5 years ago

MDA Technologies 4/2015

MDA Technologies 4/2015


ANTRIEBE UND ANTRIEBSELEMENTE I HYBRIDANTRIEBE The birth of a Francois Malard, Hans Wiedemann Long-Ma, the dragon-scaled winged horse of Chinese mythology, had to come to life during the official ceremony in the Beijing Olympic Stadium in October 2014. France and China planned to celebrate the 50 th anniversary of their diplomatic relations. With only 12 months lead time Dintec, a well-known system integrator for electric drives and hybrid applications, accepted the challenge to power the dragon-horse. Authors: Francois Malard, Sales Manager, Dintec, Nantes, France Hans Wiedemann, Marketing Manager, Sensor-Technik Wiedemann, Kaufbeuren, Germany In October 2013 Compagnie La Machine approached their partner Dintec with the request to power a giant dragon-horse. It should allegorize Long-Ma, a fabled winged horse with dragon scales in Chinese mythology. Very quickly it became obvious that this project would be like no other. As Long-Ma should come to life within 12 months only and then be the main attraction at the celebrations for the 50 th anniversary of the diplomatic relations between China and France, the pressure on Dintec was extreme. But being an experienced system integrator especially for off-highway applications Dintec took on the challenge and got the responsibility for the whole power system. The passion for mobile machines and for the entertainment created by the amazing creatures of Compagnie La Machine allowed Dintec to master the system from power generation, storage and distribution to control and sensors. Dintec dedicated a multidisciplinary team of 5 engineers who started by understanding the energy balance of the animal and the constraints in terms of operating mode (hybrid, fully electric for 45 minutes). After 1,800 hours of engineering work a complete hybrid architecture was defined (Figure 1) in detail and the software for the power management written and compiled. So only 7 months after the kick-off a prototype of the system could already be seen working in Dintec’s workshop. 34 MDA Technologies 4/2015

DRIVE TECHNOLOGIES hybrid giant Efficient and silent In order to supply the 620 VDC electric net Dintec designed a bespoke PowerPack driven by a Perkins 6-cylinders Tier 4 Interim engine to lower emissions. The diesel engine is coupled to the STW powerMELA 140 kW E-machine. Due to its integrated inverter the powerMELA permits four quadrant operation and works here as a generator. Running at variable speed depending on real-time power demand, the combination offers best-in-class fuel consumption. Lots of efforts have also been made in terms of PowerPack enclosure as the giant Long-Ma had to remain a silent machine (Figure 2). Even when the diesel engine starts advanced noise insulation keeps Long-Ma quiet. The main electric consumers are two STW powerMELA 140kW E-machines working as motors. They supply hydraulic power for all the movements (head, body, legs, eyes…), the hydrostatic transmission and the steering system. A brake chopper has been implemented on the DC bus to avoid over-voltage in case of hard braking. The brake chopper is also equipped with an electric insulation measurement system that permanently controls the electric isolation of the DC bus from the machine chassis. A shortcut here would be hazardous to the operators of Long-Ma. All electric components (batteries, motors, generator, inverters…) are connected to the DC bus through small cabinets integrated into the machine. The giant also requests a number of additional electric networks so Dintec supplied appropriate solutions derived from the 620Vdc bus. Inverters and filters take care of the transformation to the AC world with a 400Vac-50Hz (triphases + neutral) net for air compressors and water pumps and a 230Vac-50Hz net to power small AC motors, lights, music systems. A DC/DC converter converts the voltage down to 30Vdc to supply fans, controllers, and lights. A brain with 124 I/Os After a deep benchmarking of technologies taking the duty cycle of the machine, its 01 Visual schema Long-Ma MDA Technologies 4/2015 35