Session: 18-01 Advanced Manufacturing and Design I
Paper Number: 123751
123751 - Application of CFRP Sleeve to Increase Efficiency of Air Compressor for Fuel Cell Electric Vehicle
The paper presents of analysis and experimental results on applied a composite material (CFRP) sleeve of the rotor for enhancing the motor efficiency measurements in the high-speed motor of the oil-free air compressor for fuel-cell electric vehicle (FCEV). The CFRP (Carbon Fiber Reinforced Plastic) applies two or more types of different materials for better properties; high-strength and lower density. It combines high-strength carbon fibers and polymer resins to solve the efficiency reduction problem due to eddy current loss of rotor sleeve. The predicted motor loss at the maximum speed of the oil-free air compressor compares the sleeve performance of each sleeve between the Inconel718 and CFRP. The eddy current loss of the CFRP sleeve rotor was decreased of 90% compared to the previously developed. Rotordynamic model predictions of the two types of sleeves manufactured benchmark the test data. The free-free natural frequencies of CFRP sleeve rotor is 15% decreased against Inconel718 sleeve rotor. In addition, this paper compares the analysis between 2D and 3D model. Results shows the CFRP has low isotropy compared Inconel718 sleeve rotor. This is the same trend in experiments. A series of rotor impact test compares the free-free natural frequencies of the previously developed, two different sleeve rotor; Inconel718 and CFRP sleeve. The impact test shown that CFRP sleeve rotor has different bending natural frequencies depending on high temperature and room temperature conditions, and the range of change is larger than Inconel718 sleeve rotor. The impact test results at room temperature show a 25% decrease compared to the Inconel718 sleeve rotor. The CFRP sleeve made by the prepreg of T700-class carbon yarn and epoxy resin which are commonly used, and molded by using autoclave equipment. It satisfies 1.5mm thickness through 8Ply rolling. CFRP has a significantly lower coefficient of thermal expansion compared to Inconel718, which reduces relatively shrink fitting. A series of compressor performance and saturation test from 80k, 90kRPM compares the compressor performance and efficiency of the Inconel718 sleeve rotor. A previously mass-produced compressor was used in this experiment. Our performance evaluation equipment measures performance and efficiency of test compressor. Test results reveal that the CFRP sleeve rotor has up to 2% efficiency and 10℃ temperature decreased. By reducing the eddy current loss to the rotor of the high-speed motor, the total efficiency of the compressor was increased and the temperature of the rotor was also reduced. However, CFRP sleeve rotor need necessarily the further improvement for increasing the operation speed in the high-speed motor of the oil-free air compressor, and various improvements are being made, including the raising grade of carbon yarn, applying high-temperature resin, increasing sleeve thickness, prepreg weaving, and modifying pattern.
Presenting Author: JONGSUNG LEE HANONSYSTEMS
Presenting Author Biography: For 8 years, as a senior professional R&D engineer of HANONSYSTEMS to develop an air compressor for FCEV. Majored a rotordynamics and bearing triboloy, exactly air foil bearing during M.S. under Professor Tae ho Kim. Be in charged of the internalization technology development of its in the company.
Authors:
Changha Lee Hyundai Motor CompanyJONGSUNG LEE HANONSYSTEMS
Hyunsup Yang HANONSYSTEMS
Jeong Kyu Lim Hyundai Motor Company
Young-Yoon Ko Hyundai Motor Company
Jeong Hee Park Hyundai Motor Company
Seung-Jin Dong HANKUK-FIBER
Application of CFRP Sleeve to Increase Efficiency of Air Compressor for Fuel Cell Electric Vehicle
Paper Type
Technical Paper Publication