In-person Training: EV Drive Unit Design Lubrication & Cooling

EV drive units generate many kWs of heat that must be extracted to ensure your vehicle can meet its intended performance. In many systems now the cooling function is combined with the lubrication function, for instance with gearbox oil used to cool the electric machine.

In this training learn about trends in cooling and lubrication methodologies in electric drive units, the implementation of cooling and lubrication features and how simulation tools (from Hexagon MI and elsewhere) can be used for verification and optimisation.

Highlights of the training 

  1. Discover trade-offs in selection of cooling methodology for electric drive units 
  2. Understand different calculation and simulation methods that are available to support EVs 

Who Should Attend?

  1. Engineers, scientists, and technicians involved or planning to work in lubrication & cooling system design for electric vehicle drivetrain
  2. Managers, Service and Sales professionals interested in understanding lubrication & cooling system design for electric vehicle drivetrain
  3. OEMs/ EV Consultants/ EV Start Ups

Why Should You Attend?

  1.  This course focuses on the design & analysis of lubrication and cooling system covering the entire design lifecycle process from requirements to design verification
  2. Delegates will develop a good understanding of the trade-offs in the selection of cooling methodology for electric drive units and their subsystems
  3. Attendees will gain a better understanding of various considerations & challenges in designing lubrication & cooling system
  4. Engineers will understand selection and sizing by digging deeper into different calculations, approaches and simulation methods
  5. Complimentary one-hour consultation with Hexagon's Applied Solutions India team, for projects

Agenda

The detailed agenda of our 2-days training

  Day 1 Day 2
 Session 1
 9.00 AM -   10.30 AM
   Introduction 
  • Thermals and cooling in the electric drive unit 
  • Associated failure modes and design limits 
  • Design options and trade-offs 
  • Lubrication and cooling system component overview

 

 Oil Cleanliness &       Contaminations

  • Sources of Contamination & Measuring the Cleanliness Level
  • Types of Contamination
  • Oil filtration & gearbox breathers
  • Gearbox Sealing
 Session 2
10.45 AM  - 12.15 PM
  Cooling of EV inverters
  • Heat sources and outline of how to predict
  • Cold plate design considerations

  Cooling of EV motors 

  • Heat sources and outline of how to predict
  • Motor cooling options and feature design considerations 
 Introduction of thermal and fluid   simulation methods 
  • Which approach when and why?
  • Thermal network
  • Thermo-fluid CFD 
 Thermal network simulation of     integrated EV drivetrain
  • Development of a thermal network
  • Simulation of transient and steady state events 
Session 3
12.45 PM - 2.15 PM
 Cooling and lubrication of EV   gearboxes
  • Functions of the lubricant
  • Parameters affecting film thickness
  • EV drivetrain components requiring lubrication
  • Examples of potential failure mechanisms
  • Lubrication of gears / bearings / seals 
 CFD approaches
  • Smooth Particle Hydrodynamics CFD methods and use in thermal/lubrication simulations 
  • Meshed CFD methods and use in thermal/lubrication simulations 
 Session 4
 2.30 PM -   4.30 PM
 EV Lubricant properties & selection   considerations
  • Lubricant properties 
  • Types of lubricants
  • Lubricant characteristics
  • Oil Additives
 Cooling / Lubricant Supply   System Development
  • System design process
  • Component selection 
  • Design features to improve oil distribution  
 Design Verification Planning
  • Oil distribution tests  
  • Thermal performance tests
 
 4.30 PM   to Close
AOB/Questions

 

 

Amol Korde, Design Engineer, Transmission Systems , Hexagon MI

Amol Korde is a design engineer for transmission systems at Hexagon Manufacturing Intelligence and has a degree in mechanical engineering from Dr. BAM University Aurangabad, India. He has over 25 years of experience in the field of gearbox design and gear manufacturing. His area of expertise is dynamic analysis with correlation to test data. His work includes the development of loose gear components; powertrain efficiency and noise prediction; test data correlation; gear microgeometry optimization to reduce gear whine and gear efficiency, BIW structure noise characteristics study and design modifications. He has worked on wind turbine gearboxes, trucks, off-highways, tractors, and EVs to improve design reliability. He has presented and published papers in the field of transmission design in national and international conferences.

He is currently responsible for providing technical support to all EV clients in India and ASEAN. Apart from his regular assignments, he was an adjunct faculty at College of Engineering Pune. 

 

Date 📆
  • Pune: 27 & 28 November
  • Bangalore: 30 November & 1 December 
  • Chennai: 4 & 5 December 
  • Delhi: 7 & 8 December
Time 🕘 9:00 AM - 4:30 PM
Venue 🌏 Details will be shared upon registration
Training Fee 💳 INR 30,000 + taxes

 

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