INLINE STARTER GENERATORS (ISG) AND IMPROVED MOTOR COMPONENTS FOR ELECTRIC POWER SUPPLY AND HYBRID DRIVES IN VEHICLES

This paper highlights a range of available Integrated Starter Generator (ISG) and power-electronic controller designs for power generation and hybrid vehicle applications ranging from 35 – 160kW. It addresses the potential for improved integrated system efficiency over traditional alternator-based system solutions.

Robustness of ISG-based systems is evaluated in the paper, particularly when integrated into military vehicles and placed in demanding environments. A range of product realizations is presented, from low-cost solutions intended for higher volume production, to high performance solutions employing state of the art technology. Experience in transitioning from high performance to production-ready realizations is included in support of this evaluation. ISG generators range up to 160 kW also providing considerable power at idling speed, and crank start capability at low voltage and low temperatures. Their slim design allows for flexible mounting conditions. A family of electronic inverters and converters supplies various output voltage levels at DC and AC phase conditions. The modular approach offers the combination to systems according to various customers’ requirements. An integrated device incorporating the low and high voltage DC and AC output in a common box is also available.

The components were developed to meet harsh military requirements. More than 50 systems have successfully completed customer evaluation procedures representing over 350,000 miles of satisfactory operation in TD and EMD phases. This ISG technology is the key for the up-coming high on-board and exportable power demand and provides the transition from mechanical to hybrid propulsion. The ISG in combination with MM’s compact and highly efficient electric drive motors gives synergetic hybrid drive systems. They are operated by integrated system control taking into account all electric components, the engine and the mechanical transmission in the various operational areas.