latest global innovations in the vehicle powertrain electric traction motor industry. It will give insight on how fast the major players are moving and how this affects the world marketplace. This Symposium will also give an overview on new developing supply chains. The program will address market growth projections, requirements, and cost structures for three varieties of electric traction motors: permanent magnet motors, induction motors, and switch reluctance motors. This year’s symposium will feature expanded coverage of rare earth metals, and, for the first time, presentations on testing and simulation. By offering the latest insights, knowledge and visions, the Powertrain Electric Motor Symposium will enable decision makers to make a more well-balanced consideration on investment opportunities and risks. This year’s event will be co-located with SAE 2012 World Congress, where additional electric vehicle sessions will be offered. Similar SAE Powertrain Electric Motor events are being planned to be held in Asia and Europe later during 2012.

DIRECTORS Bernard J. Challen, MSc CEng Wendy Clark Susan Collet David J. Gorsich, PhD Richard Greaves, PhD Klaus Hoehn, PhD Yoshio Kawakami Sandra Krug, PhD Sun Wing Lui, PhD Charon Morgan Victor H. Mucino, DEng Srinivas R. Srinath, PhD Robert Sump David Vasquez Mark P. Zachos

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

EVENT OVERVIEW April 22

April 23 Registration

Exhibit Open

7:00 a.m. - 3:00 p.m.

8:00 a.m. - 5:00 p.m.

graciously sponsored by

Continental Breakfast 7:30 - 8:00 a.m. Technical Session 8:00 - 9:30 a.m. Networking Break and Exhibit 9:30 - 10:00 a.m. Early Bird Registration 11:00 a.m. - 3:00 p.m.

Technical Session 10:00 a.m. - 12:30 p.m Networking Lunch and Exhibit 12:30 - 1:45 p.m. graciously sponsored by

Technical Session 1:45 - 2:45 p.m. Networking Break and Exhibit 2:45 - 3:15 p.m. Technical Session 3:15 - 5:00 p.m.

Additional Electric Motor sessions offered at SAE 2012 World Congress (separate registration required) Electric Motor & Power Electronics (PFL104) Tuesday, April 24 10:00 a.m. – Part 1 1:00 p.m. – Part 2 Cobo Center - Room O2-44 Power electronics and electric motors are essential for improving vehicle efficiency through drivetrain electrification. Technologies that support high efficiency, high power density, and low cost motors and power modules are required for the success of vehicle electrification.

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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General Information Emergency Hotline 1-800-581-9295

SAE International World Headquarters 400 Commonwealth Drive Warrendale, PA 15096-0001 USA Phone: 1-724-776-4841 Fax: 1-724-776-0790

Hours of Operation SAE Registration

Registration Package

Book Boardroom, 3rd Level

Symposium amenities include: access to the Technical Sessions, Exhibit, Networking Lunch and Refreshment Breaks, electronic copies of the presentations (provided post-event)

Sunday, April 22 11:00 a.m. – 3:00 p.m. Monday, April 23 7:00 a.m. – 3:00 p.m.

Customer Service 1-877-606-7323 (toll free U.S. and Canada) 1-724-776-4970 www.sae.org [email protected]

Automotive Headquarters 755 W. Big Beaver Rd. Troy, MI 48084 Phone: 1-248-273-2455 Fax: 1-248-273-2494

On-site Registration Fees

Registration Area Sponsored by

SAE Classic Member $830 SAE Premium Member $805 SAE Elite Member $780 Non-Member $1230 Technical Program Participant Free (includes presenters, speakers, symposium chair, panelists & moderator)

SAE 2012 Engineering Meetings Board Chairperson Dr. Kamran Rokhsaz Wichita State University Vice Chairperson Dr. Volker Sick University of Michigan-Ann Arbor Past Chairperson Dr. Walter W. Olson University of Toledo Members Air and Space Group (ASG) Chair H. Robert (Bob) Welge Robert’s Engineering Development Land and Sea Group (LSG) Chair Cornelius N. Opris Caterpillar Inc. Service Technology Program Committee (STPC) Chair Kathy Kedzior Mahle Powertrain, LLC

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Sustainable Development Program Committee (SDPC) Chair Stephen Landes Retired Technical Quality Response Team (TQRT) Chair Dr. Pranab Saha, PE Kolano and Saha Engineers, Inc. Members-at-Large David Amirehteshami The Boeing Company Joseph J. Barkai IDC Manufacturing Insights Prof. Bernard J. Challen Shoreham Services Prof. Samir N. Y. Gerges Federal University of Santa Catraina Wei-Jian Han, Ph.D. Ford Motor Company Alain P. Jablonowski Robert Bosch LLC

Patrick Leteinturier Infineon Technologies AG James C. Miller Deere & Company Matthew Newkirk Afton Chemical Corporation June Ogawa The Boeing Company Gerald S. Shoemaker Cessna Aircraft Company Nakia Simon Chrysler Group LLC Prof. Richard K. Stobart Loughborough University Arnold A. Taube, PE Deere & Company Dr. Kamal Kishore C. Vora ARAI Academy SECRETARY Patti Kreh SAE International

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

Continental Breakfast

Luncheon

Woodward Foyer, 2nd Level

Woodward Ballroom, 2nd Level

Monday, April 23 7:30 – 8:00 a.m.

Monday, April 23 12:30 – 1:45 p.m.

Exhibits

Networking Breaks

Woodward C/D, 2nd Level Monday, April 23 8:00 a.m. – 5:00 p.m.

Luncheon Sponsored by

Woodward Ballroom 2nd Level Monday, April 23 9:30 – 10:00 a.m. 2:45 – 3:15 p.m.

Technical Sessions

Conference Notepads and Pens Provided by

Woodward Ballroom, 2nd Level Monday, April 23 8:00 a.m. – 5:00 p.m.

WORLD-CLASS SOLUTIONS FOR THE AUTOMOTIVE INDUSTRY. The Rea Magnet Wire Company, Inc. is one of the world’s largest manufacturers of magnet and nonferrous wire products. Magnet wire is a required component of every motor and transformer, no matter who builds it or where in the world it’s built. Everything that is electrically driven – from cars to computers – contains magnet wire. A supplier to some of the largest automotive parts suppliers in the world, Rea Magnet Wire is developing partnerships, building world-class products and helping our customers succeed today and on the road to the future.

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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Floorplan

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P REFUNCTION LOBBY

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles JEFFERSON BOARDROOM

P REFUNCTION LOBBY

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SYMPOSIUM AGENDA 8:00 a.m.

Welcome and Introductions Ray Bakerjian, SAE International 8:00 a.m.

Monday April 23

Keynote Presentation: Racing Green Endurance: An EV Record Alexander Schey, Vantage Power (See page 10 for complete abstract & biography) 8:30 a.m.

Global Market Developments

Wolfgang Bernhart, Roland Berger Strategy Consultants (See page 11 for complete abstract &

biography)

9:00 a.m.

Hidden Costs in Motor Specifications

David A. Fulton, Remy International (See page 12 for complete abstract & biography) 9:30 a.m.

Networking Break and Exhibit 10:00 a.m.

The Supply of the Heavy Earth Metals and the Demand for them by the Global OEM Automotive Industry Jack Lifton, Technology Metals Research, LLC (See page 13 for complete abstract & biography) 10:20 a.m.

Material Technology Challenges and Opportunities for Traction Motors Yucong Wang, General Motors Company (See page 14 for complete abstract & biography) 10:40 a.m.

Metals in Motors

Invited, Ford Motor Co. (See page 15 for complete abstract & biography) 11:00 a.m.

Copper-Rotor Induction- Motors: One Alternative to Rare Earths in Traction Motors Malcolm Burwell, The Copper Alliance (See page 16 for complete abstract & biography) 11:20 a.m.

Battery Metals for 21st Century Power Trains

Jon Hykawy, Byron Capital Markets (See page 17 for complete abstract & biography) 11:40 a.m.

Rare Beef and Rare Earths: Why Process Technology Matters Larry Thomas, Primet Precision Materials (See page 18 for complete abstract & biography)

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

12:00 p.m.

Panel Discussion: Metals in Motors Moderator:

Panelists:

Wolfgang Bernhart, Roland Berger Strategy Consultants (See page 11 for

complete abstract & biography)

Jack Lifton, Technology Metals Research, LLC (See page 13 for complete abstract &

biography)



Yucong Wang, General Motors Company (See page 14 for complete abstract & biography) Larry Thomas, Primet Precision Materials (See page 18 for complete abstract &

biography)



Jon Hykawy, Byron Capital Markets (See page 17 for complete abstract & biography) Malcolm Burwell, The Copper Alliance (See page 16 for complete abstract & biography) Invited, Ford Motor Company (See page 15 for complete abstract & biography)

MONDAY April 23

12:30 p.m.

Networking Luncheon and Exhibit 1:45 p.m.

Challenges and Requirements for High Volume Production of Electric Machines

Wei (William) Cai, Jing-Jin Electric Technologies Co., Ltd. (See page 19 for complete abstract

& biography)

2:15 p.m.

Advanced Testing of Electric Drives and Motors

Voiko Loukanov, D&V Electronics Ltd. (See page 20 for complete abstract & biography) 2:45 p.m.

Networking Break and Exhibit 3:15 p.m.

Will they prevail in Electric Drive Vehicles: Comparison of IPM, Induction, FSPM, DSPM and other New Electric Machine Topologies Chunting (Chris) Mi, University of Michigan-Dearborn (See page 21 for complete abstract & biography) 3:45 p.m.

GM’s Automotive Traction Motor Field Experience and Cost Opportunities

Matthew Laba, General Motors Company (See page 22 for complete abstract & biography) 4:15 p.m.

Panel Discussion: OEM and Suppliers on Engineering Moderator:

Panelists:

Wolfgang Bernhart, Roland Berger Strategy Consultants (See page 11 for complete

abstract & biography)

Matthew Laba, General Motors Company (See page 22 for complete abstract &

biography)



Patrick Wilson, Parker Hannifin Corp. (See page 23 for complete abstract & biography) Wei (William) Cai, Jing-Jin Electric Technologies Co., Ltd. (See page 19 for



complete abstract & biography)



abstract & biography)

5:00 p.m.

Adjourn

Voiko Loukanov, D&V Electronics Ltd. (See page 20 for complete abstract & biography) Chunting (Chris) Mi, University of Michigan-Dearborn (See page 21 for complete The purpose of the sessions is to provide an open exchange of ideas. Remarks made by participants or members of the audience cannot be quoted or attributed to the individual or their company unless express permission has been granted by the individual and their company. Any record of remarks, discussion, or photographs may not be used unless express permission has been granted by the individual and their company.

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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speaker biographies and abstracts Keynote Presentation: Racing Green Endurance Alexander Schey CEO Vantage Power

While studying Mechanical Engineering at Imperial College, Alex found his passion in energy and the future of transportation. He realized that the technology for sustainable transportation was already present, but that the public was ill-informed about its potential. In January 2009, Alex set up Racing Green Endurance; a project aimed at designing and building the world’s longest range electric car, and then proving this technology to the world by driving it along the 26,000 km long Pan-American Highway from Alaska to Argentina! Documented by the BBC, the project was well received throughout the world, and helped change public perception about electric cars forever.

Abstract Racing Green Endurance: An EV Record will focus on what a small team of ambitious and talented engineers can do when they have a dream! Back in 2009, a team of graduates from Imperial College London came together to do something radical to change the public perception of electric vehicles forever. They came up with the idea to design and build the world’s longest range electric car, and then drive it down the longest and toughest road in the world; the 26,000km Pan-American Highway! Racing Green Endurance: An EV Record will share the story from start to finish, and will also focus on the technology used to achieve such a feat, with particular mention of the electric motors.

Notes

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

Global Market Developments Wolfgang Bernhart Partner, Automotive Competence Center Roland Berger Strategy Consultants

Dr. Wolfgang Bernhart has been working in the automotive industry for 17 years. In 1993, he earned his Ph.D. from the University of Karlsruhe’s Institute of Production Science (thesis paper on Calculation In Parallel To Development). After serving as Key Account Director Daimler at COVISINT in Amsterdam, he managed the European automotive activities at Arthur D. Little between 2003 and 2006. He has been Partner at Roland Berger Strategy Consultants GmbH since 2007.

Abstract The traction motor is key to the “synergy of the electric powertrain”, the overall functionality of the battery, e-motor, power control electronics, and charging system. Therefore some automakers have decided to design, develop, and produce their traction motors in house while some others are working with suppliers for their electric power train motors. Off-the-shelf motors, no matter how extensively they are adapted for a specific application, can compromise the efficiencies of the propulsion system.

He consults German and international companies on topics ranging from operating processes and organizational issues to global strategic realignment. He is a specialist on development and technology topics. Wolfgang Bernhart has clients in Germany, France, Italy, Russia, the US, China, etc. Dr. Bernhart has written various articles and lectured on various hot topics, e.g. new powertrain concepts (incl. electric and hybrid vehicles) CO2/consumption reduction, low-cost business models and challenges and opportunities in emerging markets (esp. Russia and China)

Notes

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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speaker biographies and abstracts Hidden Costs in Motor Specifications David A. Fulton, PE Director, Advanced Engineering & Technology Development Remy International

David A. Fulton received B.S. and M.S. degrees in mechanical engineering from Valparaiso University and Northwestern University, respectively. He joined Delco Remy Div. of GM in 1986, as a product engineer in starters. After moving to Remy International in 1993, he worked as quality manager and design analysis manager. In 2000, he became Remy’s director of advanced engineering, responsible for development of starters, alternators, and electric machines for hybrid and electric vehicles. David has 13 patents in the area of electric machines. He is also a licensed professional engineer, and a member of SAE.

Abstract It is a challenge to write a good motor specification. Typical spec. problems are omitted or ambiguous requirements, or overly tight tolerances that drive up cost but not value. These problems create hidden penalties in cost, performance, reliability, and development time. This presentation will describe common problems in traction motor specifications and associated penalties, as well as recommendations to avoid them. Topics will include spec.’s for demagnetization, mechanical considerations, torque ripple, performance, and others.

Notes

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

The Supply of the Heavy Earth Metals and the demand for them by the Global OEM Automotive Industry Jack Lifton

Abstract

Director Founding Principal Technology Metals Research, LLC

Jack Lifton is a Founding Principal of Technology Metals Research, LLC. He is also a consultant, author, and lecturer on the market fundamentals of the technology metals, the term that he coined to describe those strategic rare metals whose electronic properties make our technological society possible. These include the rare earths, lithium and most of the rare metals. Educated as a physical chemist, specializing in hightemperature metallurgy, Jack was first a researcher before becoming both a marketing and manufacturing executive. Finally, he became a metal trader specializing in the field of technology metals and of rare metals. Today, after 48 years of industry involvement, he advises both OEM high tech industry and the global institutionalinvestment community, on the natural resource issues that impact either a proposed business model or a highvolume manufacturing plan for the mass market. His work today is principally as a due-diligence consultant for institutional investors, looking into opportunities where rare and technology metals availability are a factor in determining the probability of commercial success of a metals-related venture. Jack is a Senior Fellow of the Institute for the Analysis of Global Security.

There has recently been a great deal of hypothesizing and prognosticating about the security of supply of the rare earths for the non-Chinese OEM automotive industry. The pundits and industry analysts have warned of demand destruction by substitution driven by sustained high prices as well as due to supply interruptions. What has been overlooked for the most part is that the issue is not about all of the rare earths; it is just about some of them, the critical rare earths. And even in that category there are two separate issues: 1) Is there enough production of the light rare earth, neodymium, to sustain current demand and can its non-Chinese production grow to meet expected non-Chinese demand? and 2.) Is there even enough production of the heavy rare earths, dysprosium and terbium, to meet current Chinese demand and is it possible to produce dysprosium a.) Outside of China, and b.) In a finished form that could be used to manufacture “under the hood’ rare earth permanent magnets outside of China? This presentation will bring the audience up to date on these issues, and will emphasize that the overwhelming majority of the OEM automotive industry demand for the rare earths critical to its products is, first and foremost, for the under the hood accessories of the powertrains of internal combustion powered vehicles, the next largest use is for the passenger cabin accessories for all vehicles, and last today is the demand from the under the hood powertrains of EVs and Hybrid Electric Vehicles. Assuming that the security and quantity of supply issues for dysprosium are resolved the growth of demand for products containing them will not depend just on the future growth of the market for EVs and HEVs, not at all.

Notes

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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speaker speaker biographies biographies and andabstracts abstracts Material Technology Challenges and Opportunities for Traction Motors Yucong Wang Manager, Department of Materials Technology General Motors Company

Dr. Yucong Wang is Manager for the Department of Materials Technology in General Motors. He leads GM’s materials technical specialist team to develop corporate materials technology strategies and implementation, and support current and advanced product development and manufacturing. Dr. Wang has been working for GM in R&D, advanced manufacturing engineering, quality and product assurance as well as materials engineering since 1990. He received numerous honors and awards in his career, including Fellow of ASM (2004), honorary award from the U.S. Department of Energy as well as the highest technical honor in North American die-casting industry - the Herman H. Doehler Award (2005), and “Asian American Engineer of the Year” (2006)

Abstract Challenges and opportunities for traction electric motors propelling hybrid and electric vehicles require scientists and engineers to discover and invent, develop and manufacture advanced materials for rotors, rare earth permanent magnets, lamination steels, stator copper wire winding and insulation system, and other components with low cost, good reliability and durability in a wide range of operating environments and driving conditions. This presentation will discuss about rare earth metals, precious metals, and other critical automotive metals, and the impact of these metals on hybrid, electric and fuel cell vehicles, as well as alternative solutions.

Dr. Wang has over 50 patents and authored or co-authored over 70 refereed technical publications. He served as president of Detroit Chinese Engineer Association, chairman of ASM Saginaw Valley Chapter, vice-chairman of Tri-City Chinese Association, as well as president, GM Chinese Affinity Group. Dr. Wang obtained his B.S. and M.S., both in Materials Science and Engineering, from Shanghai Jiaotong University, China. He taught in that university for three years before coming to the U.S. He earned his Ph.D. in Materials Science and Engineering from Michigan Tech, and his MBA from CMU. He was elected to Beta Gamma Sigma - honor society for top scholars in AACSB accredited business programs.

Notes

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

Metals in Motors Invited

Abstract

Ford Motor Company

Notes

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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speaker biographies and abstracts Copper-Rotor Induction-Motors: One Alternative to Rare Earths in Traction Motors Malcolm Burwell North American Director of Technology Development and Transfer The Copper Alliance

Malcolm Burwell is the North American Director of Technology Development and Transfer for the International Copper Association (ICA), part of The Copper Alliance. The ICA is the industry association for the worldwide copper production industry. It has, for 15 years, been leading hands-on development of copper-rotor die-casting and induction-motor design. Mr. Burwell leads the ICA’s program to develop and transfer those technologies to the supply-chain. Before joining ICA, Malcolm founded and led four electric-technology businesses, including Absolute Sensors which supplied under-hood throttle-sensing products. Earlier in his career he specialized in developing automated manufacturing equipment and designing medical devices. He holds a Masters degree in Engineering from Cambridge University.

Abstract The copper-rotor induction-motor made its debut in automotive electric traction in 1990 in GM’s Impact EV. Since then, this motor architecture has covered millions of miles on other vehicle platforms which will soon include Toyota’s RAV4-EV. With the industry’s attention focused on cost-effective alternatives to permanent-magnet traction motors, the induction motor has returned to the spotlight. This talk will overview where the copper-rotor inductionmotor is today, how the technology has evolved since the days of the GM Impact, the state-of-play in its massmanufacturing processes and today’s major supply-chain players.

Notes

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

Battery Metals for 21st Century Power Trains Jon Hykawy, Ph.D. Head of Global Research Byron Capital Markets

Dr. Hykawy is Byron’s Head of Global Research. He has extensive experience in the solar, wind, and battery industries, having conducted significant research in the area of the economics of rechargeable batteries (including rechargeable alkaline, lithium-ion and flow batteries) and wind power technologies. Jon began his career in the investment industry in 2000 when he began work as a research analyst broadly covering the technology sector. His focus was later refined to clean technologies and alternative energy companies, and at Byron has become further refined to the materials and technologies surrounding the electrification of transportation. The Byron “Electric Metals” team (a term coined by Byron Capital Markets in 2009), headed by Dr. Hykawy, has become one of the leading sources of new insight and deep levels of analysis within the financial industry on materials such as lithium, vanadium, cobalt, rare earths, uranium and graphite. •

Ph.D. (Physics), University of Manitoba, 1991



MBA, Queen’s University, 1997

Abstract As the need to develop better and less expensive batteries for automotive applications continues, we will likely need to examine potential tradeoffs between enhanced performance and costs. In particular, the choice of cathode materials automatically involves changes in performance and material costs. We will examine some of the possible cathode materials for use in next-generation battery packs, and the financial implications regarding those materials.

Notes

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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speaker biographies and abstracts Rare Beef and Rare Earths: Why Process Technology Matters Larry Thomas

Abstract

President & CEO Primet Precision Materials

Those who are concerned about access to rare earths and other critical minerals for EV powertrains are focused on the exact wrong problem. The presentation discusses why it’s control of process technology, not the raw ores themselves, that dictates cost, availability and performance.

Larry Thomas is the President and CEO of Primet Precision Materials, a process technology company focused on meeting the auto industry’s need for world-scale production of high-performance battery materials. Larry joined Primet in January, 2008, guiding the company through its transformation from a science experiment in nanotechnology to the world’s process technology leader in low-cost production of highly-engineered materials. A career professional in the specialty chemical industry, Larry has served in a variety of general management and leadership positions at Air Products & Chemicals and Dow Chemical. Throughout, he has created profitable growth strategies in both high-volume mature businesses and new growth platforms through combinations of R&D, external collaborations, licenses and investments. He holds a BS in Chemical Engineering from the University of Virginia and an MBA from the University of Chicago. He is an Adjunct Professor in Entrepreneurship at Lehigh University. Larry has served on the Boards of Directors of technology start-ups Solicore (Lakeland, FL), NovaCentrix (Austin, TX) and Nanogate Advanced Materials (Saarbrucken, Germany), and for Lehigh Valley philanthropic organizations Hispanic American Organization and Child Advocacy Center of Lehigh County.

Notes

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

Challenges and Requirements for High Volume Production of Electric Machines Wei (William) Cai, Ph.D. Chief Technology Officer Jing-Jin Electric Technologies Co., Ltd.

William Cai, Ph.D., is the Chief Technology Officer of Jing-Jin Electric Technologies Co., Ltd. His experience includes the design, control and modeling of electrical machines and drives for vehicular electrification, numerical computation of electromagnetic fields, and mechanical structures, vibration, and noise of electrical machine systems. Dr. Cai is a leading expert in the HEV/EV motor industry and has designed two mode HEV motors for a number of HEVs including the Cadillac Escalade, Mercedes-Benz ML450, BMW X6, Chevrolet Tahoe, GMC Yukon, Dodge Durango, Chrysler Aspen, Chevrolet Silverado pick-up truck etc. He has also co-designed Allison hybrid transmission motors and is currently working on the design, development and manufacturing of the hybrid electric vehicle drive systems, pure EV traction motors, integrated starter alternator damper (ISAD), belt-driven starter generator (BSG) and high power alternator and starters for automotive applications. Under his technical leadership, Jing-Jin is developing e-motors for a number of China’s leading vehicle manufacturers including: Geely, FAW, BAIC, SAIC, Futon, Hege and Yutong. Dr. Cai’s JJE manufacturing team built the first volume production line of EV/HEV motors in China.

Abstract With automotive electrification, the electric machines show a tendency to share or even replace the dominant role of internal combustion engines in future vehicles. Besides the design and innovation of different electric machines to meet the needs of powertrain and drivetrain performances, high volume production becomes a challenging topic and an un-avoided requirement. Flexible line and sharing line will help the variation of production rate and volume, while the dedicated unique line contributes to large scale of E-motor production. Supplier chain from raw materials, parts to processes has to be built from ground-zero or low grade to mature stage within quality specification and time limitation. Multi function skills, cross area technologies and complex management etc are all required for E-motor manufacturer to grow up with component and equipment suppliers. Reducing cost, improving quality and guaranteeing safety are always the thematic series. Manufacturers, suppliers and material innovators from China are aggressively pushing the high volume production of E-motors for global vehicle electrification.

Notes

Dr. Cai is an IEEE senior member and stands in both US SAE and China SAE Standard Committee of Electric Machines for New Energy Vehicles. He has organized and presented at many international conferences and chaired electric motor and drive sessions. He is reviewer of China National Natural Science Foundation and editor of several global technical journals. He is a scholar professor at Harbin University of Science and Technology and is chief scientist of China Education Ministry Automotive Electronics Engineering Center. Dr. Cai has nearly 20 European and American as well as Chinese patents (including pending patents), published two books and over 40 technical papers.

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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speaker biographies and abstracts Advanced Testing of Electric Drives and Motors Voiko Loukanov, Ph.D.

Abstract

Founder and CEO D&V Electronics, Ltd.

This presentation will cover an overview of challenges and key discussion points for advanced electric motor and drive testing. The presentation will visit some examples of how D&V approaches these issues and also some suggestions for how the industry can view these intriguing problems as opportunities. The presentation will also delve into current testing developments that involve resolver, load bank and power measurement devices by highlighting solutions in the market today. There will also be a cursory look into the future of electric motor testing and what we can expect in the near term.

Voiko Loukanov is the founder and CEO of D&V Electronics, a Canadian capital equipment manufacturer that offers advanced automotive testing systems. Voiko’s extensive academic and professional background in electronics R&D lends him credence to becoming a key player in tester development for starters, alternators and traction drives as well as e-motors. Mr. Loukanov has a wide breadth of experience in the fields of electronics, data processing, control systems, process measurements and analysis. As an innovative, dynamic entrepreneur, Voiko Loukanov has brought D&V forward to become a leading supplier of automotive testing equipment within aforementioned markets. Voiko Loukanov earned his M.Sc. and PhD in Electronics Engineering from the Technical University of Sofia in Bulgaria. During his professorship at University of Sofia, Mr. Loukanov had the honor of teaching Electronics Engineering for a number of years before founding D&V Electronics in Toronto, Canada. Under his academic tenure, he had the opportunity to champion numerous scientific research projects resulting in authorship of 50 published journal articles and 3 notable design patents.

Notes

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

Will they prevail in Electric Drive Vehicles: Comparison of IPM, Induction, FSPM, DSPM and other New Electric Machine Topologies Chunting (Chris) Mi, Ph.D. Associate Professor University of Michigan, Dearborn

Dr. Chris Mi is Associate Professor of Electrical and Computer Engineering and Director of DTE Power Electronics Laboratory at the University of Michigan, Dearborn, Michigan, USA. Dr. Mi a leading expert in electric and hybrid vehicles, and has taught tutorials and seminars on the subject of HEV/ PHEV for the Society of Automotive Engineers (SAE), the IEEE, National Society of Professional Engineers, major automotive OEMs and suppliers, including GM, Ford, Chrysler, and Delphi. He has offered the tutorials in six countries including the US, China, Korea, Italy, Singapore, and Mexico. Dr. Mi has conducted extensive research in EV/HEV space and has published more than 100 articles and delivered more than 50 invited talks and keynote speeches, and served as panelists. Dr. Mi is the recipient of the 2009 Distinguished Research Award of the University of Michigan-Dearborn, 2007 SAE Environmental Excellence in Transportation (also known as E2T) Award for Innovative Education and Training Program in Electric, Hybrid and Fuel Cell Vehicles, the 2005 Distinguished Teaching Award of the University of Michigan-Dearborn, IEEE Region 4 Outstanding Engineer Award, and IEEE Southeastern Michigan Section Outstanding Professional Award. He is also the recipient of the National Innovation Award (1992) and the Government Special Allowance Award (1994) given by the China Central Government. In December 2007, Dr. Mi became a member of the Eta Kappa Nu, the Electrical and Computer Engineering Honor Society, for being a leader in education and an example of good moral character.

Dr. Mi is the associate editor of IEEE Transactions on Vehicular Technology, associate editor of IEEE Transactions on Power Electronics C Letters; editorial board of IET Transactions on Electrical Systems in Transportation, associate editor of Journal of Circuits, Systems, and Computers (2007-2009); the editorial board member of International Journal of Electric and Hybrid Vehicles; a guest editor of IEEE Transactions on Vehicular Technology, Special Issue on Vehicle Power and Propulsion (2009-2010); and guest editor of International Journal of Power Electronics, Special Issue on vehicular Power Electronics and Motor Drives (20092010). Dr. Mi served as the Vice Chair (2006, 2007) and Chair (2008) of the IEEE Southeastern Michigan Section. He was the General Chair of the Fifth IEEE International Vehicle Power and Propulsion Conference held in Dearborn, Michigan, September 7-11, 2009. Dr. Mi served on the review panel for the National Science Foundation, the U.S. Department of Energy (2006,C2010), and the Natural Sciences and Engineering Research Council of Canada (2010). Dr. Mi is one of the two Topic Coordinators for the 2011 IEEE International Future Energy Challenge Competition.

Abstract Permanent magnet (PM) motors with both magnets and armature windings on the stator have attracted considerable attention lately. But will they prevail? This presentation will compare the suitability of flux switching PM motor, doubly salient PM motor, induction motor, and IPM for advantages and suitability for use in plug in electric vehicles.

Dr. Mi holds a BS and an MS degree from Northwestern Polytechnical University, China, and a Ph.D degree from the University of Toronto, Canada. He was the Chief Technical Officer of 1Power Solutions from 2008 to 2010. Dr. Mi worked with General Electric Company from 2000 to 2001. From 1988 to 1994, he was a member of the faculty of Northwestern Polytechnical University. From 1994 to 1996, he was an Associate Professor and an Associate Chair with the Department of Automatic Control Systems, Petroleum University, China. SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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speaker biographies and abstracts GM’s Automotive Traction Motor Field Experience and Cost Opportunities Matthew Laba

Abstract

Engineering Group Manager General Motors Company

GM’s electrified vehicles have accumulated hundreds of millions of miles in the hands of customers and great reliability has been experienced. This is a positive result, but as with all electrified vehicle components, overall motor cost remains a challenge. There are several possible directions for cost reduction. Each may be pursued, but must be considered with care not to compromise the product reliability and total customer experience in electrified vehicles.

Matt serves as Engineering Group Manager of GM’s Electric Motor Development and Validation department and is responsible to oversee the development of all of GM’s high voltage traction motors. For the past 10 years, in various roles, he has managed the development of a number of electric traction systems for a number of GM’s hybrid systems. Matt has worked on electric vehicle systems since 1996. Prior to his current assignment, Matt started his career with General Motors by working on GM’s EV1 and Electric S-10 pickup truck as a release engineer for the Electric Drive Unit. In the past, he has worked at General Dynamics Land Systems in various engineering roles. Matt holds a BSE in Mechanical Engineering from the University of Michigan, Ann Arbor, and a MS in Mechanical Engineering from Wayne State University.

Notes

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

Panel Discussion: OEM and Suppliers on Engineering Patrick Wilson Business Unit Manager Gear Heads & Motor Parker Hannifin Corporation

Parker Hannifin’s Rotary and Gearhead Business Unit is responsible for the design, manufacturing and commercialization of Parker Hannifin’s e-Motors. Mr. Wilson leads this Business Unit and through his implementation of Parker Hannifin’s Win Strategy has increased Parker’s global presence within the Hybrid and Electric Vehicle marketplace as it relates to e-motors. He has achieved significant and sustainable results to increase the Business Unit’s bottom-line. The e-motor portfolio of the Business Unit includes traction motors, auxiliary motors and other vehicle-duty motors that directly couple to Parker Hannifin’s global mobile hydraulic actuation systems. These e-motors are being tested, used and integrated into some of the world’s most recognized on- and off- and ‘above’road OEMs to achieve their electrification goals. More information on motors and Parker Hannifin’s ability to provide complete hybrid solutions can be viewed at http://hev.parker.com. Pat’s 23 year career with Parker Hannifin started in 1988 in the R&D lab for the development of Parker’s first digital Servo Drive. 1992 Operations manager Rohnert Park, Ca

Notes

2003 Division Lean Manager / Operations Manager for Motors, New Ulm, MN 2008 to Present Business Unit Manager (Gear head and Motor) New Ulm, MN Patrick Wilson graduated “cum lade” with his Bachelor of Science, Information Systems Management from the University of San Francisco, in 2002.

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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exhibit Directory Exhibitor Directory text is published as submitted by exhibiting companies.

A

H

ANSYS Inc

Hitachi Metals America Ltd

275 Technology Dr Canonsburg, PA 15317 United States www.ansys.com

2 Manhattanville Rd Ste 301 Purchase, NY 10577 United States www.hitachimetals.com

ANSYS brings clarity and insight to customers’ most complex design challenges through fast, accurate and reliable engineering simulation. Our technology enables organizations to predict with confidence that their products will thrive in the real world. Customers trust our software to help ensure product integrity and drive business success through innovation.

Hitachi Metals is an integrated supplier of highly functional component materials that draw on its competitive core materials technologies. Its NEOMAX division provides automotive OEMs and electrical motor manufacturers with the optimal solutions to demanding fuel efficiency and high-performance required for next generation EV/HEV technologies.

C

J

BOOTH #8

CD-adapco 60 Broadhollow Rd Melville, NY 11747 United States www.cd-adapco.com

Remy International

Silver Partner

BOOTH #6

Custom Sponsor

BOOTH #10

CD-adapco is the world’s largest independent CFDfocused provider of engineering simulation software, support and services. We have over 30 years of experience in delivering industrial strength engineering simulation. The scope of our activities extends well beyond software development to encompass a wide range of CAE engineering services in both CFD and FEA.

Copper Development Association Inc 260 Madison Ave New York, NY 10016 United States www.copper.org

Jing-Jin Electric Technologies (Beijing) Co Ltd Building A5 No5 Jiangtai Rd Chaoyang District Beijing 100015 China www.jjecn.com

Friend of the Industry

Booth #12

Jing-Jin Electric (JJE) develops and manufactures high-performance electric motor’s system and electric drive components for hybrid electric vehicles (HEV), plug-in hybrid electric vehicles (PHEV), battery electric vehicles (EV) and other electrically driven automobiles and control. Headquartered in Beijing, China’s technology capital, JJE combines China’s technology talent, manufacturing advantage with global best practices to provide “World’s Best Electric Motors” for the “Electrification of Automobiles”, the critical path for the sustainable future of the global automotive industry.

BOOTH #3

Copper Development Association, Inc. (CDA) is a U.Sbased, not-for-profit association of the global copper industry, influencing the use of copper and copper alloys through research, development, education, and end-user support. CDA assists the industry by engaging in pre-competitive R & D with manufacturers. The display showcases the advantages of AC induction motors using cast copper rotors and other copperbased technologies that enable greater efficiency in electric drivetrains.

D D & V Electronics Ltd. 130 Zenway Boulevard Woodbridge, Ontario L4H 2Y7 Canada www.dvelectronics.com

Gold Partner

BOOTH #1

D&V Electronics is testing the future of hybrid / electric vehicle motors and controllers combining proven reliability with performance, accuracy and modularity. D&V’s EPT series of electric powertrain testers are built for endurance, laboratory and end of line production testing including the complete vehicle simulation of motors, inverters and batteries.

P Parker Hannifin Corporation 5500 Business Park Dr Rohnert Park, CA 94928 United States http://hev.parker.com

Booth #9

Parker Hannifin designs and manufactures a broad array of electric vehicle drivetrain systems with maximum power density, highest efficiency, broad scalability and US-based manufacturing. Traction motors/generators and controllers have a power range from 25kW to 350kW. Parker’s electric traction systems are ideal for use on NEVs to Class-8 trucks.

R Rea Magnet Wire 3600 E Pontiac St Fort Wayne, IN 46803 United States www.reawire.com

BOOTH #2

The Rea Magnet Wire Company, Inc. is one of the world’s largest manufacturers of magnet and nonferrous wire products. Rea produces copper and aluminum insulated magnet wire and bare wire used in the manufacture of motors, transformers and coils. See our ad on page 5

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600 Corporation Dr Pendleton, IN 46064 United States http://www.remyinc.com/hybrid.asp

Booth #11

Remy International, is North America’s leading global manufacturer of advanced electric propulsion motors designed for hybrid and electric vehicles. Remy’s patented HVH design delivers unsurpassed power density, efficiency and durability . Remy has over 100 years of experience in “rotating electrics”, 2 billion km of proven reliability and over 90,000 motor on the road. Some partners include: Mercedes, BMW, GM, Amp, ALTe, Enova, Via, Quantum and Allison Transmission. Our strong portfolio of power dense electric motors can be found in applications ranging from passenger cars, performance motorcycles, SUVs, Medium Duty and Heavy Duty trucks, transit busses and off-road equipment. Remy’s electric motors are proven, powerful, and efficient with compact electric solutions. Find out more information on our website.

T TM4 Inc 135 J-Armand Bombardier Ste 25 Boucherville, Quebec J4B 8P1 Canada www.tm4.com

BOOTH #7

TM4’s vast expertise and cutting-edge technologies have both been integral contributors to the design of one of the world’s most advanced electric drivetrains. More than 100 breakthrough patents combine to deliver unmatched efficiency, power density and quality in a unit that is compact and affordable. TM4 is recognized as an expert in thermal management, coil winding, outer-rotor topology, and motor & inverter control algorithms, all contributing to producing the highest possible energy conversion efficiencies. The TM4 MØTIVE™ series features permanent-magnet brushless motors and power-dense electronic inverters. It is an efficient turnkey solution created expressly for a range of electric and hybrid applications with emphasis on light duty passenger and commercial platforms. Fully compatible with the TM4 NEURØ™ vehicle controller it is now available in quantity for integration into production-ready powertrains. Please visit our website for more information.

Tridus Magnetics & Assemblies 1145 W Victoria St Rancho Dominguez, CA 90220 United States www.tridus.com

BOOTH #4

Tridus is a leading US supplier of rare earth permanent magnets and assemblies. With a quality embedded supply chain that spans from rare earth processing to value added assembly products, we demonstrate high standards of quality and value.

Z Zeus Inc. 3737 Industrial Blvd. Orangeburg, SC 29118 United States www.zeusinc.com

BOOTH #5

For more than 45 years, Zeus has excelled in the field of high performance polymer extrusions. We offer an assortment of extruded tubing and heat shrink products that are designed for use in challenging environments. Our product line includes PEEK™ Insulated Wire, PEEKshrink®, high temperature insulations, and special extruded shapes.

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

Sponsors SAE International wishes to thank the following companies for their generous support Gold Partner

Monday Luncheon

Silver Partner

Lanyard & Registration Area

Bronze Partner

Conference Notepads & Pens

Custom Sponsor

Friend of the Industry

Keynote Speaker

SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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Ad Index Advertiser Name

Page

Rea Magnet Wire Co Inc

5

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SAE 2012 Powertrain Electric Motors Symposium - for Electric and Hybrid Vehicles

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