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InfineumDriveline
ELECTRIFIED
COMMERCIALVEHICLETRENDSANDeFLUID
DEVELOPMENTCHALLENGES
ZakZehnacker
DrivelineTechnologist
May2024
Novi,Michigan
Infneum)
?2024InfineumInternationalLimited.AllRightsReserved.
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
Infneum)
01
02
03
HardwareandeFluidtrends
eFluidformulationandtestmethodsConclusion
AGENDA
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
Gearingupforthefuture
eCVHARDWARE
&eFluidTRENDS
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
eCVADOPTIONACCELERATING
Truckandbuselectricproduction2030
Globalproductiontrendsoftrucksandbuses
11%full
electric
FuelCell
FullelectricAllother
NorthAmericaSouthAsia
SouthAmerica
ChinaEurope
Japan/Korea
20232030
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
FullEVswillaccountfor~11%
oftruckandbusproduction
by2030.
?2024InfineumInternationalLimited.Allrightsreserved
GEARTYPEIMPACTS
eFluidREQUIREMENTS
Infuneum)
KEY:AxleOilATF/eFluid
2020AxleOil
2030AxleOilandeFluids
E-Axle
AC-Socket
12/24/Battery
Li-lonBattery
Heater
A/C
DC-Socket
EM
Integratede-axle
EM2
EM1
AC-Socket
12/24/Battery
Li-lonBattery
Heater
A/C
DC-Socket
Distributedwheelspecific/hubmotors
eFluidrequirements
2020AxleOil&AutomaticTransmissionFluid(ATF)
2030eFluids
AC-Socket
RG
EM
Li-lonBattery
12/24/Battery
Heater
A/C
DC-Socket
Centraldrive
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
COMPARING
REQUIREMENTS
Infuneum)
KEY:MajorMinorNotRequired
ConventionalAxle
SeparateWetMotor
IntegratedWetMotor/REDoptionalHelicalGearDifferential
Gearprotection
BearingprotectionO
Electricalproperties
Onefluidtomeetallo
Shearstability
requirements,withoutO
Coppercompatibility
hypoidgearso
Lowviscosity
Frictionclutchperformance
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
Acarefulbalance
eFluidFORMULATION&
TESTMETHODS
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
eFluidRequirements
Oilcoolede-motorconsiderations
eCVFLUIDDEMANDSARESIMILARTOePV
Baseoil
enabled
Thermal
conductivity
Efficiency
Hypoidorhelicalgears
HEATTRANSFER
Coolthewindings
Futurefluidrequirementswillbedrivenby:
E-motorcompatibilityintegration
Traditionaltransmissionfluidproperties
AdditiveEnabled
Antifoam
antioxidant
+
MATERIALCOMPATIBILITY
++Copper,resin,plastic
AERATION+OXIDATION
Corrosion
/Inhibitors
AdditiveEnabled
Smallersump,fillforlife
Friction
modifiers
FRICTIONALPROPERTIES
ELECTRICALPROPERTIES
Insulation
Whenclutchesareused
Polarity
resistivity
Antiwear
agents
WEARDURABILITY
Optimumbaseoilandadditive
balancebothrequiredforsustained
eFluidperformance.
Gears,bearings,pump
Baseoil
enabled
Oil/viscosity
modifiers
EFFICIENCY
Drag&churningvs.wear
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
Acarefulbalance
FORMULATINGFORHEATTRANSFER
G
rpIII
GrpIV
●
GrpIII
4cStther
GrpIV
GrpIIIbaseoiliseferencefluid
PAG
Ester
GrpIII
GrpIII
RelativeMouromtseffNumber
.
GrpIII
2.0
1.0
0.0
0.02.04.06.08.0
KinematicViscosityat100°C(cSt)
TheMouromtseffnumber[M0]isusedtocomparetheheattransfercapabilityofturbulentfluids
eFluidsaresubjecttoturbulentflow
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
Mouromtseffnumberforturbulentfluids:
Fluidproperties:
ρ=Density[kg/m3]ρ0.8k0.67c.33
Cp=Specificheatcapacity[kJ/(kg.K)]μ0.47
μ=Dynamicviscosity[cP]
Providesformulationguidance,largelyonbaseoilselection
Increasefluidthermalconductivity
Functionofbaseoilpurity[GrpIV>GrpIII]-small
effectonM0
Reducefluiddynamicviscosity
Lowerviscosityoil-majoreffectonM0[balancevs.wear]
k=Thermalconductivity[W/(m.K)]M0=
HEATTRANSFER
Coolthewindings
Acarefulbalance
CASESTUDY:FORMULATINGFORHEATTRANSFER
Additive
technology
Fluidproperties:
Viscosity
Radialfluxmotor(OpelAmpera-e)
Motorconfigurations:
Axialfluxmotor(YASAP400S)
VARIOUSCANDIDATEFLUIDSHAVEBEEN
EVALUATEDFORHEAT
TRANSFERPERFORMANCE.
RESULTSPROVIDEINSIGHTINTOFLUIDBEHAVIOR.
Oilflowinaradialfluxmotor
hasbeenvisualizedthroughthe
introductionofatransparentwindow.
HEATTRANSFER
Coolthewindings
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
Acarefulbalance
CASESTUDY:OPELAMPERA-EE-MOTORCOOLING
EndTemperature(°C)
StatorTemperaturesAfter30min
160
0
StatorT1StatorT2StatorT3StatorT4
DIin4cStGrpIIIOilDIin4cStGrpVOilDIin2cStGrpIIIOil
140
120
100
80
60
40
20
Testfluidswerescopedunderseveraloperatingconditions:
2000rpm@50%
maxtorque
6500rpm@25%
maxtorque
HEATTRANSFER
Position4
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
Coolthewindings
Acarefulbalance
LOWVISCOSITY
OUTPERFORMEDHIGHVISCOSITY.
GRPV
OUTPERFORMED
GRPIII.
HEATTRANSFER
Coolthewindings
KEY
FINDINGS
Highpowertemperaturerisetimetests:
4500rpm@60-90%maxtorque
CASESTUDY:OPELAMPERA-EE-MOTORCOOLING
Lowviscosityfluidsdelayedderatingofstatorwindingsandshowedlowersteady
statetemperatures.
RiseTime(sec)
TemperatureRiseTime@4500rpm
0
60%70%80%in4cStGrpIIIOilDIin4cStGrpVOil
90%
DIin2cStGrpIIIOil
600
500
400
300
200
100
TorqueDI
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum?2024InfineumInternationalLimited.Allrightsreserved
Acarefulbalance
CASESTUDY:YASAP400SE-MOTORCOOLING
TempSteady
risestate
AvgTimeforWindingstoReach
ThermalLimitof120°C(sec)
HighPowerTest-FluidImpactonStatorWindingTemp(20LPM)
160
0
τ=73%ofmaxFluid=40°C
DIin4cStGrpIIIOilDIin4cStGrpVOilDIin2cStGrpIIIOil
τ=89%ofmaxFluid=40°C
τ=73%ofmaxFluid=60°C
τ=89%ofmaxFluid=60°C
140
120
100
80
60
40
20
Testfluidswerescopedunderseveraloperatingconditions:
1500rpm@27%
maxtorque
5500rpm@18%
maxtorque
3200rpm@73-89%maxtorque
YASAP400
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum?2024InfineumInternationalLimited.Allrightsreserved
KEY
FINDINGS
PERFORMANCE
DIFFERENCESWEREOBSERVEDATHIGH
POWER.
Lowviscosityfluidsdelayedderatingofstatorwindings.
HEATTRANSFER
Coolthewindings
Infnneum)
Acarefulbalance
MOTORSINTRODUCENEW
MATERIALSTOTHETRANSAXLE
Insulatingmaterial
Plastics
Cu(wire,connector)
Sealant
Al(case)
MATERIALCOMPATIBILITY
++Copper,Resin,Plastic
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
MATERIAL
COMPATIBILITY
ISCRITICALFOReFluids.
Insulationfailurecanleadtoshorts&corrosioncanerodeconnectionsandcircuits.
Infnneum)
Acarefulbalance
COPPERCOMPATIBILITY
ASTMD130modifiedtesting
(solutionandvaporphase)
Materialcompatibilitymustbe
Finishedfluid
Finishedfluid
consideredforadditiveselection:
CorrosioninhibitorshelpmitigateCu
corrosiondebits
fromotheradditives.
Extremepressure
additivesprotectthegearsbutincrease
Cucorrosion.
Spacer
structures
ThreadedrodNutInterdigitalcopper
Powered
Powered
Powered
Not
powered
Notpowered
Soaktests,atelevated
temperature.
EnergizedCircuitBoardtesting
AdditivecomponentsusedineFluidsmustbescreenedforcompatibility:
Energizedcircuitboardtests.
MATERIALCOMPATIBILITY
++Copper,Resin,Plastic
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
InfineumScreenerDevelopment:CaseStudy
ENERGIZEDCIRCUITBOARDTESTLIVEIMAGING
KEY
DIFFERENCE
Improvingenergizedcorrosionrequiresa
fundamental
understanding.
TESTCELL
BUILTWITH
PYREXWINDOW&INTERNALHEATERTOVISUALIZETHE
MECHANISM.
MATERIALCOMPATABILITY
++Copper,Resin,Plastic
TIMELAPSEVIDEO:BADREFERENCE
47SEC=>~16HRS
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
Acarefulbalance
AGING
PRODCEDURE
01
Oiltreatedwith
5000ppmwater
02
8cyclesofhigh-temp.&low-temp.shock(16days)
03
1cycle:155°Cfor40hand-45°Cfor8h
THERMALSHOCKTEST
VARNISHEDWIRE
Fresh
Aged
Fresh
Aged
?2024InfineumInternationalLimited.Allrightsreserved
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
INSULATIONPAPER
FreshAged
Noveltestthatmeasuresan
oil’sabilitytoprotectawide
varietyofinsulationmaterials
underextremethermal
MATERIALCOMPATABILITY
++Copper,Resin,Plastic
cyclingconditions.
Acarefulbalance
THERMALSHOCKTESTRESULTS
FT2015/1200DielectricStrength
(mV/m)
FT2015/1200InsulationCoating
MaterialBondStrength(N)
35
30
25
20
15
10
5
0
Infineume-Fluid
CommercialReferenceATF
Infineume-MotorCoolingFluid
30
25
20
15
10
5
0
Infineume-Fluid
CommercialReferenceATF
Infineume-MotorCoolingFluid
InfineumeFluidsshowoutstandingmotormaterial
MATERIALCOMPATABILITY
++Copper,Resin,Plastic
compatibilityperformance.
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum?2024InfineumInternationalLimited.Allrightsreserved
InfineumScreenerDevelopment:CaseStudy
HIGHSPEEDAERATIONTEST(HSAT)
InfineumHSAT
Homogenizer
ASTMSeqI-IVFoamingTest
e-Motor&
Homogenizer
GearBox
≈
+
≈
Stator
Airflow
Airflow
Sheargap
Homogenizerspinsat
Rotor
extremelyhighspeeds
(upto27,000rpm)
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
KEY
DIFFERENCE
ASTMSeqI-IVdoesnothavehighrpmchurning/shear
foundineMotors.
ENTRAINEDAIRCANLEADTO
CAVITATIONWEARAND/ORLOSSOFHYDRAULIC
PERFORMANCE.
AERATION
Smallersump,fillforlife
InfineumScreenerDevelopment:CaseStudy
HIGHSPEEDAERATIONTEST(HSAT)
ControlElectronics
AirFlowControl
Aggregator&
AirFlowTubes
Camera
HeaterBlock
Homogenizer
BADREFERENCEOIL
60?°C100?°C140?°C
GOODREFERENCEOIL
60?°C100?°C140?°C
MixingOn
for1min
Total,mL
Total,mL
MixingOff
after5seconds
Total,mL
Total,mL
AERATION
Smallersump,fillforlife
Automaticallyrunsrangeoftemperaturesturninghomogenizer&airflowon/offwhiletakingimagesasspecified
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum?2024InfineumInternationalLimited.Allrightsreserved
Acarefulbalance
MOTORSRELYONINSULATINGMATERIAL
TOISOLATEHIGHVOLTAGECOMPONENTS
Example:
Considera1cm2conductor
immersedinoilandseparatedfromgroundby1cm.
Oilwithconductivity
1x10?9S/cm(VR=10
MΩ*m)at100。Cwouldpresent1GΩresistance.
Ifdrivenby500V,
a0.5μAleakagecurrentwouldoccur.
1cm
Foroilcooledmotors,theeFluid’sresistancetocurrentflowmustbeconsidered.
HigherVRcanallowforincreasedmotorvoltageandsmallercasing,butcanleadtostaticbuild-up
andarcing.
VolumeResistivity[VR]isthe
oilresistivity[1/conductivity]multipliedbytheseparationanddividedbythearea.
Theoptimum
eFluidVRto
electric
current
isbeing
investigated.
1cm
ELECTRICALPROPERTIES
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum
?2024InfineumInternationalLimited.Allrightsreserved
Insulation
Acarefulbalance
FORMULATINGFORVOLUMERESISTIVITY
RELATIVEVOLUMERESISTIVITY
At80。C(ASTMD1169v)
Balancedcomponentsusedto
achieveelectricalperformance
whilemeetingotherrequirements.
VRdecreasesasmolecularpolarityofaformulation’scomponentsincreases.
BASESTOCK
BS
+Component[A]
BS
+Component[A+B]
BS
+Component[A+B+C]
BS
+Component[A+B+D]
CTISymposiumUSA15-16May2024,ZakZehnacker,Infineum?2024InfineumInternationalLimited.Allrightsreserved
ActualVR[log]
Compoundscontaining1
m%O,S,N,andPinGroup3
PredictedVR[log]
Modelingreducesthe
testingneededtooptimize
theVRofaformulation.
ELECTRICALPROPERTIES
Insulation
Acarefulbalance
BALANCINGFZGWITHVR
cuffing-R1166/9
12
(FailureLoadStage)
11
10
9
8
7
6
5
4
InfineumeFluid
MTF:
HighFZGLowVR
ATF/DCTF:
LowFZG,LowtoHighVR
HighFZG&HighVR
Infineume-MotorCoolingFluid
HighVR
010
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