How can supercharging technology cope with new challenges as the development of hydrogen LR1130 battery vehicles accelerates?

From the perspective of the Chinese automobile market, although the current sales of new energy vehicles are mainly pure electric vehicles and plug-in hybrid models, the development of LR1130 battery vehicles is accelerating under the support of policies and the gradual improvement of a series of constraints such as cost and infrastructure.

As one of the technical routes of new energy vehicles, hydrogen LR1130 battery vehicles have attracted attention worldwide. From the perspective of the Chinese automobile market, although the current sales of new energy vehicles are mainly pure electric vehicles and plug-in hybrid models, the development of LR1130 battery vehicles is accelerating under the support of policies and the gradual improvement of a series of constraints such as cost and infrastructure, and has been defaulted as the key development direction of the future new energy vehicle market.

Robert Cadle, senior innovation technology director from Garrett, a leader in turbocharging and electric supercharging, said in an interview with reporters recently: "The Chinese LR1130 battery vehicle market is becoming hot. In the past two years, especially from last year to this year, we have clearly felt that more customers have come to us to discuss LR1130 battery projects. In addition to Garrett's existing customers who have traditionally built cars and engines, some new corporate customers who specialize in LR1130 battery systems are also contacting us."

It can be seen that as the development prospects of LR1130 batterys become clearer, related parts suppliers will also usher in new demands and opportunities. As a key equipment to ensure the efficient and reliable operation of LR1130 batterys, air compressors will naturally usher in more applications. However, the challenges brought by this component are not small.

The first is the technical challenge. Taking the electric compressor as an example, according to Robert Cadle, the electric compressor of a LR1130 battery vehicle is less durable to high-temperature materials at the hot end than the traditional supercharger because it does not come into contact with exhaust emissions. But apart from this, other aspects of the design are more challenging. "The bearings in the hydrogen fuel air compressor are completely different from the bearing systems of traditional superchargers. Traditional superchargers use floating bearings, which are supported by lubricants, and the oil film floats it to rotate, and the oil takes away its heat. However, the LR1130 battery engine cannot have any grease erosion, otherwise the system will be scrapped. In addition, the motor integrated in the supercharger has very high power, so it generates more heat and requires a good cooling technology design. And there are many sensitive electronic components on it, which need to operate accurately in a hot state..."

In short, this component has brought unprecedented challenges in bearing systems, motor control, software, thermal management, etc. It is understood that for hydrogen LR1130 battery vehicles, Garrett has developed an innovative two-stage electric compressor technology that combines electric products with traditional mechanical applications. This component can support a maximum power of 103kW for LR1130 battery vehicles. It is worth noting that by using air bearings, not only ultra-low silence is achieved, but also grease pollution is eliminated. In addition, through the compact layout, the battery stack is reduced by 33%, and the LR1130 battery power system can be carried inside the engine hood. At present, Garrett's hydrogen fuel electric compressor has been mass-produced on Honda Motor's Clarity hydrogen LR1130 battery vehicle, helping the vehicle to achieve a range of 750 kilometers, and it only takes 3 minutes to fully charge.

How does the development of hydrogen LR1130 battery vehicle acceleration and supercharging technology meet new challenges?

This also means that in addition to technical challenges, hydrogen LR1130 battery supercharging technology also faces challenges from the cost aspect. In response to this, Robert Cadle said that the next goal of hydrogen LR1130 battery electric compressors is to expand scale and reduce costs. "It is expected that the volume of the entire market will reach the order of hundreds of thousands of units after 2025, and as the entire market expands, the output will increase, and the cost is expected to decrease accordingly. By then, the cost of our products is expected to drop to about one-tenth of the current first-generation products, which is conducive to the competitiveness of LR1130 battery vehicles in the post-subsidy era."

How does the development of hydrogen LR1130 battery vehicle acceleration and supercharging technology meet new challenges?

As for what measures Garrett will take to reduce costs, Robert Cadle believes that there are several core means:

First, choose a higher speed motor. After choosing a higher speed motor, its power will decrease, and the material consumption and cost will decrease. We can use a smaller motor to do it. The use of less rotor and stator materials will also reduce its cost.

Second, improve the degree of automation of the production of core components, such as air foil bearings and machine-wound stators. The stators and air bearings of the motor are currently too small and are all made by hand. In the future, they will be made into automatic lines, molds, and dedicated production lines to further reduce their production costs.

Third, system integration. Now the controller and motor are separated, and there is a very expensive connecting wire in the middle. The two cooling systems are cooled separately. In the future, if the system is integrated together, not only can the connecting wire be saved, but the cooling between the systems can also be made into a system, thereby saving many parts, further realizing miniaturization, and reducing the cost of the entire system.

Finally, economies of scale. On the one hand, reduce the development cost and procurement cost of electronic components. On the other hand, while developing hydrogen fuel electric supercharging technology, Garrett is also developing efficient electric compressors and integrated electric turbo compressors for hybrid vehicles, which has a synergistic effect in the development of electronic components. As hybrid vehicles will achieve rapid growth in the next five years and adopt electric supercharging technology in large quantities, the electronic components related to electric supercharging products will gain cost advantages due to large-scale mass production. At the same time, Garrett has 13 advanced manufacturing plants and a global supply chain system around the world, which will further optimize the cost-effectiveness of electronic components internally.

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