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Technical￿training.
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I01￿High-voltage￿Components
BMW￿Service

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  • Page 1 Technical￿training. Product￿information. I01￿High-voltage￿Components BMW￿Service...
  • Page 2 General￿information Symbols￿used The￿following￿symbol￿is￿used￿in￿this￿document￿to￿facilitate￿better￿comprehension￿or￿to￿draw￿attention to￿very￿important￿information: Contains￿important￿safety￿information￿and￿information￿that￿needs￿to￿be￿observed￿strictly￿in￿order￿to guarantee￿the￿smooth￿operation￿of￿the￿system. Information￿status￿and￿national-market￿versions BMW￿Group￿vehicles￿meet￿the￿requirements￿of￿the￿highest￿safety￿and￿quality￿standards.￿Changes in￿requirements￿for￿environmental￿protection,￿customer￿benefits￿and￿design￿render￿necessary continuous￿development￿of￿systems￿and￿components.￿Consequently,￿there￿may￿be￿discrepancies between￿the￿contents￿of￿this￿document￿and￿the￿vehicles￿available￿in￿the￿training￿course. This￿document￿basically￿relates￿to￿the￿European￿version￿of￿left￿hand￿drive￿vehicles.￿Some￿operating elements￿or￿components￿are￿arranged￿differently￿in￿right-hand￿drive￿vehicles￿than￿shown￿in￿the graphics￿in￿this￿document.￿Further￿differences￿may￿arise￿as￿the￿result￿of￿the￿equipment￿specification￿in specific￿markets￿or￿countries. Additional￿sources￿of￿information Further￿information￿on￿the￿individual￿topics￿can￿be￿found￿in￿the￿following: • Owner's￿Handbook • Integrated￿Service￿Technical￿Application. Contact:￿conceptinfo@bmw.de ©2013￿BMW￿AG,￿Munich Reprints￿of￿this￿publication￿or￿its￿parts￿require￿the￿written￿approval￿of￿BMW￿AG,￿Munich The￿information￿contained￿in￿this￿document￿forms￿an￿integral￿part￿of￿the￿technical￿training￿of￿the BMW￿Group￿and￿is￿intended￿for￿the￿trainer￿and￿participants￿in￿the￿seminar.￿Refer￿to￿the￿latest￿relevant information￿systems￿of￿the￿BMW￿Group￿for￿any￿changes/additions￿to￿the￿technical￿data. Information￿status:￿July￿2013 BV-72/Technical￿Training...

  • Page 3: Table Of Contents

    I01￿High-voltage￿Components Contents Introduction ................................................Important￿Notes .............................................. 2.1. Identification￿of￿the￿high-voltage￿components ....................... 2.2. Safe￿working￿practices￿for￿working￿on￿a￿high-voltage￿system ............2.2.1. Preparations ....................................2.2.2. Disconnect￿the￿high-voltage￿system￿from￿the￿supply ..........2.2.3. Provide￿the￿high-voltage￿system￿with￿a￿safeguard￿against unintentional￿restarting ............................... 2.2.4. Verifying￿safe￿isolation￿from￿the￿supply .................... 2.3. Removing￿and￿connecting￿the￿high-voltage￿connector ................2.3.1. Removing￿the￿flat￿high-voltage￿connector ................... 2.3.2. Removing￿the￿round￿high-voltage￿connector ..............2.4. Connections￿for￿potential￿compensation￿lines ....................Electric￿Motor ..............................................3.1.
  • Page 4 I01￿High-voltage￿Components Contents 5.1.1. Technical￿data ..................................5.1.2. Installation￿location ............................... 5.1.3. System￿wiring￿diagram ............................5.2. External￿features ......................................... 5.2.1. Mechanical￿interfaces ............................... 5.2.2. Electrical￿interfaces ..............................5.2.3. Vent￿hole ......................................5.2.4. Interface￿for￿the￿refrigerant￿circuit ......................5.3. Heating￿and￿cooling￿system ................................5.3.1. Overview ......................................5.4. Internal￿structure￿of￿the￿high-voltage￿battery￿unit ..................Charging￿the￿High-voltage￿Battery ................................ 6.1. General￿information￿on￿charging ..............................
  • Page 5 I01￿High-voltage￿Components Contents 7.2.2. Three-phase￿current￿synchronous￿motor ................7.2.3. AC￿inverter ....................................7.2.4. Air￿conditioning￿compressor ........................7.3. High-voltage￿safety ....................................Electric￿Heating ............................................8.1. Location￿and￿connections ................................8.2. Operating￿principle ..................................... 8.3. Control￿system ........................................Range￿Extender￿Electrical￿Machine ..............................9.1. Introduction ..........................................9.2. Technical￿data ........................................9.3. Design ............................................. 9.3.1. Cooling ......................................9.3.2.
  • Page 6 I01￿High-voltage￿Components Contents 12.2.3. Charging￿the￿high-voltage￿battery ....................12.3. Pinpointing￿isolation￿faults ................................12.4. Start-up￿of￿the￿high-voltage￿system ..........................13. Operating￿Strategy ........................................... 13.1. Operating￿strategy￿with￿pure￿electric￿drive ......................13.2. Operating￿strategy￿for￿vehicles￿with￿range￿extender ................

  • Page 7: Introduction

    I01￿High-voltage￿Components 1.￿Introduction A￿huge￿number￿of￿the￿high-voltage￿components￿in￿the￿I01￿is￿used,￿on￿the￿one￿hand,￿for￿the￿electric motor,￿and,￿on￿the￿other￿hand,￿for￿some￿convenience￿functions. High-voltage￿components￿in￿the￿I01 Index Explanation Electric￿heating High-voltage￿battery Range￿extender￿electrical￿machine Range￿Extender￿Electrical￿Machine￿Electronics Electrical￿machine￿electronics Convenience￿charging￿electronics Electrical￿machine These￿components￿have￿one￿thing￿in￿common: They￿all￿work￿with￿high￿voltage￿ This￿is￿why￿particular￿care￿is￿needed￿in￿the￿case￿of￿a￿repair.
  • Page 8 I01￿High-voltage￿Components 1.￿Introduction Only￿Service￿employees￿who￿satisfy￿all￿the￿prerequisites￿are￿permitted￿to￿work￿on￿the￿designated high-voltage￿components:￿qualification,￿compliance￿with￿the￿safety￿rules,￿proceed￿exactly￿as￿per￿repair instructions￿(see￿also￿chapter￿"Prerequisites"). The￿diagnosis￿and￿repair￿of￿the￿high-voltage￿components￿is￿only￿allowed￿in￿a￿retail￿service center￿that￿has￿qualified￿and￿certified￿service￿technicians.￿These￿technicians￿must￿have completed￿the￿ST1403b￿I01￿High￿Voltage￿Battery￿and￿Maintenance￿instructor￿led￿course￿and successfully￿passed￿the￿hands￿on￿certification.
  • Page 9 I01￿High-voltage￿Components 2.￿Important￿Notes The￿high-voltage￿components￿of￿the￿I01￿have￿an￿intrinsically￿safe￿design.￿This￿means￿that￿faults￿which could￿lead￿to￿harming￿the￿vehicle￿user￿are￿reliably￿identified. 2.1.￿Identification￿of￿the￿high-voltage￿components Each￿high-voltage￿component￿has￿on￿its￿housing￿or￿casing￿an￿identifying￿label￿that￿enables￿Service employees￿and￿vehicle￿users￿to￿identify￿intuitively￿the￿possible￿hazards￿that￿can￿result￿from￿the￿high electric￿voltages￿used. High-voltage￿component￿warning￿sticker The￿high-voltage￿cables￿are￿a￿special￿case￿for￿identification.￿As￿they￿may￿be￿a￿few￿meterslong, identification￿with￿a￿warning￿sticker￿at￿one￿or￿two￿places￿would￿not￿make￿sense.￿The￿Service￿employee could￿easily￿oversee￿these￿stickers.￿Instead￿all￿high-voltage￿cables￿are￿marked￿in￿the￿orange￿warning color.￿Also￿the￿connectors￿at￿high-voltage￿cables,￿as￿well￿as￿the￿high-voltage￿safety￿connector,￿are marked￿in￿orange. Orange￿color￿for￿the￿high-voltage￿cables. Index Explanation High-voltage￿cables￿at￿EME...

  • Page 10: Preparations

    I01￿High-voltage￿Components 2.￿Important￿Notes 2.2.￿Safe￿working￿practices￿for￿working￿on￿a￿high-voltage￿system Before￿working￿on￿high-voltage￿components￿of￿the￿I01,￿it￿is￿essential￿to￿observe￿and￿implement￿the electrical￿safety￿rules: The￿high-voltage￿system￿must￿be￿disconnected￿from￿the￿supply The￿high-voltage￿system￿must￿be￿provided￿with￿a￿safeguard￿to￿prevent￿unintentional￿restarting The￿safe￿isolation￿of￿the￿high-voltage￿system￿must￿be￿verified The￿following￿chapters￿provide￿brief￿descriptions￿on￿how￿to￿implement￿the￿electrical￿safety￿rules￿in￿the I01. 2.2.1.￿Preparations Prior￿to￿beginning￿any￿work,￿the￿vehicle￿must￿be￿secured￿against￿rolling￿away￿(engage￿the￿parking￿lock of￿the￿transmission￿and￿activate￿the￿parking￿brake).￿Terminal￿15￿and￿terminal￿R￿must￿be￿switched￿off. Disconnect￿any￿connected￿charging￿cables.￿The￿vehicle￿should￿be￿in￿"rest￿state". 2.2.2.￿Disconnect￿the￿high-voltage￿system￿from￿the￿supply The￿high-voltage￿system￿in￿the￿I01￿is￿disconnected￿from￿the￿supply￿with￿the￿high-voltage￿safety connector.￿To￿disconnect￿from￿the￿supply,￿the￿connector￿must￿be￿pulled￿from￿the￿relevant￿socket.￿This interrupts￿the￿circuit￿of￿the￿high-voltage￿interlock￿loop. This￿image￿shows￿the￿high-voltage￿safety connector￿in￿a￿connected￿state.￿The￿circuit of￿the￿high-voltage￿interlock￿loop￿is￿not interrupted. The￿message￿"ON"￿at￿the￿high-voltage￿safety connector￿indicates￿an￿active￿high-voltage system.
  • Page 11 I01￿High-voltage￿Components 2.￿Important￿Notes In￿order￿to￿be￿able￿to￿separate￿the￿connector, the￿mechanical￿lock￿(1)￿has￿to￿be￿pressed. As￿soon￿as￿the￿mechanical￿lock￿has￿been removed,￿the￿connector￿can￿be￿pulled￿from￿the socket￿a￿few￿millimeters. Do￿not￿pull￿any￿further￿or￿harder￿if￿resistance can￿be￿felt.￿The￿high-voltage￿safety￿connector cannot￿be￿disconnected￿from￿each￿other completely. When￿the￿high-voltage￿safety￿connector￿is pulled￿out￿far￿enough￿the￿message￿"OFF"￿is visible.￿The￿high-voltage￿system￿is￿thus￿in￿a￿de- energized￿state. 2.2.3.￿Provide￿the￿high-voltage￿system￿with￿a￿safeguard￿against￿unintentional restarting Securing￿against￿restart￿is￿also￿effected￿at￿the￿high-voltage￿safety￿connector.￿A￿commercially￿available U-lock￿(for￿example,￿ABUS 45/40)￿is￿required￿for￿this￿purpose.
  • Page 12 I01￿High-voltage￿Components 2.￿Important￿Notes By￿separating￿the￿high-voltage￿safety connector,￿a￿bore￿hole￿becomes￿free￿through both￿parts.￿The￿loop￿of￿a￿typical￿U-lock￿must￿be inserted￿in￿this￿bore￿hole. The￿U-lock￿can￿now￿be￿closed.￿The￿key￿must be￿stored￿in￿a￿safe￿place￿during￿work￿on￿the high-voltage￿system￿so￿that￿an￿unauthorized person￿cannot￿unlock￿the￿lock. The￿connector￿can￿no￿longer￿be￿used￿by inserting￿and￿closing￿the￿U-lock￿at￿the￿high- voltage￿safety￿connector.￿This￿is￿an￿effective way￿of￿ensuring￿that￿the￿high-voltage￿system￿is not￿switched￿on￿again￿without￿the￿knowledge and￿consent￿of￿the￿Service￿employee. 2.2.4.￿Verifying￿safe￿isolation￿from￿the￿supply In￿BMW￿Service￿the￿de-energized￿state￿is￿not￿verified￿using￿a￿measuring￿device￿or￿via￿the￿diagnosis system.￿Instead,￿the￿high-voltage￿components￿measure￿the￿voltage￿themselves￿and￿transmit￿the measuring￿result￿via￿bus￿signal￿to￿the￿instrument￿cluster. The￿instrument￿cluster￿does￿not￿generate￿the￿Check￿Control￿message￿to￿display￿the￿de-energized state￿unless￿all￿involved￿high-voltage￿components￿consistently￿signal￿the￿de-energized￿state.￿This Check￿Control￿symbol￿in￿red￿shows￿a￿crossed-out￿flash￿symbol.￿The￿text￿message￿"High-voltage system￿switched￿off"￿also￿appears￿in￿the￿instrument￿cluster.
  • Page 13 I01￿High-voltage￿Components 2.￿Important￿Notes Check￿Control￿symbol￿"High-voltage￿system￿de-energized" Index Explanation Check￿Control￿symbol￿for￿the￿display￿of￿the￿de-energized￿state￿and￿text message￿"High-voltage￿system￿switched￿off" In￿order￿to￿verify￿the￿de-energized￿state,￿the￿Service￿employee￿must￿switch￿on￿terminal￿15￿and￿wait until￿he￿sees￿the￿Check￿Control￿message￿with￿the￿symbol￿and￿text￿shown￿above￿on￿the￿instrument cluster.￿Then,￿and￿only￿then,￿have￿you￿ensured￿that￿the￿high-voltage￿system￿is￿de-energized.￿After￿the de-energized￿state￿has￿been￿verified,￿terminal￿15￿and￿terminal￿R￿must￿be￿switched￿off￿again￿before you￿can￿start￿the￿actual￿work. If￿the￿Check￿Control￿message￿is￿not￿displayed,￿you￿must￿not￿carry￿out￿any￿work￿on￿high-voltage components￿ Refueling￿the￿vehicle￿while￿the￿high-voltage￿battery￿is￿charging￿is￿not￿permitted￿ When￿the￿charging￿cable￿is￿inserted￿do￿not￿initiate￿a￿refueling￿procedure￿and￿keep￿a￿safe￿distance￿from highly￿flammable￿materials.￿Otherwise,￿in￿the￿event￿of￿incorrect￿connection￿or￿removal￿of￿the￿charging cable￿there￿is￿a￿risk￿of￿personal￿injury￿or￿material￿damage￿by￿burning￿fuel￿for￿example. While￿the￿I01￿is￿connected￿to￿the￿AC￿voltage￿network￿for￿charging,￿no￿work￿may￿be￿performed￿at￿the high-voltage￿system. 2.3.￿Removing￿and￿connecting￿the￿high-voltage￿connector A￿certain￿sequence￿must￿be￿observed￿when￿breaking￿or￿establishing￿the￿contact￿connection￿both for￿flat￿and￿round￿high-voltage￿connectors.￿The￿individual￿steps￿are￿described￿below￿in￿the￿form￿of graphics￿and￿texts.
  • Page 14 I01￿High-voltage￿Components 2.￿Important￿Notes 2.3.1.￿Removing￿the￿flat￿high-voltage￿connector Bridge￿for￿high-voltage￿interlock￿loop Before￿the￿high-voltage￿connector￿can￿be disconnected,￿the￿bridge￿for￿the￿high-voltage interlock￿loop￿must￿first￿be￿removed.￿The￿bridge closes￿the￿circuit￿of￿the￿high-voltage￿interlock loop￿in￿a￿connected￿state.￿The￿high-voltage control￿units￿continuously￿monitor￿the￿circuit￿of the￿high-voltage￿interlock￿loop￿and￿only￿when the￿circuit￿is￿closed￿is￿the￿high-voltage￿system active. If￿the￿circuit￿of￿the￿high-voltage￿interlock￿loop is￿interrupted￿by￿removing￿the￿bridge,￿the￿high- voltage￿system￿shuts￿down￿automatically.￿This is￿an￿additional￿safety￿precaution￿as￿the￿Service employee￿has￿already￿switched￿off￿the￿high- voltage￿system￿before￿beginning￿work. Removing￿the￿mechanical￿locking Only￿after￿the￿bridge￿of￿the￿high-voltage interlock￿loop￿has￿been￿removed,￿can￿the mechanical￿locking￿be￿moved￿in￿the￿direction￿of the￿arrow.￿The￿mechanical￿locking￿is￿an￿element of￿the￿high-voltage￿connector￿on￿the￿high- voltage￿components￿(e.g.￿electrical￿machine electronics). By￿moving￿the￿lock￿in￿the￿direction￿of￿the arrow￿the￿mechanical￿guide￿of￿the￿high-voltage connector￿on￿the￿high-voltage￿cable￿is￿released which￿permits￿the￿subsequent￿disconnection.
  • Page 15 I01￿High-voltage￿Components 2.￿Important￿Notes Removing￿the￿connector￿of￿the￿high-voltage cable The￿connector￿of￿the￿high-voltage￿cable￿must now￿be￿removed￿in￿the￿direction￿of￿the￿arrow. After￿the￿connector￿has￿been￿pulled￿out￿a few￿millimeters￿(A),￿one￿encounters￿a￿higher counterforce.￿The￿connector￿must￿then￿be pulled￿out￿further￿in￿the￿same￿direction (B). Under￿no￿circumstances￿must￿the￿connector be￿pressed￿back￿into￿the￿socket￿on￿the￿high- voltage￿component￿after￿reaching￿position￿(A). This￿may￿damage￿the￿connector￿on￿the￿high- voltage￿components. The￿high-voltage￿connector￿of￿the￿high-voltage cables￿must￿be￿pulled￿out￿at￿a￿right￿angle￿in￿two steps￿and￿in￿the￿same￿direction.￿Changing￿the direction￿of￿movement￿during￿removal￿is￿not permitted. Proceed￿in￿the￿reverse￿order￿when￿reattaching￿the￿high-voltage￿cable.￿The￿following￿graphic￿shows the￿complex￿design￿of￿the￿high-voltage￿connector￿on￿the￿high-voltage￿components￿and￿explains￿why one￿must￿proceed￿with￿care￿when￿removing￿and￿inserting￿high-voltage￿cables. High-voltage￿connector￿on￿the￿high-voltage￿component...
  • Page 16 I01￿High-voltage￿Components 2.￿Important￿Notes Index Explanation Electrical￿contact￿for￿shielding Electrical￿contact￿for￿high-voltage￿cable Contact￿protection Mechanical￿locking High-voltage￿interlock￿loop￿connector/bridge 2.3.2.￿Removing￿the￿round￿high-voltage￿connector The￿procedure￿described￿here￿applies￿for￿removing￿the￿round￿high-voltage￿connector￿in￿the￿I01. The￿following￿graphics￿show￿the￿procedure￿using￿the￿example￿of￿the￿high-voltage￿connection￿at￿the electrical￿machine￿electronics,￿at￿which￿the￿high-voltage￿cable￿is￿connected￿for￿the￿electric￿heating.
  • Page 17 I01￿High-voltage￿Components 2.￿Important￿Notes The￿connector￿of￿the￿high-voltage￿cable￿(1)￿is located￿at￿the￿high-voltage￿connection￿of￿the component￿(2)￿and￿is￿locked. The￿two￿locking￿elements￿(2)￿must￿be￿pressed together￿in￿the￿direction￿of￿arrow￿(1).￿The mechanical￿lock￿of￿the￿connector￿at￿the connection￿of￿the￿high-voltage￿component￿is thus￿removed. While￿the￿locking￿elements￿are￿further￿pushed together,￿the￿connector￿must￿be￿removed lengthways￿in￿the￿direction￿of￿arrow￿(1). When￿reconnecting￿the￿high-voltage￿cable￿the￿locking￿elements￿must￿not￿be￿pushed￿together.￿It￿is sufficient￿to￿slide￿the￿connector￿lengthways￿onto￿the￿high-voltage￿connection￿of￿the￿component. Ensure￿that￿the￿locking￿elements￿engage￿("clicking"￿noise).￿In￿addition,￿the￿engaging￿of￿the￿locking elements￿should￿be￿checked￿by￿subsequent￿pulling￿on￿the￿connector.
  • Page 18 I01￿High-voltage￿Components 2.￿Important￿Notes The￿following￿graphic￿shows￿the￿design￿of￿the￿round￿high-voltage￿connector￿on￿the￿high-voltage cable. Design￿of￿the￿round￿high-voltage￿connector Index Explanation High-voltage￿cable Actuation￿points￿on￿locking￿elements Housing Locking￿element Connection￿1￿for￿bridge￿in￿the￿connector Connection￿for￿shielding High-voltage￿connection,￿pin 2￿(DC,￿minus) Mechanical￿encoding Connection￿2￿for￿bridge￿in￿the￿connector High-voltage￿connection,￿pin 1￿(DC,￿plus) The￿bridge￿in￿the￿high-voltage￿connector￿serves￿for￿electrical￿safety.￿The￿signal￿of￿the￿high-voltage interlock￿loop￿runs￿over￿this￿bridge￿when￿the￿high-voltage￿cable￿is￿connected￿to￿the￿high-voltage component.￿For￿the￿connection￿of￿the￿high-voltage￿cable￿to￿the￿EKK￿and￿to￿the￿electric￿heating￿the voltage￿supply￿of￿the￿EKK￿or￿transmission￿control￿unit￿runs￿via￿the￿bridge.￿If￿one￿of￿the￿circuits￿is interrupted,￿this￿also￿results￿in￿an￿automatic￿interruption￿to￿the￿current￿flow￿(returns￿to￿zero)￿in￿the respective￿high-voltage￿cable.￿As￿the￿two￿contacts￿of￿the￿bridge￿opposite￿the￿high-voltage￿contacts advance,￿this￿measure￿constitutes￿protection￿against￿the￿formation￿of￿an￿electric￿arc￿when￿removing the￿high-voltage￿connector. 2.4.￿Connections￿for￿potential￿compensation￿lines The￿safety￿concept￿of￿the￿high-voltage￿system￿includes￿the￿measurement￿and￿monitoring￿of￿the isolation￿resistance￿of￿the￿high-voltage￿cables￿to￿each￿other￿and￿against￿ground.￿This￿safety￿function is￿performed￿in￿the￿I01￿of￿the￿SME￿control￿unit,￿but￿should￿identify￿isolation￿faults￿in￿the￿entire￿high- voltage￿circuit.￿For￿this￿purpose,￿the￿housing￿of￿all￿high-voltage￿components￿must￿be￿connected galvanically￿to￿ground.
  • Page 19 I01￿High-voltage￿Components 2.￿Important￿Notes Electrical￿connections￿at￿the￿electric￿heating Index Explanation Potential￿compensation￿line Housing￿of￿the￿electric￿heating High-voltage￿connector The￿high-voltage￿system￿must￿not￿be￿operated￿if￿the￿potential￿compensation￿cables￿are￿not￿properly connected￿to￿the￿high-voltage￿components. If￿in￿the￿event￿of￿a￿repair￿the￿high-voltage￿components￿or￿the￿potential￿compensation￿lines￿are replaced,￿the￿following￿must￿be￿observed￿during￿assembly:￿The￿galvanic￿connection￿between￿the housing￿of￿the￿high-voltage￿components￿and￿ground￿must￿be￿properly￿re-established.￿The￿repair instructions￿must￿be￿strictly￿observed￿(tightening￿torque,￿self-cutting￿screws).￿In￿addition,￿a￿second Service￿employee￿has￿to￿check￿the￿repair￿work￿(correct￿tightening￿torque￿and￿correct￿location￿of￿bare metal)￿and￿record￿this￿in￿writing￿in￿the￿repair￿order.
  • Page 20 I01￿High-voltage￿Components 3.￿Electric￿Motor 3.1.￿Electrical￿machine The￿electrical￿machine￿in￿the￿I01￿receives￿an￿electric￿motor￿identification,￿as￿known￿from￿combustion engines.￿This￿electrical￿machine￿identification￿is￿IB1P25B. 3.1.1.￿Designation￿and￿identification￿of￿electrical￿machines Designation￿of￿electrical￿machines The￿electrical￿machine￿designations￿are￿used￿in￿the￿technical￿documentation￿for￿clear￿identification￿of the￿electrical￿machines. According￿to￿GS￿90023,￿the￿designation￿of￿the￿electrical￿machine￿used￿in￿the￿I01￿is: EMP242.130.01.250(300)-A3-X1 In￿frequent￿cases,￿however,￿only￿a￿short￿designation￿is￿used.￿This￿short￿designation￿is￿used￿to￿assign an￿electrical￿machine￿to￿an￿electrical￿machine￿family.￿For￿instance,￿the￿short￿designation￿EMP242￿is also￿used. Position Meaning Index Explanation Abbreviation Electrical￿machine Machine￿type Asynchronous￿machine Direct￿current￿machine Axial￿flow￿machine Permanently￿excited￿synchronous￿machine Switched￿reluctance￿machine Electrically￿excited￿synchronous￿machine Transverse￿flow￿machine Outer￿diameter￿of 0￿to￿... in￿millimeter￿[mm] stacks￿of￿sheet￿of￿the (242) electrical￿machine Length￿of￿stacks￿of 0￿to￿... in￿millimeter￿[mm] sheet￿of￿the￿electrical (130) machine Version Every￿change￿to￿the￿original￿version,￿e.g.
  • Page 21 I01￿High-voltage￿Components 3.￿Electric￿Motor Model Axially￿parallel￿layout Electrical￿machine￿integrated￿in￿the transmission Rear￿axle Front￿axle Crankshaft￿mounted Coaxial￿with￿separation￿clutch Wheel￿hub Assigned￿to￿the￿belt￿drive Number￿of￿phases 1￿to￿... Number￿of￿phases￿of￿the￿machine Supplier Is￿defined￿by￿the￿project Serial￿number￿of￿the -Optional machine Identification￿of￿the￿electrical￿machine￿i.a.w.￿GS￿90023 Type￿plate￿for￿electrical￿machine Index Explanation Serial￿number Designation￿i.a.w.￿GS￿90023 Country￿of￿manufacture Revision￿index Part￿number Adjustment￿value￿(angle)￿for￿rotor￿position￿sensor Production￿date Unified￿Parts￿Group The￿electrical￿machines￿have￿an￿identification￿to￿ensure￿clear￿identification￿and￿classification.￿This identification￿is￿also￿necessary￿for￿approval￿by￿government￿authorities.￿The￿identification￿of￿the electrical￿machines￿is￿equivalent￿to￿the￿identification￿of￿the￿combustion￿engines.￿The￿number￿of￿the electrical￿machine￿can￿be￿found￿under￿the￿electrical￿machine￿identification￿on￿the￿electrical￿machine. This￿consecutive￿number,￿in￿conjunction￿with￿the￿identification,￿permits￿unambiguous￿identification￿of each￿individual￿electrical￿machine.
  • Page 22 I01￿High-voltage￿Components 3.￿Electric￿Motor Position Meaning Index Explanation Engine￿developer Electrical￿machine￿in/at￿the transmission Electrical￿machine,￿BMW Electrical￿machine,￿external Engine￿type￿(outer <￿200 mm diameter￿of￿stack￿of >￿200 mm￿<￿250 mm sheets) >￿250 mm￿<￿300 mm >￿300 mm Outer￿rotor￿with￿small￿diameter Change￿to￿the￿basic 0￿or￿1 Basic￿engine engine￿concept 2￿to￿9 Changes,￿e.g.￿variation￿of￿sheet cut￿(even￿numbers￿reserved￿for motorbikes,￿odd￿numbers￿for passenger￿cars) Machine￿type￿(engine Asynchronous￿machine procedure) Direct￿current￿machine Axial￿flow￿machine Permanently￿excited￿synchronous machine Switched￿reluctance￿machine Electrically￿excited￿synchronous machine Transverse￿flow￿machine 5￿+￿6 Torque 0￿to￿...
  • Page 23 I01￿High-voltage￿Components 3.￿Electric￿Motor Principal￿structure￿of￿the￿synchronous￿machine Index Explanation Conventional￿synchronous￿machine Synchronous￿machine￿in￿the￿I01 Stator Stack￿of￿sheets,￿rotor South￿pole￿of￿a￿permanent￿magnet North￿pole￿of￿a￿permanent￿magnet To￿improve￿the￿technical￿data￿the￿structure,￿primarily￿of￿the￿rotor,￿was￿modified￿and￿optimized.￿The rotor￿has￿a￿new￿arrangement￿of￿the￿permanent￿magnets￿and￿a￿stack￿of￿sheets￿which￿has￿a￿positive influence￿on￿the￿characteristic￿of￿the￿magnetic￿field￿lines.￿On￿the￿one￿hand,￿this￿improves￿the￿torque. On￿the￿other￿hand,￿there￿are￿lower￿current￿levels￿in￿the￿stator￿coils,￿whereby￿the￿efficiency￿is￿increased in￿comparison￿to￿a￿conventional￿synchronous￿machine. The￿impressive￿performance￿data￿are￿summarized￿in￿the￿following￿table. Nominal￿voltage 360 V Nominal￿current 400 A Actual￿value Maximum￿peak￿output 125 kW/170 bhp for￿a￿maximum￿duration￿of￿30 s Maximum￿continuous￿output about￿75 kW continuous Maximum￿torque 250 Nm/184￿lb-ft in￿the￿engine￿speed￿range 0 – 5,000 rpm. Maximum￿engine￿speed about￿11,400 1￿min. Weight about￿49 kg The￿maximum￿power￿of￿125 kW￿can￿only￿be￿made￿available￿for￿a￿maximum￿duration￿of￿30￿s. Otherwise,￿the￿components￿of￿the￿drive￿train￿would￿be￿damaged￿through￿overheating￿–￿this￿affects￿not only￿the￿electrical￿machine,￿but￿also￿the￿high-voltage￿battery￿and￿the￿electrical￿machine￿electronics. The￿maximum￿power￿applies￿for￿the￿motor￿operation￿–￿in￿theory￿it￿could￿also￿be￿used￿in￿the￿alternator...
  • Page 24 I01￿High-voltage￿Components 3.￿Electric￿Motor operation￿during￿brake￿energy￿regeneration.￿However,￿in￿practice￿only￿a￿fractional￿part￿of￿this￿maximum value￿is￿used￿in￿alternator￿operation.￿As￿a￿result,￿the￿braking￿torque￿at￿the￿rear￿axle￿is￿restricted￿so￿as not￿to￿affect￿the￿driving￿stability￿by￿the￿brake￿energy￿regeneration. Power￿and￿torque￿diagram￿for￿IB1P25B￿machine￿compared￿to￿the￿N52B30U1￿engine The￿power￿and￿torque￿diagram￿shown￿here￿is￿not￿the￿full￿load￿diagram.￿Instead,￿the￿data￿was￿recorded at￿a￿lower￿supply￿voltage,￿as￿it￿occurs,￿for￿example,￿during￿a￿partially￿charged￿high-voltage￿battery. Nevertheless,￿the￿data￿of￿the￿electrical￿machine￿are￿impressive￿and￿do￿not￿need￿to￿fear￿comparison with￿the￿N52B30U1￿engine.￿The￿following￿properties￿are￿characteristic￿of￿the￿electrical￿machine IB1P25B￿in￿the￿I01:...
  • Page 25 I01￿High-voltage￿Components 3.￿Electric￿Motor • The￿maximum￿torque￿of￿250 Nm￿is￿already￿available￿from￿when￿the￿machine￿is￿at￿a￿standstill and￿is￿available￿up￿to￿average￿engine￿speeds.￿This￿is￿why￿the￿drive￿train￿of￿the￿I01￿does￿not need￿a￿clutch.￿Besides￿this￿technical￿feature,￿there￿is￿also￿another￿advantage￿for￿the￿customer: The￿I01￿has￿an￿impressive￿accelerating￿ability￿from￿standstill,￿which￿results￿in￿The￿Ultimate Driving￿Machine￿typical￿of￿BMW,￿particularly￿in￿urban￿traffic. • The￿maximum￿torque￿only￿decreases￿again￿at￿higher￿engine￿speeds.￿However,￿it￿is￿sufficient to￿be￿able￿to￿dynamically￿overtake￿in￿the￿speed￿range￿on￿national￿roads. • The￿characteristic￿of￿the￿maximum￿power￿can￿be￿deduced￿from￿the￿characteristic￿of￿the maximum￿torque:￿In￿the￿engine￿speed￿range￿in￿which￿the￿maximum￿torque￿is￿applied constantly￿the￿maximum￿power￿increases￿linear￿to￿its￿maximum.￿Despite￿the￿falling￿torque￿at higher￿engine￿speeds,￿the￿maximum￿power￿only￿decreases￿slightly￿to￿the￿maximum￿engine speed. • The￿usable￿engine￿speed￿range￿of￿the￿electrical￿machine￿is￿sufficient￿from￿0￿to￿almost 11,400 rpm.￿Owing￿to￿this￿almost￿double￿the￿engine￿speed￿range￿of￿a￿combustion￿engine,￿the I01￿manages￿without￿a￿manual￿gearbox￿and￿still￿achieves￿a￿remarkable￿maximum￿speed￿of 150 km/h.

  • Page 26: Design

    I01￿High-voltage￿Components 3.￿Electric￿Motor 3.1.3.￿Design Electrical￿machine Design￿of￿electric￿motor Index Explanation Coolant￿ducts Grooved￿ball￿bearing Drive￿shaft Inner￿housing Stack￿of￿sheets￿in￿the￿rotor Permanent￿magnets￿in￿the￿rotor Stator￿stack￿of￿sheets...
  • Page 27 I01￿High-voltage￿Components 3.￿Electric￿Motor In￿the￿graphic￿only￿the￿part￿of￿the￿stator￿without￿coil￿is￿shown.￿The￿rotor￿consists￿of￿a￿weight-optimized support￿in￿the￿inside,￿a￿stack￿of￿sheets￿and￿permanent￿magnets,￿which￿are￿arranged￿in￿two￿layers.￿The torque￿that￿can￿be￿generated￿by￿the￿machine￿is￿therefore￿increased.￿The￿rotor￿is￿shrink-fitted￿on￿the drive￿shaft. The￿number￿of￿pole￿pairs￿of￿6￿is￿a￿good￿ratio￿between￿the￿justifiable￿complexity￿of￿the￿design￿and represents￿a￿constant￿torque￿curve￿for￿each￿revolution￿where￿possible. The￿electrical￿machine￿of￿the￿I01￿does￿not￿have￿an￿oil￿filling.￿Only￿the￿two￿grooved￿ball￿bearings￿which include￿a￿grease￿filling￿are￿lubricated.￿The￿cooling￿of￿the￿electrical￿machine￿is￿effected￿using￿coolant, which￿is￿conveyed￿from￿the￿output￿of￿the￿electrical￿machine￿electronics￿to￿the￿electrical￿machine.￿In the￿electrical￿machine￿the￿coolant￿flows￿through￿a￿spiral-shaped￿coolant￿duct,￿which￿runs￿at￿the￿outer side.￿Two￿O-rings￿at￿the￿housing￿ends￿seal￿the￿coolant￿duct.￿The￿inside￿of￿the￿electrical￿machine￿is therefore￿completely￿"dry". Cooling￿of￿the￿electrical￿machine Index Explanation Connection￿for￿coolant￿line￿(input￿of￿electrical￿machine,￿coming￿from￿the electrical￿machine￿electronics) Outer￿housing Connection￿for￿coolant￿line￿(output￿of￿electrical￿machine,￿to￿the￿radiator) O-ring Cooling￿duct...
  • Page 28 I01￿High-voltage￿Components 3.￿Electric￿Motor The￿electrical￿machine￿is￿designed￿for￿a￿large￿temperature￿range.￿The￿coolant￿can￿reach￿a￿temperature of￿up￿to￿70 °C￿at￿the￿input￿(supply).￿And￿although￿the￿electrical￿machine￿demonstrates￿less￿losses during￿energy￿conversion￿than￿a￿combustion￿engine,￿its￿housing￿can￿absorb￿a￿temperature￿of￿up￿to 100 °C. Danger￿of￿injury:￿The￿housing￿of￿the￿electrical￿machine￿can￿absorb￿temperatures￿of￿up￿to￿100 °C during￿operation.￿A￿sufficiently￿long￿time￿must￿be￿waited￿for￿cooling￿if￿work￿is￿to￿be￿performed,￿for example￿the￿removal￿of￿the￿drive￿unit. Sensors In￿order￿to￿avoid￿damage￿to￿the￿components￿due￿to￿the￿high￿temperature,￿there￿are￿two￿temperature sensors￿in￿the￿electrical￿machine￿of￿the￿I01.￿Both￿temperature￿sensors￿are￿located￿in￿the￿coils of￿the￿stator.￿The￿temperature￿of￿the￿rotor￿is￿not￿measured￿directly,￿but￿can￿be￿determined￿from the￿measured￿values￿of￿the￿temperature￿sensors￿in￿the￿stator.￿The￿two￿temperature￿sensors￿are temperature-dependent￿resistors￿of￿type￿NTC.￿Their￿signals￿are￿read￿in￿and￿evaluated￿analogically￿by the￿electrical￿machine￿electronics. So￿that￿the￿voltages￿for￿the￿coils￿in￿the￿stator￿can￿be￿correctly￿calculated￿and￿generated￿by￿the electrical￿machine￿electronics￿in￿terms￿of￿amplitude￿and￿phase￿layer,￿the￿precise￿angle￿setting￿of￿the rotor￿must￿be￿known.￿This￿is￿why￿there￿is￿a￿rotor￿position￿sensor￿at￿the￿end￿of￿the￿drive￿shaft,￿which￿is turned￿away￿from￿the￿transmission. Electrical￿connections￿of￿the￿electrical￿machine...
  • Page 29 I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Outer￿housing Housing￿cover Connection￿for￿rotor￿position￿sensor Temperature￿sensor￿in￿the￿stator High-voltage￿connection￿U High-voltage￿connection￿V High-voltage￿connection￿W Rotor￿position￿sensor The￿housing￿cover￿must￿be￿replaced￿after￿disassembly￿ The￿screws￿of￿the￿high-voltage￿connections￿(U,￿V,￿W)￿must￿be￿replaced￿after￿each￿disassembly. The￿rotor￿position￿sensor￿is￿secured￿at￿the￿stator￿of￿the￿electrical￿machine￿and￿works￿according￿to the￿tilt￿sensor￿principle.￿There￿are￿three￿coils￿in￿the￿rotor￿position￿sensor.￿A￿defined￿AC￿voltage￿is fed￿to￿one￿of￿the￿coils.￿The￿other￿two￿coils￿are￿each￿moved￿90°.￿The￿voltages￿induced￿in￿these￿coils provide￿information￿about￿the￿angle￿setting￿of￿the￿rotor.￿The￿rotor￿position￿sensor￿is￿mounted￿by￿the manufacturer￿of￿the￿electrical￿machine￿at￿the￿corresponding￿alignment￿so￿that￿it￿is￿already￿correctly adjusted.￿A￿precise￿adjustment￿of￿the￿rotor￿position￿sensor￿is￿effected￿during￿production,￿after￿which the￿electrical￿machine￿and￿electrical￿machine￿electronics￿are￿joined.￿The￿adjustment￿values￿are￿stored in￿the￿control￿unit￿of￿the￿electrical￿machine￿electronics. Neither￿an￿adjustment￿nor￿a￿replacement￿of￿the￿rotor￿position￿sensor￿can￿be￿performed￿in￿BMW Service. If￿the￿electrical￿machine￿or￿the￿electrical￿machine￿electronics￿are￿replaced,￿the￿code￿for￿the￿angle￿must be￿noted￿via￿diagnosis￿in￿the￿electrical￿machine￿electronics.￿The￿code￿for￿the￿angle￿can￿be￿found￿on the￿type￿plate￿of￿the￿electrical￿machine. The￿electrical￿connection￿for￿the￿sensors￿of￿the￿electrical￿machine￿and￿the￿electrical￿machine electronics￿is￿shown￿in￿a￿wiring￿diagram￿in￿the￿chapter￿"Electrical￿interfaces".
  • Page 30 I01￿High-voltage￿Components 3.￿Electric￿Motor 3.1.4.￿External￿features￿and￿mechanical￿interfaces External￿features￿and￿mechanical￿interfaces￿of￿the￿electrical￿machine Index Explanation Carrier￿support￿for￿electrical￿machine￿electronics Connection￿for￿coolant￿line￿(output￿of￿electrical￿machine￿to￿the￿radiator) Shaft￿for￿electrical￿connections￿for￿the￿electrical￿machine￿electronics Outer￿housing Connection￿for￿coolant￿line￿(input￿of￿electrical￿machine,￿coming￿from￿the electrical￿machine￿electronics) Bore￿holes/thread￿for￿the￿mechanical￿connection￿with￿the￿transmission Drive￿shaft Anti-roll￿bar￿link￿connection The￿electrical￿machine￿electronics￿is￿located￿above￿the￿electrical￿machine.￿In￿order￿to￿obtain￿ample support,￿the￿housing￿of￿the￿electrical￿machine￿was￿"extended"￿with￿a￿carrier￿support￿at￿the￿front￿in￿the direction￿of￿travel. The￿torque￿is￿transmitted￿via￿a￿positive￿connection￿from￿the￿drive￿shaft￿of￿the￿electrical￿machine￿to￿the transmission￿input￿shaft.￿For￿this￿purpose,￿both￿shafts￿have￿gearing.￿However,￿there￿is￿no￿intended centring￿for￿the￿two￿shafts.
  • Page 31 I01￿High-voltage￿Components 3.￿Electric￿Motor When￿joining￿the￿transmission￿and￿the￿electrical￿machine￿the￿procedure￿described￿in￿the￿repair instructions￿must￿be￿followed.￿Ensure￿axial￿alignment￿of￿the￿transmission￿input￿shaft￿and￿output￿shaft to￿avoid￿distortion￿during￿assembly.￿In￿addition,￿the￿two￿gearings￿must￿be￿greased￿before￿joining.￿Do not￿exceed￿the￿specified￿quantity￿of￿grease￿ Mechanical￿interfaces￿of￿the￿transmission Index Explanation Rear￿axle￿module Output￿shaft,￿right Transmission￿housing X-sealing￿ring Output￿shaft,￿left Transmission￿input￿shaft￿with￿gearing O-sealing￿ring Bore￿holes￿for￿the￿mechanical￿connection￿with￿the￿electrical￿machine There￿is￿a￿sealing￿ring￿at￿the￿joining￿connection￿between￿housings￿of￿the￿electrical￿machines￿and￿the transmission,￿whose￿cross-section￿is￿shaped￿like￿the￿letter￿"X".￿This￿X-sealing￿ring￿must￿be￿replaced before￿joining￿and￿is￿included￿in￿the￿delivery￿specification￿of￿the￿transmission. The￿two￿connections￿for￿the￿coolant￿lines￿integrate￿the￿electrical￿machine￿in￿the￿cooling￿circuit￿of￿the electric￿motor.￿This￿is￿described￿in￿the￿chapter￿"Cooling￿of￿electric￿motor￿components".
  • Page 32 I01￿High-voltage￿Components 3.￿Electric￿Motor The￿graphics￿in￿this￿document￿show￿the￿electrical￿machine￿and￿the￿transmission￿without￿coating.￿In the￿production￿vehicle￿sometimes￿these￿components￿are￿still￿covered￿by￿a￿foam￿part.￿This￿serves￿for the￿acoustic￿encapsulation￿of￿the￿electric￿motor￿and￿absorbs￿noises￿which￿the￿customer￿may￿find irritating. The￿housing￿of￿the￿electrical￿machine￿is￿airtight￿and￿waterproof,￿as￿the￿low￿installation￿location demands￿this￿and￿to￿avoid￿damage￿by￿water￿passing￿through.￿However,￿due￿to￿the￿big￿temperature differences￿which￿may￿occur￿during￿operation￿there￿is￿a￿need￿for￿pressure￿compensation.￿This￿is effected￿via￿the￿shaft￿used￿for￿the￿electrical￿connection￿for￿the￿electrical￿machine￿electronics. The￿mounting￿and￿storage￿is￿not￿only￿related￿to￿the￿electrical￿machine￿itself,￿but￿also￿the￿entire￿drive unit￿comprising￿the￿electrical￿machine,￿transmission￿and￿electrical￿machine￿electronics. Mounting￿and￿storage￿of￿the￿drive￿unit￿(without￿range￿extender) Index Explanation Transmission Electrical￿machine￿electronics Bearing￿for￿engine￿support￿arm Engine￿support￿arm...
  • Page 33 I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Rear￿axle￿module Electrical￿machine Anti-roll￿bar￿link Output￿shaft In￿the￿direction￿of￿travel￿on￿the￿left￿an￿engine￿support￿arm￿connects￿the￿housing￿of￿the￿electrical machine￿to￿the￿rear￿axle￿module.￿This￿engine￿support￿arm￿serves￿not￿only￿to￿absorb￿the￿weight force￿of￿the￿drive￿unit.￿Via￿this￿engine￿support￿arm￿the￿drive￿torque￿is￿also￿transmitted￿to￿the￿rear axle￿module￿and￿ultimately￿supported￿at￿the￿body.￿The￿entire￿drive￿unit￿(electrical￿machine,￿electrical machine￿electronics￿and￿transmission)￿is￿also￿connected￿to￿the￿rear￿axle￿module￿via￿the￿anti-roll￿bar link. If￿the￿electrical￿machine￿has￿to￿be￿removed,￿the￿entire￿rear￿axle￿must￿be￿removed￿beforehand.￿This￿also applies￿to￿the￿removal￿of￿the￿transmission￿and￿the￿electrical￿machine￿electronics.￿Only￿then￿can￿the additional￿supports￿be￿removed￿from￿the￿housings￿and￿the￿individual￿components￿also￿removed. The￿EKK￿is￿secured￿to￿the￿electrical￿machine￿using￿three￿screws. Mounting￿of￿the￿EKK...
  • Page 34 I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Mounting￿bolts￿(3x) Electrical￿machine The￿housing￿of￿the￿electrical￿machine￿serves￿as￿a￿mounting￿and￿support￿for￿the￿EKK.￿There￿are￿bore holes￿with￿threaded￿inserts￿at￿corresponding￿points￿on￿the￿housing￿of￿the￿electrical￿machine. The￿threaded￿inserts￿for￿mounting￿the￿EKK￿cannot￿be￿replaced￿ 3.1.5.￿Electrical￿interfaces The￿electrical￿machine￿has￿electrical￿interfaces￿for￿the￿electrical￿machine￿electronics.￿The￿following graphic￿shows￿again￿the￿electrical￿interfaces￿of￿the￿electrical￿machine￿for￿the￿electrical￿machine electronics. Electrical￿interfaces￿between￿electrical￿machine￿and￿electrical￿machine￿electronics...

  • Page 35: Transmission

    I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Electrical￿machine￿electronics￿(entirety) EME￿control￿unit High-voltage￿battery Bidirectional￿DC/AC￿converter Actual￿electrical￿machine Temperature￿sensor￿in￿the￿stator Temperature￿sensor￿in￿the￿stator Rotor￿position￿sensor Electrical￿machine￿(entirety) There￿is￿a￿high-voltage￿interface￿and￿a￿low-voltage￿interface.￿The￿high-voltage￿interface￿is￿made￿up￿of three￿phases.￿A￿bidirectional￿DC/AC￿converter￿in￿the￿electrical￿machine￿electronics￿generates￿three- phase￿AC￿voltage,￿which￿is￿transmitted￿to￿the￿coils￿in￿the￿stator￿of￿the￿electrical￿machine.￿With￿this￿the electrical￿machine￿is￿controlled￿and￿its￿operating￿mode￿–￿as￿an￿engine￿or￿alternator￿–￿is￿specified.￿The electrical￿lines￿or￿connections￿are￿screwed￿and￿concealed￿under￿a￿lid. The￿low-voltage￿interface￿consists￿solely￿of￿the￿signal￿lines￿of￿the￿following￿sensors: • Temperature￿sensors￿of￿stator￿coil￿(2x) • Temperature￿sensor￿of￿rotor￿(at￿a￿bearing) • Rotor￿position￿sensor. The￿electrical￿machine￿electronics￿measures￿the￿electrical￿resistance￿of￿the￿two￿temperature￿sensors, which￿are￿designed￿as￿negative￿temperature￿coefficients,￿and￿thus￿determines￿the￿temperatures￿at the￿two￿locations￿in￿the￿electrical￿machine.￿In￿addition,￿the￿electrical￿machine￿electronics￿generates AC￿voltage￿for￿the￿rotor￿position￿sensor￿and￿evaluates￿the￿signals￿of￿this￿sensor￿(two￿induced￿AC voltages).￿The￿electrical￿connection￿consists￿of￿a￿plug￿connection,￿which￿is￿concealed￿under￿the￿same lid￿as￿the￿high-voltage￿connection. 3.2.￿Transmission 3.2.1.￿Introduction The￿transmission￿of￿the￿I01￿must￿fulfil￿the￿following￿tasks: • Transmission￿of￿engine￿speed￿and￿torque￿from￿the￿electrical￿machine￿to￿the￿output￿shafts • Engine￿speed￿adjustment￿between￿the￿two￿output￿shafts￿or￿sprockets • Securing￿the￿vehicle￿against￿rolling￿away.
  • Page 36 I01￿High-voltage￿Components 3.￿Electric￿Motor • Transmission￿gearing￿with￿two￿spur￿gear￿units￿(central￿transmission) • Differential￿integrated￿in￿the￿transmission￿housing • Electromechanically￿operated￿parking￿lock. As￿the￿electrical￿machine￿offers￿a￿large￿usable￿engine￿speed￿range,￿the￿transmission￿of￿the￿I01￿also only￿has￿to￿provide￿one￿gear,￿i.e.￿a￿fixed￿gear￿ratio.￿A￿combustion￿engine￿cannot￿deliver￿torque￿when the￿engine￿speed￿is￿zero.￿Unlike￿the￿electrical￿machine￿of￿the￿I01:￿Its￿high￿torque￿is￿already￿available when￿the￿engine￿speed￿is￿zero￿meaning￿a￿clutch￿in￿the￿transmission￿of￿the￿I01￿is￿not￿required￿–￿not￿for driving￿off￿or￿for￿shifting￿gears. Gear￿selector￿switch￿I01 The￿transmission￿in￿the￿I01￿is￿operated￿using￿a￿mono-stable￿rotary￿gear￿selector￿switch.￿The￿gear selector￿switch￿offers￿the￿option￿of￿selecting￿the￿familiar￿drive￿positions￿"P",￿"N",￿"R",￿"D".￿The￿drive positions￿are￿shown￿as￿a￿shift￿pattern￿with￿auxiliary￿lines.￿The￿current￿drive￿position￿is￿highlighted. The￿following￿table￿shows￿how￿the￿individual￿drive￿positions￿are￿realized. Drive Status￿of￿parking￿lock Activation￿of￿the￿electrical￿machine position Parking￿P Engaged De-energized Neutral￿N Disengaged De-energized Reverse￿R Disengaged Engine/Alternator￿with￿direction￿of￿rotation￿for reversing Drive￿D Disengaged Engine/Alternator￿with￿direction￿of￿rotation￿for forwards￿travel Two￿control￿units￿are￿responsible￿for￿engaging￿and￿disengaging￿the￿parking￿lock.
  • Page 37 I01￿High-voltage￿Components 3.￿Electric￿Motor Electrical￿Digital￿Motor￿Electronics￿EDME The￿EDME￿control￿unit￿contains￿the￿logics,￿i.e.￿the￿preconditions￿when￿the￿parking￿lock￿is￿to￿be engaged￿or￿disengaged.￿Via￿the￿PT-CAN￿the￿EDME￿control￿unit￿sends￿the￿corresponding￿commands to￿the￿electrical￿machine￿electronics. Electrical￿machine￿electronics￿(EME) The￿EME￿control￿unit￿activates￿the￿parking￿lock￿actuator￿directly.￿It￿behaves￿similarly￿with￿the￿function of￿the￿other￿drive￿positions￿"R"￿and￿"D".￿Also￿here￿the￿EDME￿control￿unit￿calculates￿the￿logic￿part. The￿electrical￿machine￿electronics￿is￿responsible￿for￿the￿implementation,￿for￿example￿to￿activate￿the electrical￿machine￿for￿reversing￿or￿forwards￿travel.￿Finally,￿the￿transmission￿of￿the￿I01￿also￿offers￿the functions￿shift￿lever￿interlock￿and￿interlock,￿whose￿logic￿part￿is￿also￿calculated￿in￿the￿EDME￿control￿unit (see￿section￿"Shift-by-Wire￿function").

  • Page 38: Transmission

    I01￿High-voltage￿Components 3.￿Electric￿Motor 3.2.2.￿Transmission The￿transmission￿of￿the￿I01￿was￿developed￿by￿the￿BMW Group￿and￿its￿being￿produced￿in￿the￿BMW plant￿in￿Dingolfing. The￿transmission￿has￿an￿overall￿ratio￿of￿9.7:1.￿The￿engine￿speed￿at￿the￿transmission￿input￿is￿9.7 times￿greater￿than￿at￿the￿transmission￿output.￿This￿ratio￿is￿realized￿using￿two￿spur￿gear￿units.￿In addition￿to￿the￿input￿shaft,￿there￿is￿also￿an￿intermediate￿shaft￿in￿the￿transmission.￿The￿spur￿gear￿unit at￿the￿transmission￿output￿is￿fixed￿to￿the￿differential￿cage￿and￿drives￿the￿differential.￿The￿differential distributes￿the￿torque￿to￿two￿outputs￿and￿enables￿the￿engine￿speed￿adjustment￿between￿the￿two outputs.￿The￿differential￿has￿an￿almost￿identical￿design￿to￿that￿of￿a￿front￿axle￿differential,￿as￿used in￿BMW￿vehicles￿with￿a￿four-wheel￿drive￿(front￿axle￿differential 156).￿For￿use￿in￿the￿I01￿only￿surface hardening￿measures￿and￿a￿high-strength￿material￿are￿used. Structure￿of￿the￿transmission Index Explanation View￿from￿rear￿left View￿from￿rear￿right Geared￿shaft￿as￿connection￿for￿the￿drive￿shaft￿of￿the￿electrical￿machine Transmission￿input￿shaft Spur￿gear￿unit￿1￿at￿input￿shaft Spur￿gear￿unit￿2￿at￿intermediate￿shaft Spur￿gear￿unit￿4￿at￿transmission￿output Differential...
  • Page 39 I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Connection￿for￿output￿shaft,￿left Intermediate￿shaft Spur￿gear￿unit￿3￿at￿intermediate￿shaft Connection￿for￿output￿shaft,￿right The￿following￿skeleton￿graphic￿is￿a￿simplified￿diagram￿and￿shows￿the￿torque￿transmission￿in￿the transmission. Skeletal￿graphic￿for￿transmission Index Explanation Torque￿of￿the￿electrical￿machine￿=￿Transmission￿input￿torque Transmission￿output￿torque Drive￿torque￿at￿an￿output￿shaft Drive￿shaft￿of￿the￿electrical￿machine Positive￿connection￿between￿electrical￿machine￿and￿transmission Transmission￿input￿shaft Combination￿of￿spur￿gear￿unit￿1￿and￿2 Combination￿of￿spur￿gear￿unit￿3￿and￿4 Output￿shaft,￿right Differential Output￿shaft,￿left Intermediate￿shaft...
  • Page 40 I01￿High-voltage￿Components 3.￿Electric￿Motor An￿axle￿transmission￿oil￿known￿from￿conventionally￿driven￿BMW￿vehicles￿is￿used￿as￿transmission oil￿(manufacturer￿designation,￿e.g.￿Castrol￿BOT-448).￿The￿transmission￿housing￿is￿also￿used￿as￿an oil￿sump￿and￿holds￿the￿full￿capacity￿of￿0.5 l￿transmission￿oil.￿The￿spur￿gear￿units￿and￿the￿differential run￿in￿the￿transmission￿oil￿and￿ensure￿the￿entire￿transmission￿is￿lubricated￿(oil￿sump￿lubrication).￿The transmission￿oil￿is￿designed￿for￿the￿operating￿life￿of￿the￿I01￿meaning￿there￿is￿no￿need￿for￿a￿replacement of￿the￿transmission￿oil.￿Nevertheless,￿there￿is￿an￿oil￿drain￿plug,￿as￿well￿as￿an￿oil￿filler￿plug,￿with￿which the￿oil￿level￿can￿also￿be￿checked.￿These￿are￿shown￿in￿a￿graphic￿in￿the￿chapter￿"Mechanical￿interfaces". The￿transmission￿is￿not￿integrated￿in￿the￿cooling￿system￿of￿the￿electric￿motor￿and￿therefore￿has￿no connections￿for￿coolant￿lines.￿The￿heat￿in￿the￿transmission￿which￿arises￿during￿operation￿is￿low. Sufficient￿heat￿is￿discharged￿via￿the￿air￿flowing￿by￿at￿the￿transmission￿housing￿and￿the￿connection for￿the￿electrical￿machine.￿The￿temperature￿in￿the￿transmission￿remains￿in￿a￿range￿up￿to￿a￿maximum 120 °C,￿for￿which￿the￿components￿and￿the￿transmission￿oil￿are￿designed.￿The￿transmission￿can, however,￿also￿absorb￿significantly￿lower￿temperatures:￿When￿driving￿off￿after￿a￿long￿immobilization period￿the￿components￿have￿the￿ambient￿temperature.￿As￿a￿result￿of￿the￿large￿temperature￿range excess￿pressure￿or￿a￿vacuum￿would￿occur￿in￿a￿completely￿tight￿housing.￿To￿avoid￿this￿there￿is￿a bleeding￿hole￿above￿at￿the￿transmission￿housing.￿It￿has￿a￿cap￿to￿protect￿against￿dirt￿contamination. The￿bleeding￿hole￿is￿also￿shown￿in￿a￿graphic￿in￿the￿chapter￿"Mechanical￿interfaces". 3.2.3.￿Mechanical￿interfaces Mounting￿and￿torque￿support The￿mounting￿and￿support￿of￿the￿drive￿torque￿is￿not￿only￿related￿to￿the￿transmission,￿but￿also￿the entire￿drive￿unit￿comprising￿the￿electrical￿machine,￿transmission￿and￿electrical￿machine￿electronics. The￿weight￿force￿and￿drive￿torque￿are￿transmitted￿to￿the￿rear￿axle￿module￿via￿engine￿support￿arm￿and anti-roll￿bar￿link￿and￿from￿there￿to￿the￿body. Components￿of￿the￿transmission￿visible￿from￿the￿outside...
  • Page 41 I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Parking￿lock￿module Ventilation￿opening Transmission￿housing Oil￿drain￿plug Fluid￿filler￿plug Interface￿for￿the￿electrical￿machine The￿torque￿is￿transmitted￿via￿a￿positive￿connection￿from￿the￿drive￿shaft￿of￿the￿electrical￿machine￿to￿the transmission￿input￿shaft.￿For￿this￿purpose,￿both￿shafts￿have￿gearing.￿However,￿there￿is￿no￿intended centring￿for￿the￿two￿shafts. When￿joining￿the￿transmission￿and￿the￿electrical￿machine￿the￿procedure￿described￿in￿the￿repair instructions￿must￿be￿followed.￿Ensure￿axial￿alignment￿of￿the￿transmission￿input￿shaft￿and￿output￿shaft to￿avoid￿distortion￿during￿assembly.￿In￿addition,￿the￿two￿gearings￿must￿be￿greased￿before￿joining.￿Do not￿exceed￿the￿specified￿quantity￿of￿grease￿ Mechanical￿interfaces￿of￿the￿transmission Index Explanation Rear￿axle￿module Output￿shaft,￿right Transmission￿housing X-sealing￿ring...
  • Page 42 I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Output￿shaft,￿left Transmission￿input￿shaft￿with￿gearing O-ring￿seal Bore￿holes￿for￿the￿mechanical￿connection￿with￿the￿electrical￿machine The￿O-ring￿seal￿and￿the￿X-sealing￿ring￿must￿be￿replaced￿after￿a￿disconnection￿of￿the￿transmission￿from the￿electrical￿machine￿ Water￿and￿dirt￿may￿penetrate￿the￿cavity￿within￿the￿transmission￿housing￿which￿can￿be￿seen￿in￿the graphic.￿This￿is￿not￿a￿problem￿for￿the￿transmission￿–￿however,￿water￿and￿dirt￿must￿be￿prevented￿from entering￿the￿electrical￿machine￿from￿there.￿For￿this￿purpose,￿the￿sealing￿ring￿marked￿in￿the￿graphic, which￿has￿the￿letter￿"X"￿in￿the￿cross-section,￿is￿used. There￿is￿another￿sealing￿ring￿on￿the￿transmission￿input￿shaft.￿It￿seals￿the￿hub￿space￿of￿the￿electrical machine,￿which￿is￿filled￿with￿grease.￿With￿the￿sealing￿ring￿the￿grease￿filled￿during￿installation￿remains￿in the￿hub￿space￿and￿ensures￿the￿lubrication￿during￿the￿entire￿service￿life￿of￿the￿vehicle. Ring-shaped￿through-holes￿arranged￿on￿the￿transmission￿housing￿hold￿the￿aluminium￿screws￿for connecting￿the￿housing￿of￿the￿transmission￿and￿the￿electrical￿machine. The￿aluminium￿screws￿must￿be￿replaced￿after￿disassembly￿ Interface￿for￿the￿output￿shafts The￿output￿shafts￿are￿connected￿in￿the￿outputs￿of￿the￿differential.￿The￿torque￿is￿transmitted￿by￿the positive￿connection￿(gearing)￿between￿the￿output￿shafts￿and￿the￿differential.￿A￿radial￿shaft￿seal,￿as known￿from￿conventional￿BMW￿vehicles,￿seals￿the￿oil￿chamber￿of￿the￿transmission. Covers The￿graphics￿in￿this￿document￿show￿the￿electrical￿machine￿and￿the￿transmission￿without￿its￿covers.￿In the￿vehicle￿sometimes￿these￿components￿are￿still￿covered￿by￿a￿foam￿part.￿This￿serves￿for￿the￿acoustic encapsulation￿of￿the￿electric￿motor￿and￿absorbs￿noises. 3.2.4.￿Parking￿lock Introduction The￿parking￿lock￿is￿responsible￿for￿securing￿the￿vehicle￿against￿rolling￿away,￿just￿like￿in￿a￿conventional vehicle￿with￿automatic￿transmission.￿Even￿on￿steep￿inclines/downhill￿gradients￿up￿to￿32%￿the￿parking lock￿is￿able￿to￿safely￿hold￿the￿I01￿at￿a￿standstill.￿Nevertheless,￿just￿like￿for￿conventional￿vehicles￿it￿is recommended￿to￿also￿secure￿the￿vehicle￿against￿rolling￿away￿using￿the￿parking￿brake.
  • Page 43 I01￿High-voltage￿Components 3.￿Electric￿Motor The￿driver￿can￿engage￿the￿parking￿lock￿in￿the￿I01￿using￿the￿P￿button￿at￿the￿gear￿selector￿switch.￿It is,￿however,￿automatically￿engaged￿and￿under￿the￿same￿conditions￿known￿from￿BMW￿vehicles￿with an￿electronic￿gear￿selector￿switch.￿For￿example,￿the￿parking￿lock￿is￿automatically￿engaged￿when￿it is￿detected￿that￿the￿driver￿has￿left￿the￿vehicle￿(driver's￿door￿open,￿seat￿belt￿open￿and￿the￿pedals￿not operated).￿In￿contrast￿to￿conventional￿vehicles,￿there￿is￿a￿further￿precondition,￿where￿disengaging￿the parking￿lock￿in￿the￿I01￿is￿not￿possible.￿This￿precondition￿prevents￿the￿driver￿taking￿off￿unintentionally as￿long￿as￿a￿charging￿cable￿is￿connected. The￿parking￿lock￿of￿the￿I01￿cannot￿be￿disengaged￿if￿a￿connected￿charging￿cable￿is￿identified. Structure￿and￿operating￿principle The￿parking￿lock￿comprises￿an￿electromechanical￿part￿(parking￿lock￿actuator)￿and￿a￿mechanical￿part (parking￿lock￿pawl￿and￿parking￿lock￿gear)￿in￿the￿transmission￿housing.￿The￿mechanical￿part￿functions at￿the￿transmission￿input￿shaft,￿as￿highlighted￿from￿the￿following￿transmission￿skeleton￿and￿sectioning. Position￿of￿the￿parking￿lock￿in￿transmission￿skeleton Index Explanation Drive￿shaft￿of￿the￿electrical￿machine Positive￿connection￿between￿electrical￿machine￿and￿transmission Transmission￿input￿shaft Parking￿lock￿pawl Parking￿lock￿gear Combination￿of￿spur￿gear￿unit￿1￿and￿2 Combination￿of￿spur￿gear￿unit￿3￿and￿4...
  • Page 44 I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Output￿shaft,￿right Differential Output￿shaft,￿left Intermediate￿shaft Structure￿of￿the￿mechanical￿part￿of￿the￿parking￿lock Index Explanation Return￿spring Fixing￿element Cam￿disc￿with￿two￿locking￿positions Relay￿shaft Parking￿lock￿module Transmission￿input￿shaft Parking￿lock￿pawl￿with￿return￿spring Parking￿lock￿gear...
  • Page 45 I01￿High-voltage￿Components 3.￿Electric￿Motor The￿parking￿lock￿module￿functions￿at￿a￿driving￿shaft.￿At￿the￿end￿of￿the￿driving￿shaft￿there￿is￿a￿bar￿which is￿turned￿about￿70￿degrees￿by￿the￿revolution￿of￿the￿driving￿shaft.￿As￿a￿result,￿the￿parking￿lock￿pawl￿is inserted￿into￿the￿parking￿lock￿gear￿and￿the￿transmission￿input￿shaft￿is￿blocked.￿By￿resetting￿the￿bar the￿parking￿lock￿pawl￿is￿released￿again,￿pulled￿from￿the￿parking￿lock￿gear￿by￿the￿return￿spring￿and￿the transmission￿input￿shaft￿is￿unlocked.￿The￿driving￿shaft￿is￿held￿in￿the￿two￿positions,￿"engaged"￿and "disengaged",￿by￿a￿fixing￿element.￿The￿fixing￿element￿locks￿into￿the￿respective￿recesses￿at￿the￿cam disc.￿The￿rod￿cannot￿be￿moved￿from￿these￿positions￿by￿movements￿or￿forces￿from￿the￿transmission. Both￿positions￿are￿stable￿without￿the￿supply￿of￿auxiliary￿power.￿It￿is￿also￿said: The￿parking￿lock￿of￿the￿I01￿is￿bi-stable.￿This￿means￿it￿requires￿external￿energy￿in￿order￿to￿change￿the condition￿of￿the￿parking￿lock. Energy￿is￿required￿for￿both￿disengaging￿and￿engaging￿the￿parking￿lock.￿In￿BMW￿vehicles￿with￿a conventional￿engine￿and￿automatic￿transmission￿energy￿is￿only￿required￿for￿disengaging￿the￿parking lock. The￿actuator￿of￿the￿parking￿lock￿is￿a￿direct￿current￿electric￿motor￿with￿gear/worm￿wheel￿transmission and￿two￿position￿sensors.￿All￿these￿parts￿are￿located￿in￿the￿housing￿and￿form￿one￿unit.￿The￿parking lock￿module￿is￿secured￿using￿three￿raised￿head￿Torx￿screws￿on￿the￿transmission￿housing￿and￿for￿now is￿not￿replaced￿in￿BMW￿Service. The￿parking￿lock￿module￿is￿connected￿to￿the￿parking￿lock￿via￿a￿multi-tooth￿connection￿of￿the￿actuator/ driving￿shaft￿at￿the￿transmission￿interface.￿Attention:￿The￿vehicle￿must￿be￿secured￿against￿rolling away￿by￿other￿measures￿(e.g.￿by￿operating￿the￿parking￿brake￿or￿positioning￿a￿wedge). The￿electric￿motor￿in￿the￿parking￿lock￿module￿is￿activated￿directly￿by￿an￿output￿stage￿in￿the￿electrical machine￿electronics.￿The￿output￿stage￿is￿current-limited￿to￿protect￿against￿damage￿by￿a￿short￿circuit. In￿order￿not￿to￿overload￿the￿electric￿motor,￿the￿power￿consumption￿is￿also￿measured￿and￿a￿current limitation￿performed￿in￿the￿software￿of￿the￿electrical￿machine￿electronics. The￿electric￿motor￿is￿supplied￿with￿current￿until￿the￿position￿sensors￿display￿that￿the￿parking￿lock￿has adopted￿the￿desired￿condition.￿The￿position￿sensors￿work￿according￿to￿the￿hall-effect￿principle￿and record￿the￿movement￿in￿the￿transmission￿of￿the￿parking￿lock￿module.￿As￿the￿function￿of￿the￿parking lock￿is￿relevant￿for￿safety,￿two￿redundant￿position￿sensors￿are￿used￿to￿achieve￿the￿requested￿reliability. If￿a￿sensor￿signal￿fails￿due￿to￿a￿fault,￿an￿active￿engaging￿or￿disengaging￿procedure￿can￿be￿completed￿as a￿result￿of￿the￿redundancy.￿The￿position￿sensors￿generate￿signals￿which￿are￿evaluated￿by￿the￿electrical machine￿electronics. As￿the￿position￿sensors￿record￿the￿movement￿of￿the￿electric￿motor￿in￿the￿parking￿lock￿module￿and￿not the￿movement￿of￿the￿actual￿parking￿lock￿mechanics,￿an￿initialization￿has￿to￿be￿performed￿as￿a￿one-off so￿that￿a￿conclusion￿can￿be￿drawn￿about￿the￿condition￿of￿the￿parking￿lock￿from￿the￿sensor￿signals. The￿following￿graphic￿shows￿the￿electrical￿structure￿of￿the￿parking￿lock￿module￿and￿the￿electrical connection￿for￿the￿electrical￿machine￿electronics.
  • Page 46 I01￿High-voltage￿Components 3.￿Electric￿Motor Electrical￿interfaces￿between￿parking￿lock￿module￿and￿electrical￿machine￿electronics Index Explanation Electrical￿machine￿electronics￿EME￿(entirety) PT-CAN￿connection Voltage￿supply EME￿control￿unit Output￿stage￿for￿parking￿lock￿module Electric￿motor Transmission￿of￿the￿parking￿lock￿actuator First￿position￿sensor￿according￿to￿the￿hall-effect￿principle Second￿position￿sensor￿working￿in￿the￿opposite￿direction,￿also￿according￿to the￿hall-effect￿principle Parking￿lock￿module￿(entirety)
  • Page 47 I01￿High-voltage￿Components 3.￿Electric￿Motor Service￿information The￿EME￿control￿unit￿performs￿several￿self-diagnosis￿functions￿in￿order￿to￿ensure￿the￿proper￿function of￿the￿parking￿lock￿module￿and￿to￿protect￿the￿components￿against￿damage.￿These￿self-diagnosis functions￿are: • Monitoring￿of￿lines￿for￿the￿electric￿motor,￿the￿position￿sensors￿and￿the￿solenoids￿for￿short circuit￿against￿ground￿and￿supply￿voltage,￿as￿well￿as￿for￿open￿circuit • Monitoring￿of￿the￿current￿level￿for￿the￿electric￿motor￿with￿regards￿to￿the￿maximum￿value￿and plausibility￿for￿the￿signals￿of￿the￿position￿sensors • Monitoring￿of￿the￿signals￿of￿the￿position￿sensors￿(pulse-width￿modulated￿signal￿in￿the specified￿range￿and￿plausibility￿of￿both￿signals￿to￿each￿other). If￿one￿of￿the￿self-diagnosis￿functions￿identifies￿a￿fault,￿in￿the￿EME￿control￿unit￿an￿entry￿is￿made￿in￿the fault￿memory￿which￿can￿indicate￿the￿fault￿cause.￿Depending￿on￿the￿severity￿of￿the￿identified￿fault￿the parking￿lock￿will￿either￿work￿again￿or￿remain￿in￿the￿current￿position.￿In￿each￿case,￿however,￿a￿fault￿code entry￿is￿generated￿and￿the￿customer￿is￿requested￿by￿a￿Check￿Control￿message￿to￿have￿the￿vehicle checked￿by￿BMW￿Service. If￿the￿cause￿for￿a￿malfunction￿cannot￿be￿determined￿using￿the￿fault￿code￿entry,￿the￿Service￿employee can￿perform￿the￿following￿checks￿and￿thus￿pinpoint￿the￿cause: • Check￿the￿voltage￿supply￿of￿the￿electric￿motor￿at￿the￿output￿of￿the￿electrical￿machine electronics￿with￿a￿measurement • Check￿the￿wiring￿harness￿section￿for￿open￿circuit/short￿circuit. The￿diagnosis￿system￿not￿only￿supports￿the￿Service￿employee￿during￿troubleshooting￿for￿the￿parking lock.￿The￿diagnosis￿system￿also￿offers￿Service￿functions.￿The￿most￿important￿Service￿function￿is￿used for￿the￿initialization￿of￿the￿parking￿lock.￿During￿the￿initialization￿the￿electric￿motor￿in￿the￿parking￿lock module￿approaches￿its￿end￿positions￿several￿times.￿The￿signals￿of￿the￿position￿sensors￿and￿also￿the characteristic￿of￿the￿current￿level,￿which￿the￿electric￿motor￿uses,￿are￿observed.￿The￿force￿which￿the electric￿motor￿must￿apply￿and￿also￿the￿current￿characteristic￿change￿through￿the￿locking￿positions￿at the￿cam￿disc￿and￿the￿force￿which￿the￿fixing￿element￿exerts.￿The￿EME￿control￿unit￿uses￿these￿values￿to calculate￿the￿positions￿at￿which￿the￿parking￿lock￿is￿correctly￿engaged￿or￿disengaged.￿The￿respective signal￿values￿of￿the￿position￿sensors￿are￿stored￿permanently￿in￿the￿EME￿control￿unit￿and￿are￿available from￿this￿time￿for￿the￿control￿of￿the￿operation￿of￿the￿parking￿lock. The￿initialization￿of￿the￿parking￿lock￿in￿the￿I01￿using￿the￿diagnosis￿system￿is￿necessary￿if • the￿transmission￿was￿replaced, •...
  • Page 48 I01￿High-voltage￿Components 3.￿Electric￿Motor Move￿the￿driving￿shaft￿of￿the￿parking￿lock￿into￿the￿locking￿position￿for￿"Parking￿lock￿disengaged", if￿necessary.￿by￿moving￿70°￿anti-clockwise. Install￿the￿new￿parking￿lock￿module. An￿emergency￿operation￿of￿the￿parking￿lock￿module￿is￿not￿intended￿￿The￿I01￿cannot￿be￿towed￿away.￿It can￿only￿be￿transported￿on￿a￿loading￿platform. 3.3.￿Drive￿control The￿electric￿motor￿of￿the￿I01￿is￿a￿distributed￿system￿with￿a￿variety￿of￿components.￿This￿is￿also discernible￿in￿the￿electronic￿part,￿the￿drive￿control,￿because￿several￿components￿(control￿units)￿are￿also involved￿here.￿The￿master￿role￿for￿the￿control￿of￿the￿electric￿motor￿in￿the￿I01￿is￿assumed￿by￿the￿engine control.￿It￿is￿modelled￿after￿vehicles￿with￿a￿gasoline￿engine￿with￿"Electrical￿Digital￿Motor￿Electronics" EDME. Installation￿location￿of￿the￿EDME As￿the￿most￿important￿partner￿control￿unit￿of￿the￿EDME,￿the￿electrical￿machine￿electronics￿assumes the￿activation￿of￿the￿electrical￿machine￿and￿the￿supply￿of￿energy￿to￿the￿low-voltage￿vehicle￿electrical system.￿Other￿partner￿control￿units￿of￿the￿EDME￿include￿the￿battery￿management￿electronics￿SME and￿the￿convenience￿charging￿electronics￿KLE. 3.3.1.￿System￿overview The￿following￿graphics￿shows￿the￿electrical￿connection￿of￿the￿key￿components￿of￿the￿drive￿control.
  • Page 49 I01￿High-voltage￿Components 3.￿Electric￿Motor System￿wiring￿diagram￿for￿the￿drive￿control...

  • Page 50: Functions

    I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Electric￿heating￿(EH) Electric￿fan Power￿distribution￿box￿at￿front￿in￿BDC Brake￿vacuum￿pressure￿sensor Relay￿for￿switching￿on￿the￿electric￿fan Fuel￿pump￿relay Intelligent￿battery￿sensor￿(IBS) 12 V￿battery Safety￿battery￿terminal￿(SBK) Power￿distribution￿box￿at￿front￿in￿BDC Body￿Domain￿Controller￿(BDC) Driving￿experience￿switch Combined￿expansion￿and￿shutoff￿valve￿(without￿heat￿pump) Integrated￿supply￿module Charging￿interface￿module￿(LIM) Range￿Extender￿Digital￿Engine￿Electronics￿(RDME) Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Electrical￿machine￿electronics￿(EME) Secondary￿air￿pump High-voltage￿safety￿connector￿(Service￿Disconnect) Electric￿coolant￿pump Battery￿management￿electronics￿(SME) Crash￿Safety￿Module￿(ACSM) Accelerator￿pedal￿module Electronic￿gear￿selector￿switch￿(GWS) Electrical￿Digital￿Motor￿Electronics￿(EDME) Electrical￿vacuum￿pump 3.3.2.￿Functions The￿drive￿control￿includes￿the￿following￿primary￿functions: • Evaluation￿of￿the￿driver's￿choice￿(accelerator￿pedal) • Coordination￿of￿torque￿demands • Operating￿strategy￿including￿behavior￿in￿emergency￿operation...
  • Page 51 I01￿High-voltage￿Components 3.￿Electric￿Motor • Activation￿of￿the￿electrical￿machine • Heat￿management • Evaluation￿of￿the￿electronic￿gear￿selector￿switch￿(Shift-by-Wire￿function) • Power￿management￿for￿the￿low-voltage￿vehicle￿electrical￿system.
  • Page 52 I01￿High-voltage￿Components 3.￿Electric￿Motor Activation￿of￿the￿electrical￿machine Input/Output￿for￿the￿drive￿control...
  • Page 53 I01￿High-voltage￿Components 3.￿Electric￿Motor Index Explanation Accelerator￿pedal￿module Signal,￿accelerator￿pedal￿angle Electronic￿gear￿selector￿switch￿(GWS) Operating￿signals￿of￿the￿electronic￿gear￿selector￿switch Battery￿management￿electronics￿(SME) Signals￿about￿the￿state￿of￿charge￿and￿the￿available￿electric￿power￿of￿the￿high- voltage￿battery Dynamic￿Stability￿Control￿(DSC) Signals￿about￿the￿dynamic￿handling￿characteristics,￿e.g.￿the￿driving￿speed Electrical￿Digital￿Motor￿Electronics￿(EDME) Electrical￿machine Phase￿voltages￿for￿the￿coils￿of￿the￿electrical￿machine Electrical￿machine￿electronics￿(EME) Requested￿drive￿torque￿(engine/alternator) Electric￿coolant￿pump Power￿requirement￿at￿electric￿coolant￿pump Electric￿fan Power￿requirement￿at￿electric￿coolant￿pump Instrument￿cluster Display￿information￿on￿the￿condition￿of￿the￿electric￿motor￿and￿Check￿Control messages￿in￿the￿event￿of￿a￿fault The￿upper￿graphic￿shows￿that￿the￿EDME￿control￿unit￿acts￿as￿a￿master￿and￿coordinator￿for￿the￿primary functions￿of￿the￿drive￿control. Before￿a￿drive￿torque￿is￿applied,￿the￿EDME￿must￿check￿whether￿the￿driving￿readiness￿is￿established. The￿EDME￿also￿queries￿whether￿all￿subsystems￿of￿the￿electrical￿drive￿train￿are￿functioning￿trouble- free,￿which￿is￿also￿a￿prerequisite￿for￿the￿provision￿of￿a￿drive￿torque.￿Finally,￿the￿EDME￿still￿has￿to consider￿the￿available￿electrical￿power￿for￿the￿electric￿motor￿which￿is￿primarily￿determined￿by￿the condition￿of￿the￿high-voltage￿battery.￿The￿SME￿control￿unit￿communicates￿this￿condition￿to￿the￿EDME control￿unit￿via￿corresponding￿bus￿signals.￿As￿a￿result￿of￿these￿checks￿the￿EDME￿identifies￿whether and￿in￿what￿scope￿the￿drive￿torque￿can￿be￿provided.￿In￿the￿case￿of￿fault￿statuses￿or￿in￿the￿event￿of limited￿availability,￿the￿EDME￿issues￿an￿appropriate￿Check￿Control￿message￿via￿the￿instrument￿cluster. The￿functions￿described￿here￿can￿be￿summarized￿under￿the￿term￿"Operating￿strategy". An￿important￿input￿signal￿for￿the￿determination￿of￿the￿drive￿torque￿is￿the￿accelerator￿pedal￿angle,￿which is￿transmitted￿via￿direct￿wiring￿from￿the￿accelerator￿pedal￿module￿to￿the￿EDME.￿Using￿this￿signal￿the EDME￿determines￿the￿torque￿request￿of￿the￿driver.￿The￿EDME￿must￿compare￿and￿coordinate￿this torque￿request￿and￿any￿other￿torque￿requests￿made￿at￿the￿same￿time,￿for￿example￿from￿the￿cruise control￿or￿the￿DSC.￿Using￿this￿input￿information￿the￿EDME￿can￿calculate￿the￿actual￿drive￿torque...
  • Page 54 I01￿High-voltage￿Components 3.￿Electric￿Motor In￿order￿to￿generate￿the￿drive￿torque￿using￿the￿electrical￿machine,￿the￿phase￿voltages￿(size,￿frequency and￿phase)￿have￿to￿be￿generated￿at￿the￿coils￿of￿the￿electrical￿machine.￿This￿task￿is￿not￿completed￿by the￿EDME￿itself,￿but￿by￿the￿electrical￿machine￿electronics￿EME.￿Via￿bus￿signals￿on￿the￿PT-CAN2￿the EDME￿sends￿the￿requested￿drive￿torque￿to￿the￿EME.￿The￿EME￿control￿unit￿then￿calculates￿the￿phase voltages￿and￿the￿power￿electronics￿of￿the￿EME,￿which￿is￿located￿in￿its￿own￿housing,￿generates￿the phase￿voltages. Shift-by-Wire￿function Another￿important￿function￿of￿the￿drive￿control￿is￿the￿shift-by-wire￿function,￿which￿evaluates￿the electronic￿gear￿selector￿switch￿and￿other￿signals,￿in￿order￿to￿simulate￿the￿drive￿positions￿of￿a conventional￿automatic￿transmission￿(P ,￿R,￿N,￿D). The￿change￿between￿the￿drive￿positions￿is￿achieved￿in￿the￿I01￿the￿same￿way￿as￿in￿conventional vehicles￿with￿automatic￿transmission￿and￿electronic￿gear￿selector￿switch.￿Some￿important preconditions￿and￿functions￿are￿listed￿below: • Interlock:￿Change￿from￿P￿to￿another￿drive￿position￿only￿when￿driving￿readiness￿is￿switched￿on • Shift￿lever￿interlock:￿Change￿from￿P￿or￿N￿to￿D￿or￿R￿only￿when￿brake￿pedal￿is￿operated￿at￿the same￿time • Change￿from￿P￿or￿R￿to￿N￿or￿D￿only￿when￿selector￿lever￿is￿operated￿at￿the￿same￿time • Automatic￿engaging￿of￿P:￿P￿is￿automatically￿engaged￿from￿the￿other￿drive￿positions￿(at￿vehicle standstill)￿if￿neither￿the￿brake￿pedal￿or￿accelerator￿pedal￿are￿operated,￿the￿driver's￿door￿is open￿and￿the￿driver's￿seat￿belt￿is￿not￿inserted￿in￿the￿seat￿belt￿buckle.￿P￿is￿also￿automatically engaged￿if￿the￿driving￿readiness￿is￿switched￿off • Car￿wash￿function:￿When￿the￿driving￿readiness￿is￿switched￿on￿engage￿drive￿position￿N,￿switch off￿driving￿readiness.￿N￿remains￿engaged. As￿the￿transmission￿of￿the￿I01￿only￿has￿a￿fixed￿ratio,￿there￿are￿no￿gears￿and￿thus￿also￿no￿adaptive￿EGS, no￿Sport￿program￿and￿also￿no￿manual￿program.￿The￿transmission￿also￿has￿no￿clutch￿to￿interrupt￿or establish￿the￿power￿transmission.￿There￿is￿also￿no￿reverse￿gear￿in￿the￿transmission￿of￿the￿I01.￿The following￿table￿shows￿how￿the￿drive￿control￿in￿the￿EDME￿realizes￿the￿individual￿drive￿positions: Drive￿position Activation￿of￿the￿electrical￿machine Actuator￿for￿parking lock Drive￿D Direction￿of￿rotation￿forwards,￿engine￿or...
  • Page 55 I01￿High-voltage￿Components 3.￿Electric￿Motor The￿selector￿level￿position￿N￿is￿thus￿not￿achieved￿by￿opening￿a￿clutch￿in￿the￿transmission.￿Instead,￿the electrical￿machine￿is￿activated￿so￿that￿it￿neither￿generates￿an￿engine￿nor￿alternator￿torque.￿One￿can therefore￿imagine￿as￿if￿the￿coils￿of￿the￿stator￿were￿open￿and￿no￿voltage￿is￿applied￿from￿outside.￿There is￿in￿fact￿voltage,￿generated￿by￿the￿electrical￿machine￿electronics￿–￿however,￿this￿is￿adjusted￿in￿the amplitude,￿frequency￿and￿phase￿so￿that￿the￿rotor￿can￿rotate￿without￿a￿load￿(torque￿0 Nm). The￿difference￿between￿the￿drive￿positions￿N￿and￿P￿is￿solely￿in￿the￿condition￿of￿the￿parking￿lock module.￿In￿N￿it￿is￿disengaged,￿in￿P￿it￿is￿engaged. Power￿management￿function For￿historical￿reasons￿and￿due￿to￿an￿indirect￿relation￿to￿the￿drive￿functions,￿other￿functions￿are integrated￿in￿the￿drive￿control￿units,￿especially￿in￿the￿EDME￿control￿unit. For￿many￿years￿the￿electrical￿power￿management￿of￿conventional￿vehicles￿has￿been￿integrated￿as a￿function￿in￿the￿engine￿control.￿The￿evaluation￿of￿the￿12 V￿battery￿state￿of￿charge￿via￿the￿IBS￿and the￿consumer￿shutdown￿are￿examples￿for￿this￿power￿management￿function.￿This￿tradition￿is￿also continued￿in￿the￿I01:￿The￿EDME￿control￿unit￿performs￿the￿power￿management￿function￿for￿the￿low- voltage￿vehicle￿electrical￿system.￿The￿power￿management￿in￿the￿low-voltage￿vehicle￿electrical￿system includes￿the￿following￿subfunctions: • Determination￿of￿the￿current￿energy￿requirement￿of￿the￿electrical￿consumers￿(signals￿in￿the form￿of￿bus￿signals,￿e.g.￿switch-on￿status￿of￿exterior￿lights￿by￿the￿Body￿Domain￿Controller BDC) • Determination￿of￿state￿of￿health,￿state￿of￿charge￿and￿charge￿current/discharge￿current￿of￿the 12 V￿battery￿(signals￿from￿the￿IBS) • Controling￿the￿power￿of￿the￿DC/DC￿converter • Monitoring￿of￿the￿standby￿current • Switch-off￿of￿terminals￿or￿consumers￿in￿order￿to￿protect￿the￿12 V￿battery￿against￿heavy discharge. The￿task￿of￿the￿conventional￿12 V￿alternator￿is￿assumed￿in￿the￿I01￿by￿the￿DC/DC￿converter￿in￿the electrical￿machine￿electronics.￿Depending￿on￿the￿power￿required,￿the￿power￿management￿in￿the EDME￿requests￿corresponding￿power￿from￿the￿electrical￿machine￿electronics￿via￿bus￿signals. 3.3.3.￿Electrical￿Digital￿Motor￿Electronics￿(EDME) The￿designation￿"Electrical￿Digital￿Motor￿Electronics￿(EDME)"￿reflects￿the￿electric￿motor￿in￿the￿I01 (in￿comparison￿to￿the￿conventional￿drive￿with￿a￿combustion￿engine).￿The￿manufacturer￿of￿the￿EDME control￿unit￿is￿"Delphi￿Electronics￿Group".￿The￿manufacturer's￿internal￿designation￿is￿"DCM 3.8"￿–￿this Delphi￿engine￿control￿unit￿is￿already￿used￿by￿other￿vehicle￿manufacturers￿and￿was￿adapted￿for￿the￿I01 in￿terms￿of￿the￿electrical￿interfaces.
  • Page 56 I01￿High-voltage￿Components 3.￿Electric￿Motor Installation￿location￿of￿the￿EDME Active￿cooling￿of￿the￿EDME￿is￿not￿intended￿as￿at￿the￿installation￿location￿there￿is￿a￿significantly￿lower temperature￿level￿as￿a￿result￿of￿no￿combustion￿engine￿in￿the￿I01.￿The￿EDME￿control￿unit￿also￿has considerably￿fewer￿output￿stages￿in￿comparison￿to￿an￿engine￿control￿for￿combustion￿engines￿and therefore￿less￿heat￿loss￿occurs￿in￿the￿control￿unit￿itself. The￿electrical￿interfaces￿of￿the￿EDME￿control￿unit￿are￿described￿in￿the￿list￿below: • 12 V￿voltage￿supply￿of￿the￿EDME￿control￿unit￿(terminal￿30B,￿ground￿connection) • Accelerator￿pedal￿module￿with￿two￿hall-effect￿sensors:￿Supply￿voltage,￿ground￿and￿sensor output￿signals￿with￿output￿voltage￿range￿of￿0 V￿to 2.5 V￿and￿0 V to 5.0 V • Brake￿light￿switch￿and￿brake￿light￿test￿switch:￿inverse,￿redundant￿signals￿(actuated/not actuated),￿supply￿via￿terminal￿R • Local￿interconnect￿network￿bus:￿Reading￿of￿the￿signals￿from￿the￿IBS￿and￿control￿of￿the￿electric coolant￿pump￿(cooling￿circuit￿between￿electrical￿machine/electrical￿machine￿electronics￿and charging￿electronics) • Control￿of￿the￿electric￿fan:￿The￿power￿of￿the￿electric￿fan￿for￿cooling￿the￿cooling￿package￿at the￿front￿can￿be￿controlled￿via￿a￿pulse-width￿modulated￿signal￿by￿the￿EDME.￿For￿emergency operation￿there￿is￿a￿relay￿with￿which￿the￿electric￿fan￿can￿be￿switched￿on￿at￿full￿power￿by￿the EDME. • Body￿Domain￿Controller￿BDC￿(start￿enable) • PT-CAN￿(no￿terminating￿resistor￿in￿the￿EDME) • PT-CAN2￿(no￿terminating￿resistor￿in￿the￿EDME) • FlexRay￿(terminating￿resistor￿in￿the￿EDME). The￿functions￿of￿the￿drive￿control￿are￿already￿described￿in￿detail￿in￿the￿chapter￿"Functions".￿The following￿list￿summarizes￿again￿the￿functions￿which￿the￿EDME￿control￿unit￿calculates￿and￿performs:...
  • Page 57 I01￿High-voltage￿Components 3.￿Electric￿Motor • Torque￿coordination￿(driver's￿choice,￿assist￿systems) • Operating￿strategy • Shift-by-Wire • Low-voltage￿power￿management • Heat￿management • Activating￿the￿electrical￿vacuum￿pump • Fault￿management￿and￿emergency￿operation.

  • Page 58: Introduction

    I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics 4.1.￿Electrical￿machine￿electronics￿(EME) 4.1.1.￿Introduction The￿electrical￿machine￿electronics￿EME￿serves￿mainly￿as￿control￿electronics￿for￿the￿electrical￿machine, which￿drives￿the￿I01.￿It￿assumes￿the￿task￿of￿converting￿the￿DC￿voltage￿(up￿to￿about￿400 V￿DC)￿from the￿high-voltage￿battery￿into￿a￿three-phase￿AC￿voltage￿(up￿to￿about￿360 V￿AC)￿for￿activating￿the electrical￿machine￿as￿a￿motor.￿Vice￿versa,￿when￿the￿electrical￿machine￿works￿as￿an￿alternator,￿the electrical￿machine￿electronics￿converts￿the￿three-phase￿AC￿voltage￿of￿the￿electrical￿machine￿to￿a direct￿current￿voltage￿and￿can￿thus￿charge￿the￿high-voltage￿battery.￿This￿takes￿place￿during￿brake energy￿regeneration.￿For￿these￿two￿operating￿modes￿a￿bidirectional￿DC/AC￿converter￿is￿necessary which￿can￿work￿as￿both￿an￿inverter￿and￿a￿rectifier. The￿DC/DC￿converter￿which￿is￿also￿integrated￿in￿the￿electrical￿machine￿electronics￿ensures￿the￿voltage supply￿to￿the￿12 V￿vehicle￿electrical￿system.￿The￿electrical￿machine￿electronics￿has￿another￿control unit￿which￿bears￿the￿same￿name,￿"EME"￿for￿short. The￿entire￿electrical￿machine￿electronics￿of￿the￿I01￿is￿located￿in￿an￿aluminium￿housing.￿The￿control unit￿of￿the￿bidirectional￿AC/DC￿converter￿for￿the￿conversion￿of￿the￿AC￿voltage￿to￿direct￿current￿voltage for￿charging￿the￿high-voltage￿battery,￿as￿well￿as￿conversion￿of￿the￿direct￿current￿voltage￿from￿the￿high- voltage￿battery￿to￿3-phase￿AC￿voltage￿and￿the￿DC/DC￿converter￿for￿the￿voltage￿supply￿of￿the￿12 V vehicle￿electrical￿system￿are￿located￿in￿this￿housing. The￿housing￿of￿the￿electrical￿machine￿electronics￿cannot￿be￿opened￿in￿Service. The￿electrical￿machine￿electronics￿of￿the￿I01￿is￿developed￿and￿supplied￿by￿the￿relevant￿departments￿of BMW￿AG.￿The￿production￿is￿carried￿out￿in￿a￿division￿of￿the￿plant￿in￿Dingolfing. Only￿Service￿employees￿who￿satisfy￿all￿the￿prerequisites￿are￿permitted￿to￿work￿on￿the￿designated high-voltage￿components:￿suitable￿qualifications,￿compliance￿with￿the￿safety￿rules,￿procedure following￿the￿exact￿repair￿instructions. The￿diagnosis￿and￿repair￿of￿the￿high-voltage￿components￿is￿only￿allowed￿in￿a￿retail￿service center￿that￿has￿qualified￿and￿certified￿service￿technicians.￿These￿technicians￿must￿have completed￿the￿ST1403b￿I01￿High￿Voltage￿Battery￿and￿Maintenance￿instructor￿led￿course￿and successfully￿passed￿the￿hands￿on￿certification. 4.1.2.￿Installation￿location The￿electrical￿machine￿electronics￿is￿installed￿in￿the￿rear￿of￿the￿I01,￿in￿an￿area￿separated￿from￿the luggage￿compartment.
  • Page 59 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Access￿to￿the￿electrical￿machine￿electronics￿from￿the￿luggage￿compartment Index Explanation Luggage￿compartment￿trim￿panel Cover Mounting￿bolts￿of￿lid Electrical￿machine￿electronics Gasket In￿order￿to￿access￿the￿connections￿of￿the￿electrical￿machine￿electronics,￿the￿part￿of￿the￿luggage compartment￿panel￿shown￿in￿the￿graphic￿must￿first￿be￿removed.￿A￿then￿visible￿lid￿must￿also￿be removed,￿thereby￿creating￿an￿opening￿for￿Service.￿The￿lid￿is￿secured￿to￿the￿body￿using￿a￿screw connection￿and￿also￿sealed￿by￿a￿gasket. The￿accesses￿described￿are￿not￿sufficient￿for￿the￿removal￿and￿installation￿of￿the￿electrical￿machine electronics.￿Instead,￿the￿entire￿drive￿unit￿(comprising￿transmission,￿electrical￿machine￿and￿electrical machine￿electronics)￿must￿be￿removed.

  • Page 60: Connections

    I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics 4.1.3.￿Connections The￿connections￿at￿the￿electrical￿machine￿electronics￿can￿be￿divided￿into￿four￿categories: • Low-voltage￿connections • High-voltage￿connections • Connections￿for￿potential￿compensation￿lines • Connections￿for￿coolant￿lines. The￿following￿graphic￿shows￿all￿connections￿of￿the￿electrical￿machine￿electronics.￿Details￿of￿the individual￿categories￿are￿provided￿in￿the￿following￿chapters. Connections￿of￿the￿electrical￿machine￿electronics￿with￿lines...
  • Page 61 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Index Explanation Voltage￿supply￿of￿the￿electric￿motor￿in￿the￿parking￿lock￿module￿and￿signal￿lines from/to￿the￿parking￿lock￿module Coolant￿line￿(supply,￿electrical￿machine￿electronics) Output,￿DC/DC￿converter￿-￿12 V Low-voltage￿connector Low-voltage￿connector Output,￿DC/DC￿converter￿+12 V High-voltage￿cable￿(DC)￿for￿the￿high-voltage￿battery High-voltage￿cable￿(DC)￿for￿the￿range￿extender￿EME Housing￿of￿the￿electrical￿machine￿electronics Connection￿for￿potential￿compensation￿line Connection￿for￿potential￿compensation￿line Coolant￿line￿(return,￿electrical￿machine￿electronics,￿to￿electrical￿machine) Low-voltage￿connector￿EME￿(signal￿connector) Low-voltage￿connector￿EKK High-voltage￿cable￿for￿the￿EKK High-voltage￿cable￿for￿electric￿heating High-voltage￿cable￿for￿AC￿charging Ground￿connection Low-voltage￿connections In￿the￿multipolar￿low-voltage￿connector￿at￿the￿electrical￿machine￿electronics,￿which￿is￿visible￿from￿the outside,￿the￿following￿lines￿and￿signals￿are￿combined: • Voltage￿supply￿for￿the￿EME￿control￿unit￿(terminal￿30B￿from￿the￿power￿distribution￿box￿at￿the front￿and￿ground) • Terminal 30C￿from￿the￿safety￿battery￿terminal￿(is￿evaluated￿by￿the￿EME￿control￿unit￿in￿order￿to identify￿an￿accident) • Bus￿system￿PT-CAN2￿(In￿the￿EME￿control￿unit￿there￿is￿a￿terminating￿resistor￿with￿120 Ω￿for the￿PT-CAN2) • Wake-up￿line • Control￿line￿for￿the￿convenience￿charging￿electronics￿to￿enable￿the￿charging￿procedure •...
  • Page 62 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics • Electromechanical￿parking￿lock:￿Voltage￿supply￿and￿signal￿of￿the￿position￿sensors,￿voltage supply￿of￿the￿solenoid￿and￿the￿electric￿motor • Brake￿vacuum￿sensor￿(supply￿and￿evaluation￿of￿a￿pressure-dependent￿resistance) • Voltage￿supply￿of￿the￿electrical￿vacuum￿pump. These￿lines￿and￿signals￿have￿relatively￿low￿current￿levels.￿The￿electrical￿machine￿electronics￿is connected￿to￿the￿12 V￿vehicle￿electrical￿system￿(terminals￿30￿and￿31)￿via￿two￿separate￿low-voltage connections￿and￿lines￿with￿large￿cross-section.￿Via￿this￿connection￿the￿DC/DC￿converter￿in￿the electrical￿machine￿electronics￿provides￿the￿entire￿12 V￿vehicle￿electrical￿system￿with￿energy.￿These two￿lines￿are￿not￿connected￿to￿the￿electrical￿machine￿electronics￿via￿a￿plug￿connection,￿but￿a￿screw connection. The￿connections￿of￿the￿electrical￿machine￿electronics￿to￿the￿electrical￿machine￿are￿not￿visible￿from￿the outside.￿They￿are￿located￿under￿a￿lid￿on￿the￿right￿side￿of￿the￿electrical￿machine. Electrical￿connection￿of￿the￿electrical￿machine￿electronics￿to￿the￿electrical￿machine Index Explanation Electrical￿machine￿electronics Screw￿connection￿for￿high-voltage￿connection,￿stator￿coil 1 Screw￿connection￿for￿high-voltage￿connection,￿stator￿coil 2 Screw￿connection￿for￿high-voltage￿connection,￿stator￿coil 3 Low-voltage￿connector The￿screw￿connections￿for￿the￿supply￿of￿the￿stator￿coils￿(high-voltage￿connections)￿and￿a￿plug connection,￿via￿which￿the￿following￿signals￿are￿transmitted,￿are￿located￿under￿the￿lid:...
  • Page 63 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics • Rotor￿position￿sensor￿of￿the￿electrical￿machine￿(supply￿and￿sensor￿signals) • Signals￿of￿the￿two￿temperature￿sensors￿in￿the￿electrical￿machine. The￿following￿graphic￿summarizes￿again￿the￿low-voltage￿connections￿of￿the￿electrical￿machine electronics￿in￿the￿form￿of￿a￿simplified￿wiring￿diagram. Low-voltage￿connections￿of￿the￿electrical￿machine￿electronics...
  • Page 64 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Index Explanation Electrical￿vacuum￿pump Electric￿motor￿for￿parking￿lock Position￿sensors￿(hall-effect￿sensors) Parking￿lock￿module Temperature￿sensors￿2￿x￿(negative￿temperature￿coefficient) Electrical￿machine￿(entirety) Rotor￿position￿sensor 12 V￿battery Signal￿lines￿of￿the￿high-voltage￿interlock￿loop Crash￿Safety￿Module Brake￿vacuum￿pressure￿sensor Body￿Domain￿Controller Output￿stage￿for￿the￿activation￿of￿the￿parking￿lock￿module Output￿stage￿for￿the￿activation￿of￿the￿electrical￿vacuum￿pump Terminating￿resistor￿for￿PT-CAN Terminating￿resistor￿for￿PT-CAN￿2 EME￿control￿unit Electrical￿machine￿electronics￿EME￿(entirety) DC/DC￿converter Temperature￿sensor￿(negative￿temperature￿coefficient)￿at￿the￿DC/DC￿converter Bidirectional￿DC/AC￿converter Temperature￿sensor￿(negative￿temperature￿coefficient)￿at￿the￿DC/AC￿converter High-voltage￿connections At￿the￿electrical￿machine￿electronics￿there￿is￿a￿total￿of￿five￿high-voltage￿connections￿to￿establish contact￿between￿the￿lines￿and￿other￿high-voltage￿components:...
  • Page 65 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Connection￿to Number￿of￿contacts, Type￿of Contact￿protection components... voltage￿type, connection shielding Electrical￿machine -￿3-phase Busbars￿screwed￿to Mechanical￿through￿lid -￿AC￿voltage lines￿of￿the￿electrical at￿electrical￿machine -￿1￿shielding￿for￿all￿3 machine lines High-voltage￿battery -￿Two-pin Flat￿high-voltage -￿Cover￿over￿the -￿Direct￿current connector￿with contact￿blades voltage mechanical￿lock -￿High￿voltage￿interlock -￿1￿shielding￿per￿line loop Convenience -￿Two-pin Flat￿high-voltage -￿Cover￿over￿the charging￿electronics -￿Direct￿current connector￿with contact￿blades voltage mechanical￿lock...
  • Page 66 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics High-voltage￿connections￿of￿the￿electrical￿machine￿electronics Index Explanation Convenience￿charging￿electronics Electrical￿machine High-voltage￿battery Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Range￿extender￿electrical￿machine 12 V￿battery Electric￿heating Electrical￿machine￿electronics￿(entirety)
  • Page 67 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Index Explanation Bidirectional￿DC/AC￿converter￿in￿the￿electrical￿machine￿electronics Overcurrent￿fuse￿in￿the￿supply￿line￿for￿the￿convenience￿charging￿electronics Overcurrent￿fuse￿in￿the￿supply￿line￿for￿the￿electric￿heating Overcurrent￿fuse￿in￿the￿supply￿line￿for￿the￿EKK DC/DC￿converter￿in￿the￿EME 4.1.4.￿Structure￿and￿functions The￿electrical￿machine￿electronics￿is￿made￿up￿internally￿of￿four￿subcomponents:￿the￿bidirectional￿DC/ AC￿converter,￿the￿unidirectional￿AC/DC￿converter,￿the￿DC/DC￿converter￿and￿the￿EME￿control￿unit.￿The link￿capacitors￿are￿also￿an￿element￿of￿the￿power￿electronics￿switching￿in￿order￿to￿smooth￿the￿voltage and￿filter￿high-frequency￿parts. It￿performs￿the￿following￿functions￿with￿help￿of￿the￿subcomponents￿mentioned: • Control￿of￿the￿internal￿subcomponents￿by￿the￿EME￿control￿unit • Supply￿of￿the￿12 V￿electrical￿system￿via￿the￿DC/DC￿converter • Control￿of￿the￿electrical￿machine￿(engine￿speed,￿torque)￿using￿DC/AC￿converter • High-voltage￿power￿management • Contacting￿of￿the￿electric￿motor￿via￿busbars • Contact￿of￿the￿high-voltage￿battery • Charging￿the￿high-voltage￿battery￿when￿stationary • Contact￿of￿the￿convenience￿charging￿electronics • Contact￿of￿the￿EKK • Contact￿of￿the￿electric￿heating • Contact￿of￿the￿Range￿Extender￿Electrical￿Machine￿Electronics • Communication￿with￿other￿control￿units,￿in￿particular￿the￿EDME •...
  • Page 68 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics • Standby￿(also￿in￿the￿event￿of￿a￿component￿fault￿or￿short￿circuit,￿power￿electronics￿off) • Buck￿mode￿(Energy￿flow￿to￿the￿low-voltage￿side.￿Converter￿controls￿voltage￿on￿low-voltage side) • Discharging￿the￿high-voltage￿link￿capacitor￿(interlock￿fault,￿accident,￿request￿from￿master). The￿DC/DC￿converter￿is￿in￿"Standby"￿mode￿when￿the￿electrical￿machine￿electronics￿is￿not￿in operation.￿This￿is￿the￿case￿when￿the￿EME￿control￿unit￿is￿not￿supplied￿with￿voltage￿due,￿for￿example, to￿a￿terminal￿status.￿But￿also￿if￿there￿is￿a￿fault￿the￿EME￿control￿unit￿prompts￿the￿DC/DC￿converter￿to assume￿"Standby"￿mode.￿In￿this￿operating￿mode￿there￿is￿no￿energy￿transfer￿between￿the￿two￿vehicle electrical￿systems￿and￿they￿remain￿galvanically￿separated. Buck￿mode￿is￿the￿normal￿operating￿mode￿when￿the￿high-voltage￿system￿is￿active.￿The￿DC/DC converter￿transfers￿electrical￿energy￿from￿the￿high-voltage￿electrical￿system￿to￿the￿12 V￿vehicle electrical￿system￿and￿assumes￿the￿function￿of￿the￿alternator￿in￿a￿conventional￿vehicle.￿The￿DC/DC converter￿must￿reduce￿the￿varying￿voltage￿from￿the￿high-voltage￿electrical￿system￿to￿the￿voltage￿in￿the low-voltage￿vehicle￿electrical￿system.￿The￿voltage￿in￿the￿high-voltage￿electrical￿system￿is￿dependent, for￿example,￿on￿the￿state￿of￿charge￿of￿the￿high-voltage￿battery￿(about￿260 V￿to￿about￿390 V).￿The voltage￿in￿the￿low-voltage￿vehicle￿electrical￿system￿controls￿the￿DC/DC￿converter￿so￿that￿the￿12 V battery￿is￿optimally￿charged￿and￿sets￿a￿voltage￿of￿about￿14 V￿depending￿on￿the￿state￿of￿charge￿and￿the temperature￿of￿the￿battery.￿The￿EME￿control￿unit￿communicates￿with￿the￿EDME￿control￿unit,￿in￿which the￿12 V￿power￿management￿functions￿are￿performed.￿The￿result￿is￿the￿setpoint￿value￿specification￿for the￿voltage,￿which￿the￿DC/DC￿converter￿should￿adjust￿in￿the￿low-voltage￿vehicle￿electrical￿system.￿The continuous￿output￿power￿of￿the￿DC/DC￿converter￿is￿2500 W.
  • Page 69 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Operating￿principle￿of￿the￿DC/DC￿converter Index Explanation Voltage￿of￿the￿high-voltage￿electrical￿system,￿about￿250 V￿to￿about￿410 V Down￿conversion DC/DC￿converter￿in￿the￿EME Voltage￿of￿the￿low-voltage￿vehicle￿electrical￿system,￿about￿14 V The￿technology￿of￿the￿DC/DC￿converter￿in￿the￿I01￿would￿also￿enable￿the￿operating￿mode￿"Boost mode",￿such￿as￿the￿DC/DC￿converter￿in￿the￿F04.￿However,￿this￿operating￿mode￿is￿not￿used￿in￿the￿I01. Charging￿of￿the￿high-voltage￿battery￿of￿the￿I01￿is￿not￿possible￿using￿energy￿from￿the￿12 V￿vehicle electrical￿system. The￿last￿operating￿mode￿of￿the￿DC/DC￿converter￿is￿assumed￿during￿(regular￿or￿quick)￿shutdown￿of￿the high-voltage￿system.￿For￿the￿shutdown￿of￿the￿high-voltage￿system￿the￿system￿must￿be￿discharged to￿a￿safe￿voltage￿less￿than￿60 V￿within￿a￿specified￿time.￿The￿DC/DC￿converter￿has￿a￿discharge￿circuit for￿the￿link￿capacitors.￿First￿of￿all,￿these￿try￿to￿transmit￿the￿energy￿stored￿in￿the￿link￿capacitors￿to the￿low-voltage￿vehicle￿electrical￿system.￿If￿this￿does￿not￿lead￿to￿a￿sufficiently￿quick￿reduction￿of￿the voltage,￿the￿discharging￿is￿effected￿via￿an￿active￿resistor.￿This￿way￿the￿high-voltage￿electrical￿system is￿discharged￿in￿less￿than￿5￿seconds.￿For￿safety￿reasons￿there￿is￿also￿a￿so-called￿passive￿discharge...
  • Page 70 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics resistor￿(switched￿in￿parallel).￿This￿enables￿a￿reliable￿discharge￿of￿the￿high-voltage￿electrical￿system￿if the￿first￿two￿measures￿do￿not￿work￿for￿discharging￿due￿to￿a￿fault.￿The￿period￿up￿until￿the￿discharge￿to￿a voltage￿below￿60 V￿is￿longer￿and￿is￿maximum￿120 s. Discharge￿of￿the￿high-voltage￿link￿capacitor Index Explanation Electrical￿machine Connection￿to￿the￿12 V￿vehicle￿electrical￿system DC/DC￿converter￿in￿the￿EME Electrical￿machine￿electronics￿(entirety) High-voltage￿battery￿unit EME￿control￿unit Relay￿for￿short-circuit￿of￿the￿coils￿of￿the￿electrical￿machine Relay￿for￿active￿discharging￿of￿the￿capacitors Bidirectional￿DC/AC￿converter￿in￿the￿electrical￿machine￿electronics SME￿control￿unit Electromechanical￿switch￿contactor￿in￿the￿high-voltage￿battery￿units High-voltage￿battery Link￿capacitors Passive￿discharge￿resistor pass Active￿discharge￿resistor...
  • Page 71 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics The￿temperature￿of￿the￿DC/DC￿converter￿is￿measured￿using￿a￿temperature￿sensor￿and￿monitored by￿the￿EME￿control￿unit.￿If￿the￿temperature￿exceeds￿the￿permissible￿range￿despite￿cooling￿using￿the coolant,￿the￿EME￿control￿unit￿reduces￿the￿power￿of￿the￿DC/DC￿converter￿to￿protect￿the￿components. Power￿electronics￿for￿activation￿of￿the￿electrical￿machine The￿power￿electronics￿for￿the￿activation￿of￿the￿electrical￿machine￿are￿mainly￿made￿up￿of￿the bidirectional￿DC/AC￿converter.￿It￿is￿a￿pulse￿converter￿with￿a￿two-pin￿DC￿voltage￿connection￿and￿a￿3- phase￿AC￿voltage￿connection.￿This￿DC/AC￿converter￿can￿work￿as￿an￿inverter￿and￿conduct￿electrical energy￿from￿the￿high-voltage￿battery￿to￿the￿electrical￿machine￿when￿it￿should￿work￿as￿an￿engine. However,￿it￿can￿also￿work￿as￿a￿rectifier￿and￿transfers￿electrical￿energy￿from￿the￿electrical￿machine￿to the￿high-voltage￿battery.￿This￿operating￿mode￿occurs￿during￿brake￿energy￿regeneration￿in￿which￿the electrical￿machine￿works￿as￿an￿alternator￿and￿"generates"￿electrical￿energy. Operating￿modes￿of￿the￿bidirectional￿DC/AC￿converter...
  • Page 72 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Index Explanation Schematic￿illustration Schematic￿diagram￿with￿components High-voltage￿battery Operating￿mode￿as￿inverter,￿electrical￿machine￿works￿as￿an￿engine Operating￿mode￿as￿rectifier,￿electrical￿machine￿works￿as￿an￿alternator DC/AC￿converter Current￿sensors Electrical￿machine The￿operating￿mode￿of￿the￿DC/AC￿converter￿is￿defined￿by￿the￿EME￿control￿unit.￿The￿EME￿control unit￿also￿receives￿the￿setpoint￿values￿(essential￿input￿variables)￿from￿the￿EDME￿control￿unit￿for￿which torque￿(amount￿and￿sign)￿the￿electrical￿machine￿should￿supply.￿From￿this￿setpoint￿value￿and￿the current￿operating￿condition￿of￿the￿electrical￿machine￿(engine￿speed￿and￿torque)￿the￿EME￿control unit￿determines￿the￿operating￿mode￿of￿the￿DC/AC￿converter,￿as￿well￿as￿the￿amplitude￿and￿frequency of￿the￿phase￿voltages￿for￿the￿electrical￿machine.￿According￿to￿these￿specifications,￿the￿power semiconductors￿of￿the￿DC/AC￿converter￿are￿activated￿in￿sync. In￿addition￿to￿the￿DC/AC￿converter,￿the￿power￿electronics￿also￿contains￿current￿sensors￿in￿all￿three phases￿on￿the￿AC￿voltage￿side￿of￿the￿DC/AC￿converter.￿Using￿the￿signals￿from￿the￿current￿sensor,￿the EME￿control￿unit￿monitors￿the￿electrical￿power￿which￿is￿used￿in￿the￿power￿electronics￿and￿electrical machine￿and￿what￿torque￿the￿electrical￿machine￿generates.￿The￿control￿loop￿of￿the￿electrical￿machine electronics￿is￿closed￿by￿the￿signals￿of￿the￿current￿sensors￿and￿the￿rotor￿position￿sensor￿in￿the￿electrical machine. The￿performance￿data￿of￿the￿electrical￿machine￿electronics￿and￿the￿electrical￿machine￿are￿coordinated in￿development.￿The￿electrical￿machine￿electronics￿must￿be￿able￿to￿provide￿continuous￿electrical power￿of￿75 kW￿and￿supply￿a￿maximum￿power￿of￿125 kW￿for￿a￿short￿time.￿In￿order￿to￿avoid￿overloading the￿power￿electronics,￿there￿is￿also￿another￿temperature￿sensor￿at￿the￿DC/AC￿converter.￿If￿an￿excessive temperature￿of￿the￿power￿semiconductor￿is￿identified￿using￿this￿signal,￿the￿EME￿control￿unit￿reduces the￿power￿delivered￿to￿the￿electrical￿machine￿in￿order￿to￿protect￿the￿power￿electronics.￿The￿customer is￿informed￿via￿a￿Check￿Control￿message￿in￿the￿case￿of￿a￿noticeable￿power￿reduction.￿The￿customer receives￿the￿same￿error￿response￿(power￿reduction)￿and￿the￿same￿Check￿Control￿message￿if￿the temperature￿of￿the￿electrical￿machine￿exceeds￿the￿permissible￿range. Check￿Control￿symbol￿for￿power￿reduction￿due￿to￿high￿temperature￿of￿electric￿motor￿components...
  • Page 73 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics High-voltage￿power￿management The￿power￿management￿for￿the￿high-voltage￿electrical￿system￿includes￿two￿subfunctions:￿one￿for driving￿and￿one￿for￿charging￿mode.￿In￿driving￿mode￿the￿energy￿flows￿from￿the￿high-voltage￿battery to￿the￿high-voltage￿consumers￿are￿coordinated.￿The￿following￿steps￿are￿performed￿by￿the￿EME￿and repeated￿constantly: Query￿of￿the￿power￿available￿from￿the￿high-voltage￿battery￿(signal￿source:￿SME) Query￿of￿the￿requested￿power￿from￿the￿electric￿motor￿(signal￿source:￿EDME) Query￿of￿the￿requested￿power￿for￿climate￿control￿(electric￿heating,￿EKK,￿IHKA) Decision￿on￿the￿distribution￿of￿the￿electrical￿power￿and￿communication￿to￿the￿control￿units￿of￿the consumers. For￿charging￿mode￿the￿task￿of￿the￿high-voltage￿power￿management￿is￿different:￿It￿controls￿the￿energy flow￿from￿outside￿the￿vehicle￿via￿the￿EME￿and/or￿the￿convenience￿charging￿electronics￿KLE￿to￿the high-voltage￿battery￿and￿if￿required￿to￿the￿electric￿heating￿or￿to￿the￿EKK.￿The￿procedure￿constantly repeated￿in￿the￿EME￿consists￿of￿the￿following￿individual￿steps: Query￿of￿the￿available￿power￿from￿outside￿(signal￿source:￿LIM) Query￿of￿the￿power￿which￿the￿high-voltage￿battery￿can￿use￿(SME) Query￿of￿the￿power￿which￿is￿required￿for￿the￿climate￿control￿(IHKA) Requesting￿the￿necessary￿power￿from￿the￿(EME/KLE) Communication￿of￿the￿available￿partial￿powers￿to￿the￿receiver￿of￿the￿high-voltage￿battery￿(SME control￿unit)￿and￿heating￿and￿air-conditioning￿system￿(IHKA￿control￿unit). The￿externally￿available￿power￿cannot￿be￿at￿a￿high￿level;￿it￿is￿restricted￿by￿the￿power￿network￿and￿the EME/KLE.￿Therefore,￿the￿available￿power￿must￿be￿queried￿first￿before￿it￿can￿be￿distributed.￿The￿high- voltage￿battery￿cannot￿absorb￿much￿power,￿for￿example￿due￿to￿its￿state￿of￿charge,￿which￿is￿why￿this value￿is￿also￿queried￿first.￿Depending￿on￿the￿temperature￿of￿the￿high-voltage￿battery￿or￿on￿a￿heating￿or an￿air-conditioning￿request￿by￿the￿driver,￿the￿heating￿and￿air-conditioning￿system￿also￿needs￿electrical power,￿whose￿amount￿is￿the￿third￿important￿input￿signal￿for￿the￿high-voltage￿power￿management￿in￿the charging￿mode.￿Using￿this￿information￿the￿externally￿requested￿power￿is￿controlled￿and￿distributed￿to the￿consumers. Voltage￿supply￿for￿other￿high-voltage￿consumers The￿electrical￿machine￿electronics￿supplies￿voltage￿not￿only￿to￿the￿electrical￿machine.￿The￿high- voltage￿consumers￿"EKK"￿and￿"electric￿heating"￿also￿receive￿their￿high-voltage￿supply￿from￿the electrical￿machine￿electronics. However,￿there￿is￿no￿complex￿control￿function￿in￿the￿electrical￿machine￿electronics.￿Instead,￿the electrical￿machine￿electronics￿serves￿as￿a￿simple￿distributor￿of￿the￿high-voltage￿direct￿current￿voltage, which￿is￿provided￿by￿the￿high-voltage￿battery.￿In￿order￿to￿protect￿the￿high-voltage￿cable￿for￿the￿two high-voltage￿consumers￿against￿overloading￿in￿the￿event￿of￿a￿short￿circuit,￿the￿electrical￿machine electronics￿contains￿a￿high-voltage￿fuse￿for￿the￿EKK￿and￿a￿high-voltage￿fuse￿for￿the￿electric￿heating. Both￿high-voltage￿fuses￿have￿a￿nominal￿current￿level￿of￿40 A.
  • Page 74 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Activation￿of￿the￿parking￿lock The￿electromechanical￿parking￿lock￿of￿the￿I01￿including￿its￿operating￿principle￿and￿activation￿is described￿in￿detail￿in￿the￿section￿"Electric￿motor".￿Therefore,￿only￿the￿key￿aspects￿of￿the￿activation￿are mentioned￿here.￿The￿electrical￿machine￿electronics￿contains￿the￿following￿components￿required￿for the￿parking￿lock: • Output￿stage￿for￿the￿activation￿of￿the￿electric￿motor￿in￿the￿parking￿lock￿module • Current￿sensor￿for￿the￿monitoring￿of￿the￿electric￿motor • Evaluation￿electronics￿for￿sensor￿signals. The￿output￿stage￿for￿the￿activation￿of￿the￿electric￿motor￿only￿comprises￿one￿bridge￿circuit￿of￿power transistors.￿It￿is￿able￿to￿supply￿the￿electric￿motor￿with￿the￿necessary￿current￿of￿about￿3 A￿to￿4 A￿during the￿operation,￿as￿well￿as￿supply￿the￿high￿starting￿current￿for￿the￿electric￿motor￿of￿up￿to￿10 A.￿The bridge￿circuit￿is￿designed￿so￿that￿it￿will￿not￿suffer￿damage￿in￿the￿event￿of￿a￿short￿circuit￿at￿the￿output (current￿limitation).￿In￿order￿to￿protect￿the￿electric￿motor￿and￿the￿line￿against￿overloading,￿the￿EME control￿unit￿monitors￿the￿current￿level￿of￿the￿output￿stage￿and￿also￿restricts￿it￿if￿required.￿For￿this purpose,￿the￿output￿stage￿contains￿a￿current￿sensor,￿whose￿signal￿is￿evaluated￿by￿the￿EME￿control unit. The￿two￿redundant￿position￿sensors￿in￿the￿parking￿lock￿module￿are￿hall-effect￿sensors.￿The￿EME control￿unit￿provides￿the￿voltage￿supply￿for￿the￿sensors.￿It￿also￿reads￿in￿the￿signals￿from￿the￿position sensors,￿validates￿their￿plausibility￿and￿evaluates￿them.￿Using￿the￿signals￿of￿the￿position￿sensors the￿EME￿control￿unit￿determines￿the￿status￿of￿the￿parking￿lock￿(engaged/disengaged)￿and￿makes the￿status￿available￿as￿a￿bus￿signal.￿This￿is￿read￿in￿for￿example￿by￿the￿EDME￿control￿unit￿where￿the transmission￿functions,￿e.g.￿engaging￿the￿drive￿positions,￿are￿calculated. The￿familiar￿graphic￿from￿the￿chapter￿"Electric￿motor￿>￿Transmission >￿Parking￿lock"￿shows￿the electrical￿interface￿between￿the￿parking￿lock￿module￿and￿the￿electrical￿machine￿electronics.
  • Page 75 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Electrical￿interfaces￿between￿parking￿lock￿module￿and￿electrical￿machine￿electronics Index Explanation Electrical￿machine￿electronics￿(EME) PT-CAN2￿connection Voltage￿supply EME￿control￿unit Output￿stage￿for￿parking￿lock￿module Electric￿motor Worm￿gear First￿position￿sensor￿according￿to￿the￿hall-effect￿principle Second￿position￿sensor￿working￿in￿the￿opposite￿direction￿to￿the￿first,￿also according￿to￿the￿hall-effect￿principle Parking￿lock￿module...
  • Page 76 I01￿High-voltage￿Components 4.￿Electrical￿Machine￿Electronics Activation￿of￿the￿electrical￿vacuum￿pump The￿electrical￿machine￿electronics￿provides￿the￿hardware￿for￿the￿evaluation￿of￿the￿signals￿of￿the brake￿vacuum￿sensor￿and￿for￿the￿activation￿of￿the￿electrical￿vacuum￿pump.￿The￿function￿logic￿for the￿activation￿of￿the￿electrical￿vacuum￿pump￿is￿located￿not￿in￿the￿EME￿control￿unit,￿but￿in￿the￿DSC control￿unit.￿The￿EME￿and￿DSC￿control￿unit￿exchange￿sensor￿signals￿and￿the￿switch-on￿request￿for￿the electrical￿vacuum￿pump￿via￿bus￿signals￿at￿the￿PT-CAN￿and￿PT-CAN2. The￿brake￿vacuum￿sensor￿is￿mainly￿known￿from￿conventionally￿driven￿vehicles￿with￿automatic￿engine start-stop￿function.￿Similar￿to￿those￿vehicles,￿it￿is￿also￿installed￿in￿the￿I01￿at￿the￿housing￿of￿the￿brake servo. The￿sensor￿is￿supplied￿with￿voltage￿from￿the￿electrical￿machine￿electronics￿and￿returns￿a￿voltage signal￿depending￿on￿the￿vacuum￿in￿the￿brake￿servo.￿This￿analog￿sensor￿signal￿is￿converted￿by￿the￿EME control￿unit￿to￿the￿actual￿brake￿vacuum￿and￿sent￿as￿a￿bus￿signal￿to￿the￿DSC￿control￿unit. The￿DSC￿control￿unit￿evaluates￿the￿brake￿vacuum￿signal,￿includes￿dynamic￿handling￿characteristics (e.g.￿the￿driving￿speed)￿and￿the￿accelerator￿pedal￿actuation￿and￿determines￿whether￿the￿electrical vacuum￿pump￿should￿be￿switched￿on.￿The￿function￿logic￿in￿the￿DSC￿control￿unit￿also￿takes￿into consideration￿a￿hysteresis￿so￿that￿the￿electrical￿vacuum￿pump￿is￿not￿constantly￿switched￿on￿and￿off. Instead,￿it￿remains￿switched￿on￿until￿a￿requested￿minimum￿level￿of￿the￿brake￿vacuum￿is￿reached.￿The DSC￿control￿unit￿sends￿back￿the￿switch-on￿request￿from￿the￿electrical￿vacuum￿pump￿as￿a￿bus￿signal￿to the￿EME￿control￿unit. The￿electrical￿machine￿electronics￿contains￿an￿output￿stage￿(semiconductor￿relay),￿with￿whose￿help the￿voltage￿supply￿of￿the￿electrical￿vacuum￿pump￿can￿be￿switched￿on￿and￿off.￿Upon￿request￿the output￿voltage￿of￿the￿DC/DC￿converter￿can￿be￿shifted￿through￿directly￿to￿the￿electrical￿vacuum￿pump. Switch-on￿currents￿of￿up￿to￿30 A￿can￿occur￿in￿the￿process.￿The￿current￿level￿is￿restricted￿electronically to￿protect￿the￿output￿stage￿and￿the￿line.￿There￿is￿no￿control￿of￿the￿power￿or￿engine￿speed￿for￿the electrical￿vacuum￿pump￿–￿it￿is￿simply￿switched￿on￿and￿off. A￿malfunction￿of￿the￿electrical￿vacuum￿pump￿is￿identified￿using￿a￿brake￿vacuum￿sensor￿by￿means￿of the￿no￿longer￿available￿vacuum.￿At￿least￿the￿legally￿prescribed￿deceleration￿(increased￿brake￿pedal force)￿is￿available.￿The￿DSC￿will￿realize￿a￿type￿of￿hydraulic￿brake-servo￿assistance,￿i.e.￿depending￿on the￿driver￿pressure￿a￿hydraulically￿reinforced￿circuit￿pressure￿is￿generated. Advantage:￿Lower￿brake￿pedal￿force￿also￿in￿this￿fault￿scenario Disadvantage:￿Modified￿brake￿pedal￿response.

  • Page 77: Overview

    I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit The￿high-voltage￿battery￿unit￿is￿the￿energy￿storage￿device￿for￿the￿electric￿motor￿of￿the￿I01.￿It￿is￿the equivalent￿to￿the￿fuel￿tank￿of￿a￿conventional￿vehicle￿with￿a￿combustion￿engine.￿Also￿in￿BMW￿active hybrid￿vehicles￿there￿is￿already￿a￿high-voltage￿battery￿unit,￿which￿supplies￿the￿electric￿motor￿with energy.￿In￿the￿BMW￿active￿hybrid￿the￿high-voltage￿battery￿is￿charged￿when￿the￿electrical￿machine￿is operated￿as￿an￿alternator.￿This￿happens￿during￿brake￿energy￿regeneration￿or￿by￿a￿load￿point￿increase of￿the￿combustion￿engine.￿In￿the￿I01￿the￿high-voltage￿battery￿can￿also￿be￿partially￿charged￿during brake￿energy￿regeneration.￿However,￿it￿is￿mainly￿charged￿using￿energy￿from￿an￿external￿power network.￿An￿optional￿range￿extender￿can￿also￿provide￿electrical￿energy￿using￿a￿gasoline￿engine￿and another￿electrical￿machine.￿However,￿this￿is￿primarily￿used￿for￿maintaining￿the￿state￿of￿charge￿when￿the high-voltage￿battery￿is￿already￿heavily￿discharged.￿The￿range￿of￿the￿I01￿can￿be￿increased. 5.1.￿Overview The￿high-voltage￿battery￿of￿a￿vehicle￿with￿an￿electric￿motor￿is￿the￿equivalent￿to￿the￿fuel￿tank￿in￿a￿vehicle with￿a￿combustion￿engine:￿It￿is￿the￿energy￿storage￿device￿for￿the￿electric￿motor.￿In￿order￿to￿achieve the￿desired￿range￿of￿the￿I01,￿the￿amount￿of￿energy￿to￿be￿stored￿is￿correspondingly￿high,￿which￿is why￿the￿volume￿and￿weight￿of￿the￿energy￿storage￿device￿are￿also￿high.￿Nevertheless,￿some￿vehicle characteristics￿were￿positively￿influenced￿by￿the￿installation￿of￿the￿high-voltage￿battery￿unit￿in￿the￿Drive module￿of￿the￿I01: • Thanks￿to￿the￿low￿installation￿location￿the￿center￿of￿gravity￿of￿the￿vehicle￿is￿lowered,￿which reduces￿the￿roll￿tendency￿in￿bends,￿in￿particular. • The￿passenger￿compartment￿is￿not￿restricted￿by￿the￿high-voltage￿battery￿unit. • The￿high-voltage￿battery￿unit￿is￿well￿accessible￿in￿Service,￿which￿reduces￿the￿repair￿costs. 5.1.1.￿Technical￿data The￿high-voltage￿battery￿unit￿of￿the￿I01￿is￿made￿up￿of￿the￿following￿fundamental￿components: • Cell￿modules￿with￿the￿actual￿battery￿cells • Cell￿supervision￿circuits • Heat￿exchanger￿with￿coolant￿ducts￿and￿heating • Control￿unit,￿battery￿management￿electronics￿(SME) • Wiring￿harnesses • Safety￿box •...
  • Page 78 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit the￿anode￿material￿(high￿energy￿density,￿high￿cycle￿number).￿Graphite￿is￿normally￿used￿for￿the￿cathode. The￿lithium￿ions￿are￿deposited￿in￿the￿cathode￿during￿discharging.￿As￿a￿result￿of￿the￿materials￿used the￿total￿nominal￿voltage￿of￿the￿battery￿cells￿is￿3.75 V.￿The￿following￿table￿lists￿the￿most￿essential technical￿data￿of￿the￿high-voltage￿battery￿in￿the￿I01. Voltage 360 V￿(nominal￿voltage) 259 V￿–￿396 V￿(voltage￿range) Battery￿cells 96￿battery￿cells￿in￿series,￿each￿3.75 V￿and￿60 Ah Storable￿amount￿of￿energy 21.8 kWh￿(gross) 18.8 kWh￿(net,￿practical￿use) Maximum￿power￿(discharge) 147 kW￿(short-term),￿at￿least￿40 kW￿(continuous) Maximum￿power￿(charge) 20 kW￿(rapid￿charge￿to￿80%￿SoC),￿about￿3.6 kW￿(full￿charge to￿100%￿SoC￿in￿8￿hours) Total￿weight 233 kg Dimensions 1584 mm￿x￿892 mm￿x￿171 mm￿(volume￿213 l,￿incl.￿housing) Cooling￿system by￿refrigerant￿R134a Heating Electric,￿maximum￿1000 W￿(optional￿equipment)
  • Page 79 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit 5.1.2.￿Installation￿location Installation￿location￿of￿the￿high-voltage￿battery￿unit Index Explanation Vent￿hole High-voltage￿connection High-voltage￿battery￿unit Frame￿(Drive￿module) Refrigerant￿lines Label Low-voltage￿connection Combined￿expansion￿and￿shutoff￿valve...
  • Page 80 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit The￿high-voltage￿battery￿unit￿also￿has￿a￿low-voltage￿connection,￿as￿well￿as￿the￿high-voltage connection.￿The￿integrated￿control￿units￿are￿supplied￿with￿voltage,￿data￿bus,￿sensor￿and￿monitoring signals￿via￿this￿interface.￿It￿is￿incorporated￿in￿the￿refrigerant￿circuit￿for￿cooling￿the￿high-voltage￿battery. The￿label￿on￿the￿high-voltage￿battery￿unit￿informs￿people￿working￿with￿these￿components￿about￿the technology￿used￿and￿possible￿electrical￿and￿chemical￿dangers. The￿electrical￿voltage￿of￿the￿high-voltage￿battery￿unit￿is￿well￿over￿60 V.￿This￿is￿why￿before￿any￿work￿at the￿high-voltage￿battery￿unit￿the￿electrical￿safety￿rules￿must￿be￿observed: Disconnect￿the￿system￿from￿the￿power￿supply Provide￿a￿safeguard￿to￿prevent￿unintentional￿restarting Establish￿that￿the￿system￿is￿isolated￿from￿the￿power￿supply. The￿electrical￿lines￿(high-voltage￿and￿low-voltage),￿as￿well￿as￿the￿refrigerant￿lines,￿can￿be￿disconnected without￿having￿to￿remove￿the￿high-voltage￿battery￿unit. The￿high-voltage￿battery￿unit￿is￿located￿outside￿the￿passenger￿compartment.￿If￿the￿battery￿cells generate￿excess￿pressure￿due￿to￿a￿massive￿fault,￿the￿arising￿gases￿cannot￿be￿transported￿outwards￿via a￿vent￿pipe.￿A￿vent￿hole￿at￿the￿housing￿of￿the￿high-voltage￿battery￿unit￿is￿sufficient￿to￿allow￿pressure compensation. The￿high-voltage￿safety￿connector￿(Service￿Disconnect)￿is￿not￿an￿element￿of￿the￿high-voltage￿battery unit,￿just￿like￿in￿current￿BMW￿active￿hybrid￿vehicles.￿It￿is￿located￿below￿the￿engine￿compartment￿lid.
  • Page 81 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit 5.1.3.￿System￿wiring￿diagram System￿wiring￿diagram￿of￿high-voltage￿battery￿unit...
  • Page 82 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit Index Explanation Electric￿heating￿(EH) High-voltage￿battery￿unit Battery￿management￿electronics￿(SME) Electrical￿machine Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Convenience￿charging￿electronics￿(KLE) Charging￿socket￿at￿the￿vehicle Electrical￿machine￿electronics￿(EME) 5.2.￿External￿features 5.2.1.￿Mechanical￿interfaces The￿housing￿of￿the￿high-voltage￿battery￿unit￿is￿connected￿mechanically￿to￿the￿Drive￿module￿of￿the I01￿using￿a￿total￿of￿26￿screws.￿This￿way￿the￿weight￿and￿the￿acceleration￿forces￿occurring￿during￿the journey￿are￿supported￿at￿the￿body.￿The￿mounting￿bolts￿are￿accessible￿directly￿from￿below,￿without having￿to￿first￿disassemble￿the￿underbody￿paneling￿.￿For￿the￿removal￿of￿the￿high-voltage￿battery unit￿firstly￿all￿preliminary￿work￿specified￿in￿the￿repair￿instructions￿(diagnosis,￿disconnecting￿from￿the power￿supply,￿etc.)￿has￿to￿be￿performed.￿Before￿the￿mounting￿bolts￿are￿slackened￿the￿special￿tool￿for lowering￿(mobile￿table￿lift￿MHT 1200)￿must￿be￿positioned￿below￿the￿high-voltage￿battery￿unit. The￿electrical￿connection￿is￿established￿between￿the￿housing￿and￿Drive￿module￿by￿another￿potential compensation￿screw. The￿low￿resistance￿connection￿between￿the￿housing￿of￿the￿high-voltage￿battery￿unit￿and￿ground￿(= Drive￿module)￿is￿a￿crucial￿prerequisite￿for￿the￿fault-free￿function￿of￿the￿automatic￿isolation￿monitoring. This￿is￿why￿it￿is￿important￿to￿ensure￿the￿correct￿tightening￿torque￿is￿applied￿for￿this￿potential compensation￿screw. It￿is￿also￿important￿to￿ensure￿that￿neither￿the￿housing￿of￿the￿high-voltage￿battery￿unit￿nor￿the￿Drive module￿at￿the￿respective￿bore￿holes￿is￿painted,￿corroded￿or￿dirty.￿The￿bare￿metal￿must￿be￿exposed￿if necessary￿before￿the￿potential￿compensation￿screw￿is￿mounted.
  • Page 83 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit Mounting￿of￿the￿high-voltage￿battery￿unit￿at￿the￿Drive￿module Index Explanation Frame￿(Drive￿module) High-voltage￿battery￿unit Mounting￿bolts Potential￿compensation￿screw If￿the￿potential￿compensation￿screw￿can￿no￿longer￿be￿tightened￿to￿the￿required￿torque￿after￿a￿number of￿removal￿and￿installation￿procedures,￿a￿new￿bore￿hole￿for￿the￿potential￿compensation￿screw￿must￿be created.￿The￿rough￿position￿of￿the￿bore￿hole￿is￿shown￿in￿the￿following￿graphic￿-￿the￿exact￿position￿can be￿found￿in￿the￿repair￿instructions.
  • Page 84 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit Bore￿hole￿for￿potential￿compensation￿screw Index Explanation Frame￿(Drive￿module) New￿bore￿hole￿for￿potential￿compensation￿screw￿in￿the￿event￿of￿a￿repair Housing￿of￿high-voltage￿battery￿unit Original￿bore￿hole￿for￿potential￿compensation￿screw￿ex￿works Similar￿to￿vehicles￿with￿a￿frame￿design,￿the￿Life-Drive￿concept￿is￿made￿up￿of￿two￿independent￿modules separated￿horizontally.￿The￿"Life"￿module￿consists￿mainly￿of￿a￿high-strength￿and￿very￿lightweight passenger￿cell￿made￿of￿carbon￿reinforced￿plastic.￿The￿"Drive"￿module,￿the￿chassis,￿forms￿the stable￿base,￿in￿which￿the￿high-voltage￿battery￿unit￿is￿integrated.￿Crash-active￿structures￿made￿from aluminium￿at￿the￿front￿end￿and￿rear￿end￿of￿the￿Drive￿module￿ensure￿additional￿safety￿in￿the￿event￿of a￿head-on￿and￿rear-end￿collision.￿The￿high-voltage￿battery￿unit￿is￿located￿in￿the￿vehicle￿underbody for￿the￿best￿possible￿protection￿as￿a￿vehicle￿suffers￿the￿least￿amount￿of￿deformation￿in￿this￿area￿in the￿event￿of￿a￿crash.￿In￿the￿event￿of￿a￿side￿collision￿the￿high-voltage￿battery￿unit￿also￿benefits￿from the￿crash￿properties￿of￿the￿Life￿module,￿as￿the￿entire￿energy￿is￿collected￿here￿and￿does￿not￿advance as￿far￿as￿the￿energy￿storage￿device.￿Overall,￿the￿high-strength￿carbon￿passenger￿compartment￿in conjunction￿with￿the￿intelligent￿force￿distribution￿in￿the￿LifeDrive￿module￿creates￿the￿prerequisite￿for optimal￿occupant￿safety. Three￿labels￿are￿attached￿at￿the￿high-voltage￿battery￿unit￿of￿the￿I01:￿one￿type￿plate￿and￿two￿warning stickers.￿The￿type￿plate￿provides￿logistical￿information￿(e.g.￿part￿number)￿and￿the￿key￿technical￿data (e.g.￿nominal￿voltage).￿The￿two￿warning￿stickers￿draw￿attention￿to￿the￿lithium-ion￿technology￿and￿the high￿electrical￿voltage￿used￿in￿the￿high-voltage￿battery￿unit￿and￿alert￿people￿to￿associated￿possible dangers.￿The￿following￿graphic￿shows￿where￿the￿three￿labels￿are￿located￿at￿the￿high-voltage￿battery unit.
  • Page 85 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit Labels￿on￿the￿housing￿of￿the￿high-voltage￿battery￿unit Index Explanation Housing￿cover￿of￿high-voltage￿battery￿unit High-voltage￿component￿warning￿sticker Warning￿sticker Label￿with￿technical￿data 5.2.2.￿Electrical￿interfaces High-voltage￿connection There￿is￿a￿two-pin￿high-voltage￿connection￿at￿the￿high-voltage￿battery￿unit￿with￿which￿the￿high-voltage battery￿unit￿is￿connected￿to￿the￿high-voltage￿electrical￿system.
  • Page 86 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit Connections￿of￿the￿high-voltage￿battery￿unit,￿left Index Explanation Vent￿hole High-voltage￿interlock￿loop￿connector/bridge Mechanical￿slide Separate￿contact￿for￿high-voltage￿cable Contact￿for￿shielding Contact￿protection A￿contact￿is￿available￿for￿shielding￿around￿each￿of￿the￿two￿electrical￿contacts￿for￿the￿high-voltage cables.￿The￿shielding￿of￿the￿high-voltage￿cable￿(shielding￿for￿each￿cable)￿is￿continued￿into￿the￿housing of￿the￿high-voltage￿battery￿unit￿and￿thus￿contributes￿to￿the￿electromagnetic￿compatibility￿(EMC). In￿addition,￿the￿high-voltage￿connection￿provides￿protection￿against￿contact￿with￿live￿parts.￿The actual￿contacts￿are￿coated￿in￿plastic￿so￿that￿nobody￿can￿touch￿them￿directly.￿Only￿when￿the￿cable￿is connected￿is￿the￿coating￿pushed￿away￿and￿the￿contact￿established.￿The￿plastic￿slide￿serves￿as￿the mechanical￿latch￿mechanism￿of￿the￿connector.￿In￿addition,￿it￿is￿also￿an￿element￿of￿a￿safety￿function:￿If the￿high-voltage￿cable￿is￿not￿connected,￿the￿slide￿conceals￿the￿connection￿for￿the￿bridge￿of￿the￿high- voltage￿interlock￿loop.￿Only￿when￿the￿high-voltage￿cable￿is￿properly￿connected￿and￿the￿connector is￿locked,￿is￿this￿connection￿accessible￿and￿the￿bridge￿can￿be￿inserted.￿This￿guarantees￿that￿only when￿a￿high-voltage￿cable￿is￿connected￿is￿the￿circuit￿of￿the￿high-voltage￿interlock￿loop￿also￿closed. This￿principle￿applies￿to￿all￿high-voltage￿connections￿in￿the￿I01,￿for￿instance￿connections￿at￿the￿high- voltage￿battery￿unit,￿at￿the￿electrical￿machine￿electronics,￿at￿the￿convenience￿charging￿electronics and￿at￿the￿range￿extender￿electrical￿machine￿electronics.￿The￿high-voltage￿system￿can￿only￿be￿active when￿all￿high-voltage￿cables￿are￿connected.￿This￿is￿additional￿protection￿against￿contact￿with￿contact surfaces,￿which￿otherwise￿may￿carry￿voltage.
  • Page 87 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit High-voltage￿connection Index Explanation High-voltage￿connection￿with￿connected￿high-voltage￿cable High-voltage￿connection￿with￿disconnected￿high-voltage￿cable Bridge￿for￿high-voltage￿interlock￿loop￿(connected) Mechanical￿slide High-voltage￿connector￿of￿the￿high-voltage￿cable Bridge￿for￿high-voltage￿interlock￿loop￿(disconnected) High-voltage￿connection The￿high-voltage￿connection￿can￿be￿replaced￿as￿a￿separate￿component,￿just￿like￿all￿other￿components of￿the￿high-voltage￿battery￿unit. The￿diagnosis￿and￿repair￿of￿the￿high-voltage￿components￿is￿only￿allowed￿in￿a￿retail￿service center￿that￿has￿qualified￿and￿certified￿service￿technicians.￿These￿technicians￿must￿have completed￿the￿ST1403b￿I01￿High￿Voltage￿Battery￿and￿Maintenance￿instructor￿led￿course￿and successfully￿passed￿the￿hands￿on￿certification. Low-voltage￿connections There￿are￿two￿low-voltage￿connections￿at￿the￿high-voltage￿battery￿unit￿of￿the￿I01: Connection￿for￿lines￿to￿the￿SME￿control￿unit Connection￿for￿the￿activation￿of￿the￿combined￿expansion￿and￿shutoff￿valve The￿connection￿for￿the￿SME￿control￿unit￿has￿the￿following￿lines: • Voltage￿supply￿of￿the￿SME￿control￿unit￿with￿terminal￿30F￿and￿ground￿connection • Terminal￿30C￿for￿the￿voltage￿supply￿of￿the￿electromechanical￿switch￿contactors • Wake-up￿line￿from￿the￿BDC...
  • Page 88 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit • Input￿and￿output￿of￿the￿line￿for￿the￿high-voltage￿interlock￿loop • Output￿(+12 V￿and￿ground)￿for￿the￿activation￿of￿the￿combined￿shutoff￿and￿expansion￿valve (without￿heat￿pump) • PT‐CAN2 • Two￿unused￿signals￿(only￿for￿development￿purposes). Connections￿of￿the￿high-voltage￿battery￿unit,￿right Index Explanation Connection￿for￿combined￿expansion￿and￿shutoff￿valve Connection￿for￿refrigerant￿intake￿pipe Combined￿expansion￿and￿shutoff￿valve Housing￿of￿high-voltage￿battery￿unit Low-voltage￿connection￿of￿the￿high-voltage￿battery￿unit Connection￿for￿refrigerant￿pressure￿line With￿the￿optional￿heat￿pump￿the￿actuating￿wires￿coming￿from￿the￿SME￿control￿unit￿for￿the￿combined expansion￿and￿shutoff￿valve￿initially￿lead￿into￿the￿wiring￿harness.￿From￿there￿they￿are￿guided￿directly to￿this￿valve.￿There￿are￿no￿other￿electrical￿vehicle￿components￿involved￿which￿may￿influence￿this activation￿signal.￿With￿the￿optional￿heat￿pump￿the￿activation￿of￿the￿combined￿expansion￿and￿shutoff valve￿is￿assumed￿by￿the￿heat￿pump￿control￿unit￿and￿not￿the￿SME￿control￿unit.￿The￿SME￿control￿unit only￿communicates￿the￿cooling￿requirement￿for￿the￿high-voltage￿battery￿which￿is￿performed￿via￿the IHKA￿and￿the￿heat￿pump￿control￿unit.
  • Page 89 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit 5.2.3.￿Vent￿hole The￿vent￿hole￿has￿two￿tasks.￿The￿first￿task￿of￿the￿vent￿hole￿is￿to￿offset￿large￿pressure￿differences between￿the￿inside￿and￿outside￿of￿the￿high-voltage￿battery￿unit.￿Such￿pressure￿differences￿can￿only arise￿in￿the￿event￿of￿a￿damaged￿battery￿cell.￿For￿safety￿reasons￿the￿housing￿of￿the￿cell￿module￿with￿the damaged￿battery￿cell￿is￿opened￿to￿reduce￿the￿pressure.￿The￿gases￿are￿initially￿located￿in￿the￿housing of￿the￿high-voltage￿battery￿unit.￿From￿there￿they￿can￿be￿transported￿outwards￿via￿the￿vent￿hole. The￿second￿task￿of￿the￿vent￿hole￿is￿to￿transport￿outwards￿condensate￿arising￿in￿the￿inside￿of￿the￿high- voltage￿battery￿unit.￿Besides￿the￿technical￿components,￿there￿is￿also￿air￿inside￿the￿high-voltage￿battery unit.￿If￿the￿air￿or￿the￿housing￿is￿cooled￿by￿a￿lower￿ambient￿temperature￿or￿by￿a￿refrigerant￿through￿the activation￿of￿the￿air￿conditioning￿function,￿some￿of￿the￿water￿vapor￿from￿the￿air￿condenses.￿This￿means small￿amounts￿of￿liquid￿water￿can￿form￿in￿the￿inside￿of￿the￿high-voltage￿battery￿unit.￿This￿has￿no￿affect on￿the￿function.￿During￿the￿next￿heating￿of￿the￿air￿or￿the￿housing￿the￿water￿evaporates￿again￿and,￿at￿the same￿time,￿the￿pressure￿in￿the￿housing￿rises￿slightly.￿The￿vent￿hole￿permits￿pressure￿compensation￿by allowing￿the￿warm￿air￿to￿escape￿outwards.￿The￿water￿vapor￿in￿the￿air￿is￿also￿transported￿outwards￿and also￿the￿previously￿liquid￿condensate. To￿fulfil￿these￿tasks￿the￿vent￿hole￿has￿a￿permeable￿diaphragm￿for￿gases￿(and￿water￿vapor)￿and￿an impermeable￿diaphragm￿for￿fluids.￿There￿is￿a￿two-piece￿cover￿located￿above￿the￿diaphragm￿with￿which the￿diaphragm￿is￿protected￿against￿coarse￿dirt￿contamination. Vent￿hole Index Explanation Mounting￿bolts￿(x4) Vent￿hole The￿venting￿unit￿can￿be￿replaced￿in￿Service￿as￿an￿entire￿unit.￿A￿replacement￿makes￿sense￿if￿the venting￿unit￿is￿heavily￿contaminated￿or￿has￿suffered￿mechanical￿damage.

  • Page 90: Overview

    I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit If￿the￿housing￿of￿the￿high-voltage￿battery￿unit￿is￿also￿damaged,￿for￿example￿a￿crack,￿contact￿must￿be established￿with￿Technical￿Support￿to￿determine￿a￿suitable￿course￿of￿action. 5.2.4.￿Interface￿for￿the￿refrigerant￿circuit It￿is￿incorporated￿in￿the￿refrigerant￿circuit￿of￿the￿heating￿and￿air-conditioning￿system￿for￿cooling￿the high-voltage￿battery.￿In￿order￿to￿be￿able￿to￿perform￿condition-based￿cooling,￿there￿is￿an￿electrically activated￿combined￿expansion￿and￿shutoff￿valve￿at￿the￿high-voltage￿battery￿unit. There￿are￿two￿versions￿of￿this￿valve.￿Which￿version￿is￿installed￿in￿the￿I01￿depends￿on￿the￿equipment without/with￿heat￿pump￿(option 4T9).￿Without￿the￿optional￿heat￿pump￿the￿combined￿shutoff￿and expansion￿valve￿is￿hard-wired￿to￿the￿SME￿control￿unit￿and￿is￿activated￿directly￿by￿this￿control￿unit.￿The valve￿is￿closed￿currentless,￿i.e.￿no￿refrigerant￿flows￿into￿the￿high-voltage￿battery￿unit.￿The￿valve￿only knows￿two￿positions,￿"closed"￿and￿"open".￿The￿amount￿of￿flowing￿refrigerant￿is￿adjusted￿thermally. With￿the￿optional￿heat￿pump￿the￿combined￿expansion￿and￿shutoff￿valve￿is￿a￿constantly￿activated￿valve. The￿precise￿operating￿principle￿is￿described￿in￿the￿product￿information￿bulletin￿"I01￿Heating￿and￿Air- Conditioning￿System". The￿exact￿installation￿location￿of￿this￿valve￿is￿shown￿in￿a￿graphic￿in￿the￿chapter￿"Low-voltage connections".￿The￿operating￿principle￿of￿the￿cooling￿system￿is￿described￿in￿the￿next￿chapter. 5.3.￿Heating￿and￿cooling￿system 5.3.1.￿Overview To￿maximizethe￿service￿life￿of￿the￿high-voltage￿battery￿and￿obtain￿the￿greatest￿possible￿power,￿it￿is operated￿in￿a￿defined￿temperature￿range.￿The￿high-voltage￿battery￿unit￿is￿essentially￿operational￿in the￿range￿of￿-40 °C￿to￿+50 °C.￿These￿temperature￿limits,￿however,￿relate￿to￿the￿actual￿temperature of￿the￿cell,￿not￿the￿ambient￿temperature.￿In￿terms￿of￿temperature￿behavior￿the￿high-voltage￿battery unit￿is￿a￿slow-action￿system,￿i.e.￿it￿takes￿several￿hours￿until￿the￿cells￿assume￿the￿ambient￿temperature. Therefore￿having￿the￿battery￿spend￿a￿short￿period￿of￿time￿in￿an￿extremely￿hot￿or￿cold￿environment does￿not￿mean￿that￿the￿cells￿will￿already￿have￿assumed￿this￿temperature. The￿optimal￿range￿of￿the￿temperature￿of￿the￿cell￿with￿regard￿to￿service￿life￿and￿performance￿is￿more limited.￿It￿is￿between￿+25 °C￿and￿+40 °C.￿Mainly￿if￿the￿cell￿temperature￿is￿continuously￿significantly outside￿this￿range￿and,￿at￿the￿same￿time,￿high￿power￿is￿required,￿this￿would￿reduce￿the￿service￿life of￿the￿battery￿cells.￿To￿counteract￿this￿effect￿and￿ensure￿maximum￿performance￿at￿any￿ambient temperature,￿there￿is￿automatic￿heating￿and￿cooling￿for￿the￿high-voltage￿battery￿unit￿of￿the￿I01. The￿I01￿is￿equipped￿as￿standard￿with￿a￿cooling￿system￿for￿the￿high-voltage￿battery.￿For￿this￿purpose it￿is￿incorporated￿in￿the￿refrigerant￿circuit￿of￿the￿heating￿and￿air-conditioning￿system,￿similar￿to￿current BMW￿active￿hybrid￿vehicles.￿If￿the￿customer￿orders￿optional￿equipment￿494￿(Seat￿heating)￿for￿driver and￿front￿passenger,￿his￿I01￿also￿has￿heating￿for￿the￿high-voltage￿battery.￿The￿heat￿effect￿of￿the electrical￿current￿is￿used￿for￿heating￿up￿the￿high-voltage￿battery.￿This￿heating￿including￿the￿control￿is located￿inside￿the￿high-voltage￿battery￿unit.￿At￿a￿very￿low￿ambient￿temperature￿or￿cell￿temperature￿and with￿a￿connected￿charging￿cable,￿the￿heating￿is￿automatically￿activated￿if￿required￿in￿order￿to￿warm￿up the￿battery￿cells.￿This￿way￿the￿otherwise￿restricted￿performance￿is￿improved￿considerably￿at￿very￿low...
  • Page 91 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit The￿following￿graphic￿provides￿an￿overview￿of￿the￿entire￿system￿for￿the￿heating￿and￿cooling￿of￿the high-voltage￿battery￿unit. Entire￿cooling￿system￿of￿the￿high-voltage￿battery￿unit Index Explanation Combined￿expansion￿and￿shutoff￿valve Refrigerant￿lines￿for￿cooling￿of￿the￿high-voltage￿battery￿unit High-voltage￿battery￿unit Expansion￿valve￿for￿passenger￿compartment￿cooling Capacitor￿in￿the￿refrigerant￿circuit Refrigerant￿lines The￿subsystems￿for￿heating￿and￿cooling￿are￿shown￿individually￿below.
  • Page 92 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit Cooling￿system￿of￿the￿high-voltage￿battery The￿high-voltage￿battery￿unit￿in￿the￿I01￿is￿cooled￿directly￿by￿refrigerant.￿The￿refrigerant￿circuit￿of￿the air￿conditioning￿system￿is￿therefore￿made￿up￿of￿two￿parallel￿branches:￿One￿for￿cooling￿the￿passenger compartment￿and￿one￿for￿cooling￿the￿high-voltage￿battery￿unit.￿For￿each￿branch￿there￿is￿a￿combined expansion￿and￿shutoff￿valve￿in￿order￿to￿be￿able￿to￿control￿the￿cooling￿functions￿independent￿of each￿other.￿The￿battery￿management￿electronics￿can￿activate￿and￿open￿the￿combined￿expansion and￿shutoff￿valve￿by￿applying￿voltage.￿In￿this￿way￿refrigerant￿can￿flow￿to￿the￿high-voltage￿battery, expanding,￿evaporating￿and￿cooling￿in￿the￿process.￿The￿cooling￿of￿the￿passenger￿compartment￿is￿also effected￿in￿a￿condition-based￿manner.￿The￿combined￿expansion￿and￿shutoff￿valve￿upstream￿from￿the evaporator￿can￿also￿be￿activated￿electrically￿and￿by￿the￿EDME. Entire￿heating/cooling￿system￿of￿the￿high-voltage￿battery Index Explanation Capacitor￿in￿the￿refrigerant￿circuit Electric￿fan,￿refrigerant￿circuit￿for￿passenger￿compartment Dryer￿flask High-voltage￿battery￿unit Combined￿expansion￿and￿shut-off￿valve￿in￿the￿refrigerant￿circuit￿(for￿cooling high-voltage￿battery)
  • Page 93 I01￿High-voltage￿Components 5.￿High-voltage￿Battery￿Unit Index Explanation Heat￿exchanger Blower￿for￿passenger￿compartment Combined￿expansion￿and￿shutoff￿valve￿in￿the￿refrigerant￿circuit￿(for￿cooling￿the passenger￿compartment) Evaporator,￿passenger￿compartment During￿cooling￿the￿battery￿cells￿emit￿heat￿energy￿to￿the￿refrigerant.￿While￿the￿battery￿cells￿are￿cooled down,￿the￿refrigerant￿is￿heated.￿The￿EKK￿compresses￿the￿refrigerant￿again￿and￿in￿the￿capacitor￿it returns￿to￿a￿liquid￿state.￿As￿a￿result,￿the￿refrigerant￿is￿once￿again￿able￿to￿absorb￿heat￿energy.￿This￿way the￿maximum￿cooling￿power￿of￿about￿1000 W￿can￿be￿generated.￿In￿other￿words:￿A￿heat￿output￿of￿up￿to 1000 W￿can￿be￿discharged￿by￿the￿high-voltage￿battery.￿This￿maximum￿cooling￿power￿is￿only￿required at￿a￿very￿high￿ambient￿temperature￿and,￿at￿the￿same￿time,￿a￿high￿drive￿power. In￿order￿to￿cool￿battery￿cells￿using￿refrigerant,￿there￿is￿a￿heat￿exchanger￿located￿below￿the￿cell￿modules which￿is￿made￿from￿flat￿aluminium￿pipes.￿They￿are￿connected￿to￿the￿internal￿refrigerant￿lines￿and refrigerant￿flows￿through￿them￿during￿cooling. Heating Vice￿versa,￿if￿the￿I01￿was￿parked￿outside￿for￿example￿for￿several￿days￿at￿temperatures￿below￿0 °C,￿it makes￿sense￿to￿heat￿the￿battery￿cells￿before￿departure￿and/or￿to￿their￿optimal￿temperature￿level.￿They then￿deliver￿their￿full￿power￿before￿the￿journey￿commences.￿The￿customer￿can￿use￿this￿option￿if￿the vehicle￿is￿connected￿to￿the￿power￿network￿using￿the￿charging￿cable￿and￿the￿function￿for￿the￿interior air￿temperature￿control￿of￿the￿vehicle￿was￿selected.￿In￿order￿to￿warm￿up￿the￿batteries,￿the￿high-voltage system￿is￿activated￿and￿electrical￿current￿is￿sent￿through￿a￿network￿of￿heating￿wires.￿This￿network￿of heating￿wires￿is￿arranged￿along￿the￿coolant￿ducts.￿As￿the￿coolant￿ducts￿and￿the￿cell￿modules￿touch, the￿heat￿generated￿in￿the￿heater￿coils￿is￿transmitted￿to￿the￿cell￿modules￿and￿therefore￿the￿battery￿cells. 5.4.￿Internal￿structure￿of￿the￿high-voltage￿battery￿unit The￿information￿on￿the￿internal￿structure￿and￿other￿functions￿of￿the￿high-voltage￿battery￿unit￿can￿be found￿in￿the￿product￿information￿bulletin￿"I01￿High-voltage￿Battery￿Unit". A￿repair￿of￿the￿high-voltage￿battery￿unit￿is￿only￿intended￿in￿a￿dealership￿with￿the￿Service￿format￿"BMW￿i Extended￿Battery￿Service"￿or￿"BMW￿i￿Full￿Service".

  • Page 94: Introduction

    I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery 6.1.￿General￿information￿on￿charging 6.1.1.￿Introduction The￿"charging"￿procedure￿for￿an￿electric￿vehicle￿corresponds￿to￿"refueling￿"￿a￿conventionally￿driven vehicle.￿Accordingly,￿in￿this￿chapter￿"charging"￿means: • Charging￿the￿high-voltage￿battery￿in￿the￿vehicle • while￿at￿standstill￿(not￿through￿brake￿energy￿regeneration), • by￿supply￿of￿electrical￿energy, • which￿is￿provided￿by￿an￿AC￿voltage￿network￿outside￿the￿vehicle • and￿is￿fed￿to￿the￿vehicle￿via￿a￿charging￿cable. As￿a￿charging￿cable￿is￿used,￿one￿also￿refers￿to￿conductive￿(grid-bound)￿charging.￿The￿inductive charging￿is￿not￿possible￿at￿the￿I01.￿It￿is￿still￿undergoing￿research￿and￿development. Components￿inside￿and￿outside￿the￿vehicle￿are￿required￿for￿charging.￿In￿the￿vehicle￿a￿charging￿socket and￿power￿electronics￿are￿required￿for￿the￿voltage￿conversion.￿Outside￿the￿vehicle￿a￿device￿which performs￿the￿protection￿and￿control￿functions￿is￿needed,￿in￿addition￿to￿the￿AC￿voltage￿network￿and￿a charging￿cable.￿This￿device￿is￿called￿an￿"Electric￿Vehicle￿Supply￿Equipment￿(EVSE)"￿in￿the￿standards and￿in￿development.￿The￿following￿graphic￿shows￿the￿components￿for￿the￿charging￿of￿the￿high-voltage battery￿inside￿and￿outside￿the￿electric￿vehicle￿and￿compares￿them￿to￿the￿components￿needed￿for refueling￿in￿a￿conventional￿vehicle. Components￿for￿refueling￿the￿vehicle￿and￿charging￿the￿high-voltage￿battery Index Refueling￿the￿vehicle Charging￿the￿high-voltage￿battery Filling￿station AC￿voltage￿network Petrol￿pump Electric￿Vehicle￿Supply￿Equipment￿(e.g. wallbox) Fuel￿line￿between￿fuel￿pump￿nozzle Charging￿cable and￿gasoline￿pump Fuel￿pump￿nozzle Vehicle￿connector￿at￿charging￿cable...
  • Page 95 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Fuel￿filler￿neck Charging￿socket Power￿electronics Fuel￿tank High-voltage￿battery The￿Electric￿Vehicle￿Supply￿Equipment￿can￿either￿be￿integrated￿in￿the￿charging￿cable￿or￿be￿an￿element of￿a￿fixed￿charging￿station￿(also￿called￿"wallbox").￿The￿EVSE￿establishes￿the￿connection￿to￿the￿AC voltage￿network￿and￿serves￿for￿the￿fulfilment￿of￿requirements￿for￿electrical￿safety￿when￿charging￿the vehicle.￿Communication￿to￿the￿vehicle￿can￿also￿be￿set￿up￿via￿the￿pilot￿line.￿As￿a￿result,￿it￿is￿possible to￿safely￿start￿the￿charging￿procedure￿and￿exchange￿the￿charging￿parameters￿(e.g.￿maximum￿current level)￿between￿vehicle￿and￿EVSE.￿Details￿on￿the￿possible￿versions,￿structure￿and￿functioning￿of￿the EVSE￿are￿described￿in￿one￿of￿the￿following￿chapters. The￿voltage￿of￿the￿AC￿voltage￿network￿can￿be￿in￿the￿range￿of￿110 V￿to￿240 V.￿It￿is￿fed￿to￿the￿vehicle via￿a￿single-phase￿supply.￿From￿the￿AC￿voltage￿network￿side,￿in￿theory￿a￿maximum￿charging￿power￿of  = U  x I  = 240 V x 32 A = 7.7 kW￿is￿possible. Many￿of￿the￿components￿mentioned￿for￿charging￿the￿I01￿are￿standardized￿in￿terms￿of￿their￿structure and￿functions.￿In￿European￿countries￿IEC 61851￿is￿the￿applicable￿standard.￿The￿components￿for charging￿the￿I01￿satisfy￿charging￿mode￿2￿(connection￿to￿standard￿household￿socket￿with￿additional pilot￿line)￿and￿charging￿mode￿3￿(connection￿to￿fixed￿wallbox￿with￿pilot￿line). The￿standard￿for￿America￿is￿SAE J1772.￿Charge￿Level 1￿and￿2￿are￿comparable￿to￿charging modes 2￿and￿3.￿Most￿components￿for￿charging￿the￿I01￿only￿satisfy￿both￿standards￿with￿one technical￿version.￿A￿national-market￿or￿standard-specific￿version￿is￿required￿for￿Europe￿and America￿only￿by￿the￿"Electric￿Vehicle￿Supply￿Equipment". For￿the￿employees￿in￿BMW￿Service￿the￿following￿important￿safety￿rules￿must￿be￿observed￿in￿relation￿to charging: Refueling￿the￿vehicle￿while￿the￿high-voltage￿battery￿is￿charging￿is￿not￿permitted￿ When￿the￿charging￿cable￿is￿inserted￿do￿not￿initiate￿a￿refueling￿procedure￿and￿keep￿a￿safe￿distance￿from highly￿flammable￿materials.￿Otherwise,￿in￿the￿event￿of￿incorrect￿connection￿or￿removal￿of￿the￿charging cable￿there￿is￿a￿risk￿of￿personal￿injury￿or￿material￿damage￿by￿burning￿fuel￿for￿example. While￿the￿I01￿is￿connected￿to￿the￿AC￿voltage￿network￿for￿charging,￿no￿work￿may￿be￿performed￿at￿the high-voltage￿system. During￿the￿charging￿procedure￿the￿electric￿coolant￿pump￿and￿the￿electric￿fan￿can￿be￿switched￿on automatically￿for￿cooling￿the￿power￿electronics.￿This￿is￿why￿no￿work￿can￿be￿performed￿at￿the￿cooling system￿of￿the￿electric￿motor￿and￿at￿the￿electric￿fan￿when￿a￿charging￿cable￿is￿connected￿to￿the￿I01.
  • Page 96 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Work￿at￿the￿charging￿cable,￿at￿the￿Electric￿Vehicle￿Supply￿Equipment,￿at￿household￿sockets or￿charging￿stations￿can￿only￿be￿performed￿by￿qualified￿electricians,￿and￿not￿by￿BMW￿Service employees. 6.1.2.￿Overview￿of￿charging￿options In￿general,￿the￿high-voltage￿battery￿can￿either￿be￿charged￿using￿alternating￿current￿(AC￿charging)￿or direct￿current￿(DC￿charging).￿The￿charging￿options￿of￿the￿high-voltage￿battery￿in￿the￿I01￿are￿generally specified￿by￿the￿equipment￿for￿charging￿in￿the￿vehicle,￿as￿well￿as￿the￿national-market￿charging infrastructure.￿The￿following￿table￿provides￿an￿overview￿of￿the￿different￿charging￿options￿in￿various countries.￿The￿charging￿powers￿always￿relate￿to￿the￿mains￿power￿and￿not￿the￿charging￿power￿used￿to charge￿the￿high-voltage￿battery.￿The￿charging￿power￿is￿always￿less￿than￿the￿available￿mains￿power. Markets￿(LHD) Charging￿system Charging￿interface Equipment￿(basic version,￿option) US￿market￿(LHD) AC￿charging￿7.4 kW Type￿1 Standard￿Equipment Charging￿(SA4U8￿AC Fast￿Charging) Combo￿(AC￿charging Combo￿1 Optional￿Equipment 7.4 kW￿and￿DC Charging charging￿50 kW) (SA￿4U7￿DC￿Fast Charging 6.1.3.￿Charging￿modes The￿charging￿modes￿are￿defined￿in￿the￿international￿standard￿IEC61851-1￿(IEC￿=￿International Electrotechnical￿Commission).￿The￿key￿parameters￿of￿the￿individual￿charging￿modes￿are￿summarized in￿the￿following￿table: Maximum￿power Communication Locking￿the with￿the￿vehicle charging￿plug Charging￿mode￿1...
  • Page 97 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery IEC￿Charging￿mode￿1 Index Explanation Household￿power￿socket Connector￿for￿household￿socket Circuit￿breaker Charging￿cable Charging￿plug Charging￿socket￿at￿the￿vehicle Charging￿mode￿1￿i.a.w.￿IEC61851-1￿is￿NOT￿USED￿in￿the￿I01￿due￿to￿a￿lack￿of￿communication between￿the￿vehicle￿and￿voltage￿supply. IEC￿Charging￿mode￿2￿(Occasional￿use￿cable) Index Explanation Household￿power￿socket Connector￿for￿household￿socket In-cable￿box Charging￿cable Charging￿plug￿(Europe￿and￿US￿version) Charging￿socket￿at￿the￿vehicle...
  • Page 98 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery The￿communication￿between￿vehicle￿and￿voltage￿supply￿is￿possible￿via￿the￿In-Cable￿box. IEC￿Charging￿mode￿3￿(Wallbox) Index Explanation Wallbox￿or￿charging￿station Charging￿plug￿for￿connection￿at￿wallbox￿or￿charging￿station￿(only￿in￿Europe) Charging￿cable Charging￿plug￿(Europe￿and￿US￿version)￿for￿connection￿to￿vehicle Charging￿socket￿at￿the￿vehicle In￿the￿US￿market￿the￿plug￿connection￿between￿the￿charging￿cable￿and￿AC￿charging￿station￿is permanently￿attached￿to￿the￿charging￿station￿(wallbox).￿Therefore￿the￿charging￿cable￿cannot￿be separated￿from￿the￿AC￿charging￿station￿by￿the￿customer. 6.1.4.￿Charging￿plug The￿charging￿plugs￿used￿are￿also￿standardized￿(IEC￿62196-2).￿Depending￿on￿the￿vehicle￿equipment and￿national-market￿version￿different￿charging￿sockets￿are￿used.￿The￿following￿table￿provides￿an overview￿of￿the￿most￿frequently￿used￿connectors:...
  • Page 99 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery US￿market￿(Type￿1) AC￿charging SAE￿J1772￿/ IEC￿62196–2 Combo￿charging￿plug￿(DC charging) SAE￿J1772￿/ IEC￿62196–3 Combo￿1 6.1.5.￿Electric￿Vehicle￿Supply￿Equipment The￿EVSE￿establishes￿the￿connection￿to￿the￿AC￿voltage￿network￿and￿serves￿for￿the￿fulfilment￿of requirements￿for￿electrical￿safety￿when￿charging￿the￿vehicle.￿Communication￿to￿the￿vehicle￿can￿also￿be set￿up￿via￿the￿so-called￿pilot￿line.￿As￿a￿result,￿it￿is￿possible￿to￿safely￿start￿the￿charging￿procedure￿and exchange￿the￿charging￿parameters￿(e.g.￿maximum￿current￿level)￿between￿vehicle￿and￿EVSE.￿The￿EVSE can￿either￿be￿integrated￿in￿the￿charging￿cable￿(mobile￿solution)￿or￿be￿an￿element￿of￿a￿fixed￿charging station￿(also￿called￿"wallbox"). In￿both￿cases￿the￿EVSE￿contains￿the￿following￿subcomponents: • Earth￿leakage￿circuit￿breaker￿(FI) • Display￿whether￿the￿AC￿voltage￿network￿is￿connected￿and￿available • Electronic￿disconnect￿switch￿for￿phase￿(L1)￿and￿neutral￿conductor￿(N) • Electronic￿switching￿for￿generating￿the￿pilot￿signal • Continuous￿protective￿earth￿(PE). Mobile￿solution The￿version￿integrated￿in￿the￿charging￿cable￿is￿also￿called￿"In-Cable￿box"￿and￿is￿designed￿for mobile￿use.￿The￿volume￿and￿weight￿of￿this￿solution￿is￿low￿and￿the￿charging￿and￿EVSE￿can￿be￿easily transported￿in￿the￿vehicle.
  • Page 100 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery EVSE￿for￿mobile￿use Index Explanation BMW￿i￿mobile￿EVSE Display￿for￿the￿availability￿of￿the￿voltage￿supply Display￿for￿charging Display￿for￿fault￿in￿the￿voltage￿supply Display￿for￿fault￿during￿charging As￿a￿household￿power￿socket￿is￿used￿for￿the￿connection￿of￿this￿EVSE￿to￿the￿AV￿voltage￿network,￿the maximum￿current￿level￿is￿restricted￿for￿charging.￿A￿product￿of￿this￿kind￿offered￿for￿the￿AC￿voltage network￿in￿Germany￿can￿be￿used￿up￿to￿a￿current￿level￿of￿16 A￿or￿up￿to￿a￿charging￿power￿of￿3.7 kW.￿The duration￿until￿a￿fully￿discharged￿high-voltage￿battery￿of￿the￿I01￿is￿fully￿charged￿up￿again￿(18.8 kWh￿net) would￿be￿roughly￿7￿hours￿in￿optimal￿conditions. Please￿consult￿the￿operating￿instructions￿of￿the￿respective￿manufacturer￿for￿the￿operation￿and￿use￿of￿a charging￿cable￿with￿an￿integrated￿EVSE.
  • Page 101 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Employees￿in￿BMW￿Service￿cannot￿perform￿any￿maintenance￿or￿repair￿work￿on￿the￿charging￿cable or￿the￿EVSE.￿In￿the￿event￿of￿a￿defect￿with￿or￿a￿malfunction￿of￿the￿charging￿cable￿or￿the￿EVSE,￿the manufacturer￿must￿be￿contacted. Fixed￿charging￿station This￿version￿of￿the￿Electric￿Vehicle￿Supply￿Equipment￿must￿be￿installed￿permanently￿owing￿to￿its￿size and￿electrical￿requirements,￿e.g.￿at￿the￿house￿or￿in￿the￿customer's￿garage.￿Such￿a￿charging￿station￿can also￿be￿built￿at￿public￿places,￿e.g.￿car￿parks. The￿installation,￿maintenance￿and￿repair￿of￿fixed￿charging￿stations￿can￿only￿be￿performed￿by￿suitably qualified￿electricians.￿Employees￿in￿BMW￿Service￿are￿not￿authorized￿to￿perform￿this￿work￿as￿they generally￿do￿not￿have￿this￿training. For￿the￿fixed￿charging￿stations￿(also￿called￿"wallbox")￿a￿distinction￿is￿made￿between￿AC￿charging stations￿and￿DC￿charging￿stations. AC￿charging￿stations The￿connection￿of￿the￿AC￿charging￿stations￿to￿the￿AC￿voltage￿network￿can￿be￿via￿a￿two-phase￿(US market)￿or￿three-phase￿(typical￿in￿Germany)￿supply￿–￿the￿connection￿to￿the￿I01￿is,￿however,￿always designed￿as￿a￿single-phase￿supply.￿In￿comparison￿to￿the￿mobile￿solution,￿a￿maximum￿current￿level￿of 32 A￿or￿a￿maximum￿charging￿power￿of￿7.4 kW￿is￿possible.￿These￿maximum￿values￿are,￿however,￿still dependent￿on￿the￿size￿of￿the￿line￿cross-section,￿which￿was￿used￿in￿the￿electrical￿installation￿at￿the charging￿site.￿The￿electrician￿configures￿the￿charging￿station￿during￿installation￿according￿to￿the￿line cross-section￿so￿that￿the￿applicable￿maximum￿current￿level￿is￿transmitted￿to￿the￿vehicle￿using￿the￿pilot signal. AC￿charging￿stations￿from￿other￿manufacturers￿or￿the￿versions￿for￿other￿countries￿may￿differ￿from￿the versions￿shown￿up￿to￿now. The￿following￿graphic￿shows￿an￿AC￿charging￿station￿for￿the￿US￿market.
  • Page 102 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery AC￿charging￿station￿for￿the￿US￿market,￿manufactured￿by￿AeroVironment Index Explanation Display￿of￿the￿operating￿condition Button￿for￿starting￿and￿stopping￿the￿charging￿procedure Charging￿cable￿with￿connector￿for￿the￿connection￿at￿the￿vehicle￿(stored￿in￿the AC￿charging￿station) For￿more￿information￿regarding￿the￿charging￿cable￿refer￿to￿chapter￿6.3.2￿“Charging￿Cable“￿of this￿training￿manual. In￿the￿US￿market￿a￿plug￿connection￿between￿the￿charging￿cable￿and￿AC￿charging￿station￿is permanently￿attached￿to￿the￿charging￿station￿(wallbox).￿Therefore￿the￿charging￿cable￿cannot￿be separated￿from￿the￿AC￿charging￿station￿by￿the￿customer.￿The￿connector￿visible￿in￿the￿graphic￿is￿not the￿connector￿for￿the￿connection￿to￿the￿AC￿charging￿station,￿but￿for￿the￿connection￿to￿the￿vehicle, which￿is￿only￿stored￿in￿the￿AC￿charging￿station. DC￿charging￿station...
  • Page 103 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery DC￿charging￿station The￿DC￿charging￿stations￿form￿the￿second￿group￿of￿the￿fixed￿charging￿stations.￿In￿comparison￿to￿the AC￿charging￿station,￿the￿AC￿voltage￿is￿already￿converted￿to￿direct￿current￿in￿the￿DC￿charging￿station. Therefore,￿power￿electronics￿for￿the￿conversion￿of￿the￿AC￿voltage￿to￿direct￿current￿voltage￿in￿the electric￿vehicle￿are￿not￿required. As￿the￿weight￿of￿the￿power￿electronics￿in￿the￿DC￿charging￿station￿plays￿a￿minor￿role,￿large transformers￿and￿a￿rectifier￿can￿be￿installed￿there￿to￿use￿the￿full￿network￿power.￿For￿this￿reason,￿DC charging￿stations￿generally￿deliver￿a￿much￿higher￿charging￿power￿than￿AC￿charging￿stations.￿Using￿a DC￿charging￿station￿the￿high-voltage￿battery￿can￿thus￿be￿charged￿much￿quicker. 6.2.￿AC￿charging￿with￿3.7 kW￿(Occasional￿Use￿Cable) Although￿the￿high-voltage￿battery￿of￿the￿I01￿can￿also￿be￿partially￿charged￿by￿brake￿energy regeneration,￿the￿"normal"￿charging￿procedure￿takes￿place￿when￿the￿I01￿is￿connected￿to￿the￿AC voltage￿network￿of￿the￿power￿supply￿company.￿Energy￿is￿taken￿from￿the￿AC￿voltage￿network￿and￿fed￿to the￿direct￿current￿voltage￿high-voltage￿electrical￿system￿of￿the￿I01.
  • Page 104 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Although￿AC￿charging￿with￿3.7 kW￿is￿standard￿equipment￿in￿many￿countries￿in￿the￿US￿market,￿it￿only refers￿to￿the￿charging￿via￿the￿occasional￿use￿cable￿(inserted￿into￿a￿normal￿110V￿socket).￿The￿big advantage￿of￿this￿charging￿option￿is￿that￿for￿charging￿the￿high-voltage￿battery￿the￿charging￿cable￿can be￿connected￿at￿any￿household￿power￿socket￿with￿protective￿contact.￿However,￿the￿current￿level￿for charging￿is￿also￿restricted￿to￿a￿maximum￿16￿A.￿The￿maximum￿charging￿power￿is,￿for￿example￿for￿supply at￿AC￿voltage￿network￿in￿Germany,￿3680 W￿(P￿=￿U￿x￿I￿=￿230 V￿x￿16 A).￿The￿total￿time￿it￿takes￿to￿fully charge￿a￿discharged￿high-voltage￿battery￿of￿the￿I01￿(storable￿energy:￿18.8 kW￿net)￿would￿be￿about￿7 hours.￿In￿order￿to￿reduce￿the￿use￿of￿the￿maximum￿charging￿power￿for￿houses,￿a￿charging￿procedure￿is never￿performed￿at￿maximum￿charge￿current.￿Therefore,￿the￿actual￿charging￿time￿is￿longer. The￿EME￿is￿designed￿so￿it￿can￿provide￿a￿maximum￿electrical￿power￿of￿3.7 kW￿on￿the￿output side.￿This￿is￿charging￿configuration￿is￿used￿(in￿the￿US￿market)￿only￿when￿charging￿with￿the occasional￿use￿cable￿via￿a￿household￿120￿V￿socket.￿And￿it￿sufficient￿to￿fully￿charge￿the￿I01 high-voltage￿battery￿under￿optimal￿marginal￿conditions￿in￿about￿16￿hours.
  • Page 105 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery 6.2.1.￿Wiring￿diagram Wiring￿diagram￿for￿AC￿charging￿at￿3.7 kW￿(US￿market)
  • Page 106 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Index Explanation Electrical￿Digital￿Motor￿Electronics￿(EDME) High-voltage￿battery￿unit Battery￿management￿electronics￿(SME) Charging￿interface￿module￿(LIM) Electric￿motor￿for￿the￿connector￿fastener Electric￿motor￿for￿the￿central￿locking￿system￿of￿the￿charging￿socket￿cover Locator￿and￿status￿lighting Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Range￿extender￿electrical￿machine Convenience￿charging￿electronics￿(KLE) Charging￿socket￿at￿the￿vehicle Electrical￿machine￿electronics￿(EME) 6.2.2.￿Charging￿cable Charging￿cable￿with￿integrated￿mobile￿version￿of￿the￿Electric￿Vehicle￿Supply￿Equipment￿(Charging￿mode￿2￿i.a.w.￿IEC￿61851) Index Explanation Electric￿Vehicle￿Supply￿Equipment￿(integrated,￿also￿called￿"In-Cable￿box") Connector￿for￿connection￿at￿a￿household￿power￿socket Connector￿for￿the￿connection￿at￿the￿vehicle...
  • Page 107 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery The￿charging￿cable￿is￿used￿to￿join￿the￿following￿components: • Specific￿national-market￿connection￿for￿household￿power￿socket￿with￿protective￿contact • Plug￿connection￿between￿specific￿national-market￿connector￿and￿"In-Cable￿box" • "In-Cable￿box"￿(EVSE) • Plug￿connection￿between￿"In-Cable￿box"￿and￿connector￿for￿vehicle￿connection • Connector￿for￿vehicle￿connection. The￿charging￿cable￿is￿the￿electrical￿connection￿between￿the￿AC￿voltage￿network￿and￿the￿direct￿current voltage￿high-voltage￿electrical￿system￿of￿the￿vehicle.￿The￿connection￿to￿the￿AC￿voltage￿network￿is effected￿at￿a￿typical￿household￿power￿socket￿with￿protective￿contact,￿which￿does￿not￿include￿Electric Vehicle￿Supply￿Equipment.￿In￿this￿case￿the￿switching￿and￿functions￿of￿the￿Electric￿Vehicle￿Supply Equipment￿are￿integrated￿in￿the￿charging￿cable.￿This￿is￿called￿an￿"In-Cable￿box".￿This￿charging￿cable for￿the￿I01￿is￿always￿designed￿for￿single-phase￿supply,￿in￿line￿with￿the￿charging￿socket￿at￿the￿vehicle (phase L1￿and￿neutral￿conductor N)￿and￿always￿includes￿the￿protective￿earth PE,￿as￿well￿as￿the￿pilot and￿proximity￿line.￿The￿connector￿is￿designed￿so￿that￿the￿connection￿is￿first￿made￿with￿the￿protective contact.￿The￿ground￿is￿grounded￿via￿the￿protective￿earth. The￿charging￿cable￿can￿be￿housed￿in￿the￿charging￿cable￿compartment￿under￿the￿engine￿compartment lid. Please￿consult￿the￿operating￿instructions￿of￿the￿respective￿manufacturer￿for￿the￿operation￿and￿use￿of￿a charging￿cable￿with￿an￿integrated￿EVSE. Employees￿in￿BMW￿Service￿cannot￿perform￿any￿maintenance￿or￿repair￿work￿on￿the￿charging￿cable or￿the￿EVSE.￿In￿the￿event￿of￿a￿defect￿with￿or￿a￿malfunction￿of￿the￿charging￿cable￿or￿the￿EVSE,￿the manufacturer￿must￿be￿contacted. Menu￿for￿the￿setting￿of￿the￿current￿level...
  • Page 108 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Index Explanation "Current￿settings"￿submenu Note￿"Before￿increasing￿the￿current￿level:￿Check￿suitability￿of￿voltage￿supply. For￿maximum￿charge￿current￿see￿charging￿cable." Charge￿current￿"Maximum",￿100%￿of￿possible￿current￿level￿(information￿via proximity￿line) Charge￿current￿"Reduced",￿75%￿of￿possible￿current￿level￿(information￿via proximity￿line) Charge￿current￿"Low"￿about￿6￿A "Settings"￿menu The￿driver￿has￿the￿option￿to￿restrict￿the￿maximum￿current￿level￿at￿the￿power￿socket￿via￿the￿"Settings" submenu￿in￿the￿vehicle.￿If￿the￿current￿level￿at￿the￿power￿socket￿is￿insufficient￿or￿unknown,￿it￿is recommended￿to￿adjust￿the￿current￿level￿to￿"Reduced"￿or￿"Low". Charging￿with￿Level￿1￿(occasional￿use￿cable)￿should￿take￿about￿15￿hrs.￿in￿the￿US￿market￿but this￿time￿varies￿depending￿on￿the￿on￿voltage￿supply￿and￿on￿the￿vehicle￿charge￿settings. 6.2.3.￿What￿must￿be￿observed￿when￿charging￿the￿high-voltage￿battery￿unit? Filling￿the￿fuel￿tank￿while￿the￿high-voltage￿battery￿is￿charging￿is￿not￿permitted￿ When￿the￿charging￿cable￿is￿connected￿do￿not￿fill￿the￿fuel￿tank￿and￿keep￿a￿safe￿distance￿from￿highly flammable￿materials.￿Otherwise,￿in￿the￿event￿of￿an￿improper￿connection￿or￿if￿the￿charging￿cable￿is pulled￿out,￿there￿is￿a￿risk￿of￿personal￿injury￿or￿material￿damage￿by￿burning￿fuel￿for￿example. Charging￿the￿high-voltage￿battery￿using￿a￿typical￿household￿power￿socket￿results￿in￿a￿high￿continuous load￿on￿the￿power￿socket,￿which￿does￿not￿occur￿with￿other￿household￿appliances.￿Therefore,￿the following￿information￿must￿be￿observed: • Do￿not￿use￿an￿adapter￿or￿extension￿cable • After￿charging￿plug￿the￿charging￿plug￿into￿the￿vehicle￿first￿and￿then￿into￿the￿wall • Avoid￿tripping￿hazards￿and￿mechanical￿loads￿for￿charging￿cables￿and￿power￿sockets • Do￿not￿insert￿the￿charging￿plug￿in￿damaged￿power￿sockets • Do￿not￿use￿damaged￿charging￿cables • The￿charging￿plug￿and￿charging￿cable￿may￿be￿warm￿when￿charging￿the￿high-voltage￿battery. If￿they￿become￿too￿hot,￿the￿power￿socket￿is￿not￿suitable￿for￿charging￿or￿the￿charging￿cable￿is damaged.￿Stop￿charging￿immediately￿and￿have￿the￿power￿socket￿and￿charging￿cable￿checked by￿an￿electrician...
  • Page 109 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery • Only￿use￿power￿sockets￿protected￿against￿moisture￿and￿weathering • Do￿not￿touch￿contact￿areas￿of￿power￿sockets￿with￿fingers￿or￿objects • Never￿repair￿or￿modify￿a￿charging￿cable￿yourself • Remove￿cable￿on￿both￿sides￿before￿cleaning.￿Do￿not￿immerse￿in￿fluids. • Do￿not￿go￿through￿a￿car￿wash￿during￿charging • Only￿charge￿at￿power￿sockets￿checked￿by￿an￿electrician • Observe￿special￿information￿in￿the￿operating￿instructions￿for￿charging￿at￿unknown￿or￿unfamiliar infrastructure/power￿sockets.￿Set￿the￿charging￿current￿in￿the￿vehicle￿to￿"low". 6.2.4.￿Charging￿socket￿at￿the￿vehicle The￿charging￿socket￿at￿the￿I01￿is￿located￿precisely￿where￿the￿fuel￿filler￿neck￿is￿located￿in￿a conventional￿vehicle￿with￿a￿combustion￿engine.￿Just￿like￿the￿fuel￿filler￿flap￿has￿to￿be￿opened￿in￿a conventional￿vehicle,￿the￿charging￿socket￿cover￿also￿has￿to￿be￿opened￿in￿the￿I01.￿Press￿the￿charging socket￿cover￿to￿operate￿the￿release￿button￿and￿unlock￿the￿charging￿socket￿cover.￿The￿actual￿charging socket￿is￿then￿protected￿against￿moisture￿and￿dirt￿contamination￿by￿another￿lid.￿The￿charging￿socket satisfies￿the￿protection￿class￿IP5K5.￿The￿charging￿socket￿cover￿and￿the￿connector￿assignment￿are shown￿in￿the￿following￿graphic. Charging￿socket￿at￿the￿vehicle￿for￿combo￿charging,￿type￿1￿(US￿market)
  • Page 110 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Index Explanation Connection￿for￿proximity￿line Connection￿for￿phase￿L1 Connection￿for￿protective￿earth￿(PE) Connection￿for￿neutral￿conductor￿(N) Connection￿for￿pilot￿line Protective￿cap￿for￿AC￿charging￿socket Protective￿cap￿for￿DC￿charging￿socket Connection￿for￿DC￿ground￿cable Connection￿for￿DC￿positive￿wire The￿high-voltage￿cables￿of￿the￿charging￿socket￿are￿connected￿to￿the￿electrical￿machine￿electronics (via￿the￿KLE￿in￿the￿US￿market).￿Phase L1￿and￿neutral￿conductor N￿are￿designed￿as￿shielded￿high- voltage￿cables￿and￿end￿with￿a￿flat￿high-voltage￿connector￿at￿the￿alternating￿current￿connection￿of￿the electrical￿machine￿electronics.￿The￿pilot￿line￿and￿the￿proximity￿line￿are￿simple￿signal￿lines.￿These￿signal lines￿are￿also￿shielded￿and￿end￿at￿a￿connector￿in￿the￿charging￿interface￿module￿(LIM).￿The￿protective earth￿is￿connected￿electrically￿to￿ground￿in￿close￿proximity￿to￿the￿charging￿socket.￿This￿ensures￿proper grounding. A￿C-shaped￿fiber-optic￿conductor￿runs￿around￿the￿charging￿socket￿at￿the￿vehicle.￿With￿this￿C-shaped fiber-optic￿conductor￿it￿is￿possible￿to￿show￿the￿status￿for￿charging.￿The￿lighting￿of￿the￿fiber-optic conductor￿is￿effected￿using￿two￿LEDs￿which￿are￿controlled￿by￿the￿LIM. The￿charging￿socket￿at￿the￿vehicle￿can￿only￿be￿replaced￿together￿with￿the￿high-voltage￿cable￿as￿one unit. 6.2.5.￿Charging￿interface￿module￿(LIM) The￿LIM￿enables￿communication￿between￿the￿vehicle￿and￿charging￿station.￿The￿voltage￿supply￿of￿the LIM￿control￿unit￿is￿effected￿by￿terminal￿30F.￿There￿is￿a￿terminating￿resistor￿for￿the￿PT-CAN￿in￿the￿LIM. The￿LIM￿can￿also￿wake￿up￿the￿control￿units￿in￿the￿vehicle￿electrical￿system￿when￿the￿charging￿cable￿is connected.￿There￿is￿also￿a￿line￿which￿runs￿directly￿from￿the￿LIM￿control￿unit￿to￿the￿electrical￿machine electronics.￿Only￿when￿the￿LIM￿control￿unit￿enables￿the￿charging￿procedure￿via￿a￿signal￿on￿this￿line, does￿the￿electrical￿machine￿electronics￿start￿the￿voltage￿conversion￿and￿thus￿the￿charging￿procedure.
  • Page 111 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Installation￿location￿of￿LIM The￿main￿tasks￿of￿the￿LIM￿are: • Communication￿with￿EVSE￿via￿pilot￿and￿proximity￿line • Coordinating￿the￿charging￿procedure • Activation￿of￿the￿LEDs￿for￿displaying￿the￿charging￿status • Activation￿of￿the￿electric￿motor￿for￿locking￿the￿charging￿socket￿cover...
  • Page 112 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Input/Output￿for￿charging￿interface￿module Index Explanation Electric￿Vehicle￿Supply￿Equipment Information￿whether￿the￿AC￿voltage￿network￿is￿available￿and￿the￿charging￿cable is￿correctly￿connected,￿as￿well￿as￿the￿maximum￿available￿current￿level Electrical￿machine￿electronics￿(EME) Requested￿charging￿power,￿charging￿voltage￿and￿charging￿current￿level￿(set- point￿values)
  • Page 113 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Index Explanation Body￿Domain￿Controller￿(BDC) Terminal￿status,￿driving￿readiness￿switched￿off Dynamic￿Stability￿Control￿(DSC) Vehicle￿speed Electrical￿Digital￿Motor￿Electronics￿(EDME) Status￿of￿parking￿lock￿(engaged/disengaged),￿power￿requirement￿in￿the￿high- voltage￿vehicle￿electrical￿system Charging￿interface￿module￿(LIM) Charging￿socket￿at￿the￿vehicle Status￿of￿the￿charging￿socket￿cover￿and￿the￿charging￿plug Electrical￿machine￿electronics￿(EME) Actual￿value￿of￿the￿set￿charging￿power,￿charging￿voltage￿and￿charging￿current level,￿charging￿release Electrical￿Digital￿Motor￿Electronics￿(EDME) Information￿whether￿the￿charging￿cable￿is￿connected￿and￿the￿charging procedure￿is￿active Charging￿socket Activation￿of￿LEDs￿for￿locator￿lighting￿and￿charging￿status￿display,￿status￿of￿the charging￿socket￿cover. Instrument￿cluster Signals￿for￿the￿display￿of￿charging￿information Communication￿with￿EVSE￿via￿pilot￿and￿proximity￿line The￿pilot￿line￿and￿the￿proximity￿line￿are￿realized￿as￿simple￿signal￿lines.￿These￿signal￿lines￿are￿shielded and￿end￿at￿a￿connector￿in￿the￿charging￿interface￿module￿LIM. Via￿the￿proximity￿line￿the￿connection￿of￿the￿charging￿plug￿in￿the￿charging￿socket￿at￿the￿vehicle￿is identified,￿as￿well￿as￿the￿maximum￿current￿carrying￿capacity￿of￿the￿charging￿cable￿determined.￿In￿the connector￿of￿the￿charging￿cable￿there￿is￿an￿ohmic￿resistor￿between￿the￿proximity￿connection￿and￿the protective￿earth.￿The￿LIM￿applies￿a￿measured￿voltage￿and￿calculates￿which￿value￿the￿resistance￿in the￿proximity￿line￿has.￿The￿resistance￿value￿specifies￿which￿maximum￿current￿level￿is￿allowed￿for￿the charging￿cable￿used￿(dependent￿on￿the￿line￿cross-section).￿The￿assignment￿of￿resistance￿–￿current level￿is￿specified￿in￿the￿standard￿IEC 61851. The￿pilot￿line￿is￿required￿for￿the￿determination￿and￿transmission￿of￿the￿maximum￿available￿charging current￿level.￿The￿pilot￿signal￿is￿a￿bipolar￿rectangle￿signal￿(-12 V￿to￿+12 V).￿The￿voltage￿and￿the￿duty cycle￿are￿used￿for￿the￿communication￿of￿different￿statuses￿between￿EVSE￿and￿I01: • Electric￿vehicle￿is￿ready￿to￿charge￿(Yes/No) •...
  • Page 114 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Coordinating￿the￿charging￿procedure The￿LIM￿control￿unit￿coordinates￿the￿start￿and￿finish￿of￿the￿charging￿procedure. There￿are￿two￿actions￿required￿by￿the￿customer￿at￿the￿start￿of￿the￿charging￿procedure: Set￿the￿start￿time￿for￿charging Connect￿the￿charging￿cable. Using￿the￿controller￿and￿the￿menu￿in￿the￿central￿information￿display￿CID￿the￿customer￿can￿set￿and adjust￿the￿start￿time￿for￿charging￿in￿the￿vehicle.￿The￿customer￿has￿a￿second￿range￿of￿adjustment￿with the￿"BMW￿i￿Remote￿app"￿for￿the￿iPhone™.￿The￿customer￿can￿select￿to￿start￿the￿charging￿procedure immediately￿after￿connecting￿the￿charging￿cable￿or￿specify￿a￿time￿at￿which￿the￿charging￿procedure should￿start. BMW￿i￿Remote￿app:￿Charging￿the￿high-voltage￿battery Index Explanation Settings￿for￿charging,￿e.g.￿departure￿time Switching￿climate￿control￿on/off￿at￿departure￿time Switching￿charging￿on/off￿at￿reasonable￿electricity￿rate If￿the￿customer￿connects￿the￿charging￿cable,￿the￿LIM￿control￿unit￿wakes￿up￿the￿control￿units￿in￿the vehicle￿electrical￿system￿(if￿they￿have￿not￿already￿been￿woken￿up￿by￿another￿event).￿The￿LIM￿control unit￿uses￿the￿wake-up￿line￿wired￿directly￿to￿the￿BDC￿control￿unit.￿Then￿the￿LIM￿control￿unit￿checks￿the functional￿prerequisites￿for￿charging￿and￿receives￿information￿about￿the￿conditions￿relevant￿for￿safety via￿the￿powertrain￿CAN.
  • Page 115 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery These￿checks￿are￿summarized￿in￿the￿following￿list: • Driving￿readiness￿off • Driving￿speed￿zero • Parking￿lock￿engaged • Charging￿cable￿connect￿(proximity) • Communication￿with￿Electric￿Vehicle￿Supply￿Equipment￿OK￿(pilot) • High-voltage￿system￿active￿and￿trouble-free. When￿all￿prerequisites￿for￿charging￿are￿satisfied,￿the￿high-voltage￿power￿management￿in￿the￿EME requests￿a￿charging￿power￿from￿the￿power￿electronics￿in￿the￿EME￿and￿starts￿the￿charging￿procedure. The￿EME￿control￿unit￿sends￿not￿only￿setpoint￿values￿for￿the￿charging￿power,￿but￿also￿specifies￿limit values￿for￿the￿maximum￿charging￿voltage￿and￿the￿maximum￿charge￿current.￿These￿values￿are￿based￿on the￿current￿condition￿(e.g.￿state￿of￿charge￿and￿temperature)￿of￿the￿high-voltage￿battery￿and￿according to￿the￿power￿requirement￿of￿the￿rest￿of￿the￿vehicle￿electrical￿system￿(e.g.￿for￿climate￿control).￿The EME￿control￿unit￿cleverly￿implements￿these￿setpoint￿values,￿i.e.￿it￿takes￿into￿consideration￿not￿only the￿setpoint￿values,￿but￿other￿marginal￿conditions.￿These￿include￿the￿actual￿status￿of￿the￿electrical machine￿electronics￿(fault,￿temperature),￿as￿well￿as￿the￿current￿level￿restricted￿by￿the￿AC￿voltage network￿and￿the￿charging￿cable. Only￿when￿the￿communication￿between￿the￿vehicle￿(LIM)￿and￿Electric￿Vehicle￿Supply￿Equipment has￿been￿started￿successfully￿via￿the￿pilot￿line,￿is￿the￿voltage￿applied￿to￿the￿phase L1.￿This￿also￿gives further￿protection￿for￿customers￿and￿Service￿employees￿against￿the￿dangers￿of￿electricity. Activation￿of￿the￿LEDs￿for￿displaying￿the￿charging￿status A￿C-shaped￿fiber-optic￿conductor￿runs￿around￿the￿charging￿socket￿at￿the￿vehicle.￿With￿this￿C-shaped fiber-optic￿conductor￿it￿is￿possible￿to￿show￿the￿status￿for￿charging.￿At￿the￿same￿time,￿this￿fiber-optic conductor￿is￿used￿as￿locator￿lighting￿for￿the￿charging￿socket.￿The￿lighting￿of￿the￿fiber-optic￿conductor is￿effected￿using￿two￿LEDs￿which￿are￿controlled￿by￿the￿LIM. Locator￿lighting: The￿locator￿lighting￿of￿the￿charging￿socket￿is￿used￿as￿an orientation￿aid￿by￿the￿driver￿for￿the￿connection￿and￿disconnection of￿the￿charging￿plug. The￿two￿LEDs￿light￿up￿in￿white￿as￿soon￿as￿the￿charging￿socket cover￿has￿been￿opened.￿The￿locator￿lighting￿remains￿switched￿on as￿long￿as￿the￿bus￿systems￿are￿active.￿As￿soon￿as￿a￿charging￿plug has￿been￿identified￿as￿correctly￿connected,￿the￿locator￿lighting￿is...
  • Page 116 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Initialization: The￿initialization￿starts￿immediately￿after￿the￿correct￿connection of￿the￿charging￿plug.￿The￿initialization￿phase￿takes￿up￿to￿10 seconds. The￿LEDs￿flash￿in￿an￿orange￿color￿at￿a￿frequency￿of￿1￿Hz. After￿successful￿initialization￿the￿charging￿of￿the￿high-voltage battery￿can￿be￿started. Charging￿active: The￿currently￿active￿charging￿procedure￿of￿the￿high-voltage battery￿is￿displayed￿by￿flashing￿blue￿LEDs.￿The￿flashing frequency￿is￿about￿1.42￿Hz. Charging￿interval: Charging￿interval￿or￿charging￿readiness￿present￿when￿the initialization￿phase￿was￿completed￿successfully￿and￿the￿charging start￿is￿sometime￿in￿the￿future￿(e.g.:￿charging￿at￿a￿less￿expensive time). Charging￿complete: The￿state￿of￿charge￿of￿the￿high-voltage￿battery￿"fully￿charged"￿is indicated￿by￿permanently￿green￿LEDs.
  • Page 117 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Fault￿during￿charging: If￿faults￿occur￿during￿the￿charging￿procedure,￿then￿this￿status￿is displayed￿by￿flashing￿red￿LEDs.￿The￿LEDs￿flash￿three￿times￿at￿a frequency￿of￿about￿2.0￿Hz￿and￿an￿interval￿of￿about￿0.8￿seconds between￿the￿three￿groups. The￿LEDs￿for￿these￿displays￿are￿activated￿after￿the￿charging￿plug￿is￿connected￿or￿after￿unlocking/ locking￿the￿vehicle￿for￿12￿seconds.￿If￿during￿this￿time￿the￿vehicle￿is￿unlocked/locked￿again,￿the￿display lasts￿for￿another￿12￿seconds. Locking￿the￿charging￿socket￿cover Locking￿the￿charging￿socket￿cover...
  • Page 118 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Index Explanation Electric￿motor￿for￿locking￿the￿charging￿socket￿cover Locking￿hook Bowden￿cable￿for￿the￿emergency￿operation￿of￿the￿charging￿socket￿cover The￿charging￿socket￿cover￿is￿held￿closed￿by￿a￿spring-activated￿locking￿hook.￿The￿locking￿hook￿is￿a￿part of￿the￿central￿locking￿drive￿for￿the￿charging￿socket￿cover.￿The￿unlocking/locking￿of￿the￿charging￿socket cover￿is￿effected￿using￿an￿electric￿motor.￿This￿electric￿motor￿is￿activated￿by￿the￿LIM.￿The￿request￿for unlocking/locking￿the￿charging￿socket￿cover￿comes￿from￿the￿BDC. A￿microswitch￿is￿also￿installed￿in￿the￿central￿locking￿drive.￿The￿status￿of￿the￿microswitch￿(actuated/ not￿actuated)￿provides￿information￿on￿the￿status￿of￿the￿charging￿socket￿cover￿(open/closed).￿In rest￿position,￿i.e.￿when￿the￿charging￿socket￿cover￿is￿closed,￿the￿microswitch￿is￿not￿actuated.￿The microswitch￿is￿actuated￿when￿the￿charging￿socket￿cover￿is￿open.￿The￿microswitch￿is￿also￿actuated when￿the￿charging￿socket￿cover￿is￿pressed￿and￿held. In￿the￿event￿of￿an￿electrical￿fault,￿e.g.￿failure￿of￿both￿the￿charging￿socket￿cover￿and￿the￿DC￿charging plug￿can￿be￿unlocked￿manually. Emergency￿release￿buttons Index Explanation Button￿for￿the￿emergency￿release￿of￿the￿charging￿socket￿cover Button￿for￿the￿emergency￿release￿of￿the￿DC￿charging￿plug The￿rear￿door￿on￿the￿side￿on￿which￿the￿charging￿socket￿cover￿is￿located￿must￿be￿opened. When￿the￿rear￿door￿is￿open￿two￿blue￿buttons￿are￿visible￿in￿the￿lower￿area.￿To￿unlock￿the￿charging socket￿cover￿the￿upper￿blue￿button￿must￿be￿pulled. The￿DC￿charging￿plug￿is￿unlocked￿by￿pulling￿the￿lower￿blue￿button.
  • Page 119 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery 6.2.6.￿Power￿electronics￿in￿the￿(EME) The￿power￿electronics￿for￿the￿conversion￿of￿the￿AC￿voltage￿coming￿from￿the￿charging￿socket￿to￿direct current￿voltage￿required￿for￿charging￿the￿high-voltage￿battery￿is￿housed￿in￿the￿electrical￿machine electronics.￿The￿AC￿voltage￿is￿fed￿to￿the￿electrical￿machine￿electronics￿via￿a￿single-phase￿supply.￿The input￿voltage,￿which￿can￿be￿processed￿by￿the￿electrical￿machine￿electronics,￿may￿be￿in￿the￿following range:￿100 V￿to￿240 V,￿50 Hz￿or￿60 Hz. The￿power￿electronics￿module￿is￿a￿unidirectional￿AC/DC￿converter,￿i.e.￿a￿rectifier. At￿the￿output,￿which￿is￿separated￿galvanically￿from￿the￿input,￿the￿electrical￿machine￿electronics supplies￿an￿electronically￿adjustable￿direct￿current￿voltage￿or￿an￿electronically￿adjustable￿direct￿current flows.￿The￿specifications￿for￿the￿output￿voltage￿and￿the￿output￿current￿come￿from￿the￿function￿"High- voltage￿power￿management"￿in￿the￿EME￿control￿unit.￿The￿values￿are￿calculated￿and￿adjusted￿by￿the EME￿so￿that￿the￿high-voltage￿battery￿is￿optimally￿charged￿and￿the￿other￿consumers￿in￿the￿I01￿are supplied￿with￿sufficient￿electrical￿energy. The￿EME￿is￿designed￿so￿it￿can￿provide￿a￿maximum￿electrical￿power￿of￿3.7 kW￿on￿the￿output side.￿This￿is￿charging￿configuration￿is￿used￿(in￿the￿US￿market)￿only￿when￿charging￿with￿the occasional￿use￿cable￿via￿a￿household￿120V￿socket.￿And￿it￿sufficient￿to￿fully￿charge￿the￿I01 high-voltage￿battery￿under￿optimal￿marginal￿conditions￿in￿about￿16￿hours. 6.3.￿AC￿charging￿with￿7.4 kW AC￿charging￿with￿7.4 kW￿is￿standard￿equipment￿for￿the￿US￿market￿(SA￿4U8￿AC￿Fast￿Charging)￿and￿it is￿possible￿via￿a￿permanently￿installed￿AC￿charging￿station￿(wallbox).￿In￿order￿to￿deliver￿the￿charging power￿of￿7.4 kW,￿the￿AC￿charging￿station￿must￿provide￿32￿A￿at￿a￿phase￿connection.￿P￿=￿U￿x￿I￿=￿230 V￿x 32 A￿=￿7360 W￿=￿7.4 kW.
  • Page 120 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery BMW￿i￿charging￿station Index Explanation BMW￿i￿charging￿station ON/OFF￿button Charging￿plug AC￿charging￿with￿7.4 kW￿(SA￿4U8￿AC￿Fast￿Charging)￿is￿standard￿equipment￿for￿the￿US￿market. The￿EVSE￿is￿located￿inside￿the￿AC￿charging￿station.￿With￿this￿stationary￿version￿of￿the￿EVSE,￿the time￿to￿fully￿charge￿a￿discharged￿high-voltage￿battery￿in￿the￿I01￿is￿cut￿by￿half,￿when￿compared￿to￿AC charging￿with￿3.7 kW￿(standard￿equipment￿in￿European￿vehicles). The￿same￿components￿are￿required￿for￿both￿the￿AC￿charging￿at￿7.4 kW￿(in￿the￿US)￿and￿for￿AC￿charging at￿3.7 kW￿(in￿EU).￿In￿order￿to￿deliver￿the￿additional￿3.7 kW￿of￿charging￿power,￿the￿7.4￿kW￿system requires￿a￿different￿charging￿cable￿and￿the￿installation￿of￿a￿convenience￿charging￿electronics￿(KLE). These￿two￿components￿are￿described￿here￿in￿detail.
  • Page 121 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery 6.3.1.￿Wiring￿diagram Wiring￿diagram￿for￿AC￿charging￿at￿7.4 kW￿(US￿market)
  • Page 122 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Index Explanation Electrical￿Digital￿Motor￿Electronics￿(EDME) High-voltage￿battery￿unit Battery￿management￿electronics￿(SME) Charging￿interface￿module￿(LIM) Electric￿motor￿for￿the￿connector￿fastener Electric￿motor￿for￿the￿central￿locking￿system￿of￿the￿charging￿socket￿cover Locator￿and￿status￿lighting Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Range￿extender￿electrical￿machine Convenience￿charging￿electronics￿(KLE) Charging￿socket￿at￿the￿vehicle Electrical￿machine￿electronics￿(EME) 6.3.2.￿Charging￿cable This￿charging￿cable￿for￿the￿I01￿is￿always￿designed￿for￿single-phase￿supply,￿in￿line￿with￿the￿charging socket￿at￿the￿vehicle￿(phase L1￿and￿neutral￿conductor N)￿and￿always￿includes￿the￿protective￿earth (PE), as￿well￿as￿the￿pilot￿line.￿The￿ground￿is￿grounded￿via￿the￿protective￿earth.￿Using￿the￿pilot￿line￿the correct￿connection￿to￿the￿AC￿voltage￿network￿and￿its￿maximum￿available￿charging￿current￿level￿can be￿identified￿or￿transmitted.￿In￿the￿connector￿an￿ohmic￿resistor￿is￿also￿installed￿between￿the￿proximity connection￿and￿the￿protective￿earth.￿The￿resistance￿value￿specifies￿which￿maximum￿current￿level is￿allowed￿for￿the￿charging￿cable￿used￿(dependent￿on￿the￿line￿cross-section).￿The￿assignment￿of resistance￿–￿current￿level￿is￿specified￿in￿the￿standard￿IEC 61851.￿Using￿the￿resistance￿in￿the￿proximity line￿the￿LIM￿in￿the￿vehicle￿can￿identify￿whether￿the￿charging￿cable￿is￿properly￿connected￿and￿which current￿level￿is￿allowed￿for￿this￿charging￿cable.￿The￿convenience￿charging￿electronics￿applies￿a measured￿voltage￿and￿calculates￿which￿value￿the￿resistance￿in￿the￿proximity￿line￿has. The￿connection￿with￿the￿AC￿voltage￿network￿is￿done￿via￿a￿fixed￿charging￿station,￿which￿includes￿the Electric￿Vehicle￿Supply￿Equipment.￿The￿appropriate￿charging￿cable￿for￿this￿purpose￿is￿solely￿the electrical￿connection￿between￿charging￿station￿and￿charging￿socket￿at￿the￿vehicle. The￿charging￿cable￿for￿AC￿Charging￿at￿7.4 kW￿(standard￿equipment￿in￿US)￿and￿AC￿charging at￿3.7 kW￿(Standard￿equipment￿in￿Europe)￿have￿the￿same￿connector￿for￿the￿connection￿at￿the vehicle.￿The￿connectors￿are￿only￿distinguished￿by￿their￿differing￿resistances￿in￿the￿proximity line,￿appropriate￿to￿the￿current￿carrying￿capacity￿of￿the￿charging￿cable.￿The￿following￿graphic shows￿the￿structure￿and￿the￿connections￿of￿this￿connector.
  • Page 123 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Connector￿of￿the￿charging￿cable￿for￿the￿connection￿to￿the￿vehicle￿(standardized￿i.a.w.￿IEC￿62196-2:￿Type￿1) Index Explanation View￿from￿the￿side￿of￿the￿electrical￿connection View￿from￿the￿side￿of￿the￿handle Mechanical￿locking Connection￿for￿pilot￿line Connection￿for￿protective￿earth Connection￿for￿proximity￿line Connection￿for￿phase￿L1 Connection￿for￿neutral￿conductor￿(N) Mechanical￿guide/connector￿housing Button￿for￿the￿mechanical￿unlocking￿of￿the￿connector￿before￿removal The￿connector￿of￿the￿charging￿cable￿and￿the￿charging￿socket￿in￿the￿vehicle￿are￿protected￿against direct￿contact.￿In￿addition,￿the￿geometry￿of￿the￿contacts￿is￿designed￿so￿that￿the￿following￿sequence results￿for￿the￿connection￿of￿the￿connector￿with￿the￿charging￿socket: Proximity￿line Protection￿earth￿(PE) Neutral￿conductor (N),￿phase L1 Pilot￿line.
  • Page 124 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Only￿when￿the￿communication￿between￿the￿vehicle￿(LIM)￿and￿Electric￿Vehicle￿Supply￿Equipment￿has been￿started￿successfully￿via￿the￿pilot￿line,￿is￿the￿charging￿voltage￿applied￿to￿the￿phase L1.￿This￿also gives￿further￿protection￿for￿customers￿and￿Service￿employees￿against￿the￿dangers￿of￿electricity. With￿this￿stationary￿version￿of￿the￿EVSE￿the￿lines￿can￿transmit￿up￿to￿7.4 kW.￿The￿AC/DC￿converter in￿the￿convenience￿charging￿electronics￿(3.7 kW)￿and￿in￿the￿electrical￿machine￿electronics￿(3.7 kW) ensure￿the￿conversion￿of￿the￿single-phase￿AC￿voltage￿to￿the￿direct￿current￿voltage￿required￿for charging￿the￿high-voltage￿battery.￿The￿duration￿of￿the￿full￿charge￿of￿an￿empty￿high-voltage￿battery￿of the￿I01￿can￿then￿be￿reduced￿to￿three￿to￿four￿hours. 6.3.3.￿Convenience￿charging￿electronics The￿convenience￿charging￿electronics￿(KLE)￿is￿installed￿in￿the￿rear￿of￿the￿I01,￿in￿an￿area￿separated￿from the￿luggage￿compartment. Installation￿location￿of￿the￿convenience￿charging￿electronics The￿main￿task￿of￿the￿convenience￿charging￿electronics￿(KLE)￿during￿AC￿charging￿at￿7.4 kW￿is￿the conversion￿of￿the￿AC￿voltage￿to￿direct￿current￿voltage.￿A￿rectifier￿switching￿in￿the￿KLE￿comprising￿two modules￿completes￿this￿task.￿These￿power￿electronics￿modules￿are￿controlled￿by￿a￿control￿unit,￿which also￿bears￿the￿same￿name:￿Convenience￿charging￿electronics￿(KLE). The￿convenience￿charging￿electronics￿is￿designed￿so￿it￿can￿provide￿a￿maximum￿electrical￿power￿of 3.7 kW￿on￿the￿output￿side.￿Together￿with￿the￿3.7 kW￿from￿the￿standard￿power￿electronics￿of￿the￿EME, this￿is￿sufficient￿in￿the￿I01￿to￿fully￿charge￿the￿high-voltage￿battery￿(at￿optimal￿marginal￿conditions)￿in three￿to￿six￿hours.￿This￿short￿charging￿time￿means￿enhanced￿comfort￿for￿the￿customer￿when￿using￿the I01.￿For￿this￿reason,￿this￿charging￿electronics￿was￿called￿"convenience￿charging￿electronics". The￿AC￿voltage￿is￿fed￿to￿the￿vehicle￿or￿the￿convenience￿charging￿electronics￿via￿a￿single-phase￿supply. The￿input￿voltage,￿which￿can￿be￿processed￿by￿the￿convenience￿charging￿electronics,￿may￿be￿in￿the following￿range:￿100 V￿–￿240 V,￿50 Hz￿or￿60 Hz.￿At￿the￿output,￿which￿is￿separated￿galvanically￿from the￿input,￿the￿convenience￿charging￿electronics￿supplies￿an￿electronically￿adjustable￿direct￿current voltage￿or￿an￿electronically￿adjustable￿direct￿current￿flows.￿The￿specifications￿for￿the￿output￿voltage and￿the￿output￿current￿come￿from￿the￿function￿"High-voltage￿power￿management"￿in￿the￿EME￿control unit.￿The￿values￿are￿calculated￿and￿adjusted￿by￿the￿KLE￿so￿that￿the￿high-voltage￿battery￿is￿optimally charged￿and￿the￿other￿consumers￿in￿the￿I01￿are￿supplied￿with￿sufficient￿electrical￿energy.
  • Page 125 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Although￿the￿convenience￿charging￿electronics￿works￿at￿a￿high￿degree￿of￿efficiency￿of￿well￿over￿90%, active￿cooling￿is￿required￿at￿full￿performance.￿For￿this￿reason￿it￿is￿integrated￿in￿the￿cooling￿circuit￿of￿the electric￿motor. In￿addition￿to￿the￿voltage￿conversion￿and￿energy￿provision,￿the￿convenience￿charging￿electronics￿also assumes￿safety￿functions￿which￿protect￿the￿customer￿and￿Service￿employee￿from￿the￿dangers￿of electricity.￿Nevertheless,￿the￿following￿applies: The￿convenience￿charging￿electronics￿is￿a￿high-voltage￿component￿ Only￿qualified￿Service￿employees￿can￿work￿on￿the￿convenience￿charging￿electronics￿while￿observing the￿repair￿instructions. Before￿working￿on￿the￿convenience￿charging￿electronics,￿it￿is￿essential￿to￿observe￿the￿electrical￿safety rules. Similar￿to￿all￿high-voltage￿components,￿the￿convenience￿charging￿electronics￿can￿only￿be￿replaced￿in Service￿if￿required,￿it￿cannot￿be￿opened￿or￿repairs. The￿manufacturer￿of￿the￿convenience￿charging￿electronics￿is￿"Meta￿System". Connections The￿connections￿at￿the￿convenience￿charging￿electronics￿can￿be￿divided￿into￿four￿categories: • Low-voltage￿connections • High-voltage￿connections • Connection￿for￿potential￿compensation￿line • Connections￿for￿coolant￿lines. The￿following￿graphic￿shows￿all￿connections￿of￿the￿convenience￿charging￿electronics:...
  • Page 126 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Connections￿of￿the￿convenience￿charging￿electronics￿in￿the￿version￿for￿AC￿charging￿at￿7.4 kW Index Explanation High-voltage￿cable￿(AC)￿from￿the￿charging￿socket High-voltage￿cable￿(DC)￿to￿the￿electrical￿machine￿electronics Coolant￿line￿(supply) Low-voltage￿cables High-voltage￿cable￿(AC)￿from￿KLE￿to￿EME KLE￿mounting￿(potential￿compensation￿contact) High-voltage￿cable￿(DC)￿from￿REME Coolant￿line￿(return) Convenience￿charging￿electronics￿(KLE) Low-voltage￿connections The￿multipolar￿low-voltage￿connector￿at￿the￿convenience￿charging￿electronics￿joins￿the￿following￿lines and￿signals: • Voltage￿supply￿for￿the￿KLE￿control￿unit￿(terminal￿30B,￿terminal￿30￿from￿the￿power￿distribution box￿at￿the￿front￿and￿ground) • Voltage￿supply￿via￿terminal￿30C￿(quick￿shutdown￿in￿the￿event￿of￿an￿accident) • Bus￿system￿PT-CAN2...
  • Page 127 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery • Wake-up￿lines￿to￿the￿BDC￿control￿unit￿and￿EDME￿control￿unit • Control￿line￿from￿the￿LIM,￿with￿which￿the￿charging￿procedure￿is￿released • Inputs￿and￿outputs￿of￿the￿circuit￿of￿the￿high-voltage￿interlock￿loop￿(KLE￿control￿unit￿evaluates the￿signal). The￿KLE￿control￿unit￿is￿supplied￿with￿voltage￿via￿terminal￿30￿and￿terminal￿30B￿and￿has￿two￿wake-up line￿outputs.￿The￿convenience￿charging￿electronics￿can￿also￿wake￿up￿the￿control￿units￿in￿the￿vehicle electrical￿system￿when￿the￿charging￿cable￿is￿connected. Via￿the￿bus￿system￿PT-CAN2￿the￿KLE￿control￿unit￿receives￿the￿request￿and￿the￿control￿signals for￿charging.￿There￿is￿also￿a￿line￿which￿is￿wired￿directly￿from￿the￿LIM￿to￿the￿convenience￿charging electronics.￿Only￿when￿the￿LIM￿enables￿the￿charging￿procedure￿via￿a￿signal￿on￿this￿line,￿does￿the convenience￿charging￿electronics￿start￿the￿voltage￿conversion￿and￿thus￿the￿charging￿procedure. The￿high-voltage￿connectors￿of￿the￿convenience￿charging￿electronics￿are￿also￿integrated￿in￿the￿circuit of￿the￿high-voltage￿interlock￿loop.￿Via￿the￿low-voltage￿connection￿the￿test￿signal￿is￿forwarded￿to￿the high-voltage￿interlock￿loop￿and￿to￿the￿other￿high-voltage￿components.￿The￿KLE￿control￿unit￿monitors the￿test￿signal￿and￿interrupts￿the￿charging￿procedure￿if￿it￿is￿not￿in￿the￿specified￿range. High-voltage￿connections There￿are￿three￿high-voltage￿connections￿at￿the￿convenience￿charging￿electronics￿to￿connect￿the high-voltage￿cables￿to￿the￿charging￿socket￿(1￿x)￿and￿to￿the￿electrical￿machine￿electronics￿(2￿x).￿If￿the I01￿vehicle￿is￿equipped￿with￿a￿range￿extender,￿the￿convenience￿charging￿electronics￿has￿another￿high- voltage￿connection￿in￿order￿to￿connect￿the￿range￿extender￿electrical￿machine￿electronics￿REME.
  • Page 128 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Connection￿to Number￿of￿contacts, Type￿of￿connection Contact￿protection components... voltage￿type, shielding Charging￿socket Round￿connector -￿HV￿contacts￿cannot￿be • 1-phase￿(phase touched￿with￿fingers L1￿and￿neutral -￿High-voltage￿interlock conductor￿N) loop • voltage • 1￿shielding￿for both￿lines Electrical Line￿from￿the￿AC/DC Flat￿high-voltage -￿Cover￿over￿the￿contact machine converter￿of￿the￿KLE￿to connector￿with blades electronics the￿EME mechanical￿lock -￿High-voltage￿interlock Round￿connector loop -￿HV￿contacts￿cannot￿be •...
  • Page 129 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery The￿charging￿of￿the￿high-voltage￿battery￿in￿the￿I01￿can￿only￿be￿effected￿if￿the￿potential￿compensation line￿is￿properly￿connected￿to￿the￿convenience￿charging￿electronics. Connections￿for￿coolant￿lines The￿convenience￿charging￿electronics￿is￿integrated￿in￿the￿cooling￿circuit￿of￿the￿electric￿motor.￿This cooling￿circuit￿is￿described￿in￿detail￿in￿chapter￿11￿"Cooling￿the￿electric￿motor￿components". 6.4.￿Combined￿Charging￿System The￿"Combined￿Charging￿System",￿or￿combo￿charging￿for￿short,￿is￿a￿charging￿system￿for￿electric and￿plug-in￿hybrid￿cars￿i.a.w.￿IEC￿62196￿and￿supports￿both￿AC￿charging￿(alternating￿current)￿and DC￿charging￿(direct￿current).￿A￿Phoenix￿contact￿was￿developed￿in￿cooperation￿with￿the￿automobile manufacturers￿and￿is￿essentially￿made￿up￿of￿a￿charging￿socket￿on￿the￿vehicle￿side,￿the￿so-called￿inlet, and￿a￿charging￿plug,￿in￿which￿the￿two￿individual￿charging￿plugs￿are￿integrated￿for￿AC￿and￿DC￿charging. Thanks￿to￿this￿universal￿connector￿system￿only￿one￿charging￿socket￿is￿required￿at￿the￿vehicle￿in order￿to￿cover￿the￿various￿charging￿options￿of￿AC￿and￿DC￿charging.￿A￿distinction￿is￿made￿between connections￿of￿type￿1￿(for￿the￿US￿market)￿and￿type￿2￿(for￿the￿European￿market).￿The￿contacts￿for￿the DC￿connection￿are￿the￿same￿in￿both￿versions.￿Due￿to￿the￿larger￿DC￿contacts￿in￿comparison￿to￿AC charging,￿currents￿of￿up￿to￿200￿A￿are￿possible,￿whereby￿Fast￿charging,￿for￿example￿during￿transport, can￿be￿possible. In￿the￿I01￿two￿versions￿of￿the￿combo￿charging￿are￿offered,￿depending￿on￿the￿AC￿charging￿power: • Combo￿charging￿at￿3.7 kW￿AC￿charging￿power￿(standard￿equipment￿in￿Europe) • Combo￿charging￿at￿7.4 kW￿AC￿charging￿power￿(standard￿equipment￿in￿USA) In￿US￿market￿vehicles￿option￿4U7￿DC￿Fast￿Charging￿is￿offered￿as￿optional￿equipment;￿this option￿includes￿the￿necessary￿hardware￿for￿the￿Combo￿charging￿at￿7.4￿kW￿AC￿charging￿or￿DC charging.
  • Page 130 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery 6.4.1.￿Wiring￿diagrams Wiring￿diagram￿for￿combo￿charging￿at￿7.4 kW￿(US￿market)
  • Page 131 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Index Explanation Electrical￿Digital￿Motor￿Electronics￿(EDME) Voltage￿supply￿for￿KLE￿(terminal￿30B) High-voltage￿battery￿unit Battery￿management￿electronics￿(SME) Charging￿interface￿module￿(LIM) Electric￿motor￿for￿the￿connector￿fastener Electric￿motor￿for￿the￿central￿locking￿system￿of￿the￿charging￿socket￿cover Locator￿and￿status￿lighting Charging￿socket￿at￿the￿vehicle Convenience￿charging￿electronics￿(KLE) Electrical￿machine￿electronics￿(EME) Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Range￿extender￿electrical￿machine 6.4.2.￿Charging￿socket￿at￿the￿vehicle Charging￿socket￿at￿the￿vehicle￿for￿combo￿charging,￿type￿1￿(US￿market)

  • Page 132: Lim

    I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Index Explanation Connection￿for￿proximity￿line Connection￿for￿phase￿L1 Connection￿for￿protective￿earth￿(PE) Connection￿for￿neutral￿conductor￿(N) Connection￿for￿pilot￿line Protective￿cap￿for￿AC￿charging￿socket Protective￿cap￿for￿DC￿charging￿socket Connection￿for￿DC￿ground￿cable Connection￿for￿DC￿positive￿wire The￿charging￿socket￿in￿the￿vehicle￿for￿combo￿charging￿includes￿the￿sockets￿for￿AC￿charging￿and￿the socket￿for￿DC￿charging.￿The￿advantage￿of￿this￿charging￿socket￿configuration￿is￿that￿the￿customer￿can use￿both￿AC￿charging￿stations￿and￿DC￿charging￿stations￿for￿charging￿the￿high-voltage￿battery. During￿DC￿charging￿an￿electric￿arc￿may￿form￿by￿disconnecting￿the￿charging￿plug￿during￿the￿charging procedure.￿To￿prevent￿this￿the￿charging￿plug￿is￿locked￿electromechanically￿during￿the￿charging procedure.￿This￿way￿a￿possible￿dangerous￿situation￿for￿the￿user￿is￿avoided.￿An￿ergonomic￿handle￿at the￿charging￿plug￿and￿low￿connection￿and￿disconnection￿forces￿enable￿comfortable￿operation￿of￿the connector￿using￿only￿one￿hand. Simultaneous￿charging￿via￿AC￿and￿DC￿is￿not￿possible. 6.4.3.￿LIM The￿main￿tasks￿of￿the￿LIM￿are￿already￿described￿previously￿in￿this￿chapter.￿Only￿the￿additional functions￿and￿tasks￿of￿the￿LIM￿for￿combo￿charging￿are￿described￿here.￿A￿new￿tasks￿of￿the￿LIM￿is,￿for example,￿the￿activation￿of￿the￿switch￿contactors￿in￿the￿KLE￿for￿DC￿charging. Communication Also￿for￿combo￿charging￿the￿LIM￿assumes￿the￿communication￿between￿the￿vehicle￿and￿the￿charging station.￿The￿communication￿between￿the￿vehicle￿and￿the￿charging￿station￿is￿enabled￿and￿the￿charging procedure￿is￿controlled￿via￿the￿pilot￿and￿proximity￿line. Using￿the￿proximity￿line￿the￿correct￿connection￿of￿the￿charging￿cable￿at￿the￿vehicle￿is￿identified￿and￿the maximum￿current￿carrying￿capacity￿of￿the￿charging￿cable￿is￿measured￿by￿the￿LIM￿using￿the￿resistor￿in the￿charging￿cable. The￿high-voltage￿power￿management￿in￿the￿EME￿sends￿a￿request￿to￿charge￿the￿high-voltage￿battery to￿the￿LIM￿via￿the￿PT-CAN.￿The￿LIM￿then￿starts￿the￿communication￿with￿the￿charging￿station￿via￿the pilot￿line.￿The￿information￿about￿charging￿requirement,￿charging￿range￿and￿accuracy￿is￿exchanged. Only￿after￿successful￿communication￿start￿is￿the￿charging￿voltage￿applied￿to￿the￿phase￿L1￿or￿to￿the DC￿positive￿wire￿and￿ground￿cable.￿This￿also￿gives￿further￿protection￿for￿customers￿and￿Service employees￿against￿the￿dangers￿of￿electricity. The￿LIM￿sends￿a￿signal￿for￿"Enable￿charging"￿for￿AC￿charging￿via￿the￿separate￿line￿to￿EME￿and￿KLE.
  • Page 133 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery For￿DC￿charging￿the￿LIM￿closes￿the￿two￿switch￿contactors￿in￿the￿KLE,￿thus￿enabling￿the￿shift￿through from￿the￿direct￿current￿voltage￿from￿the￿DC￿charging￿station￿to￿the￿high-voltage￿battery.￿The￿LIM￿tests after￿every￿completed￿DC￿charging￿procedure￿the￿DC￿switch￿contactors￿so￿that￿a￿switch￿contactor label￿(switch￿contactor￿cannot￿open￿the￿contacts)￿is￿identified.￿A￿switch￿contactor￿label￿(single￿or double)￿is￿identified￿by￿the￿LIM￿and￿sent￿to￿the￿EME￿as￿a￿fault￿code.￿If￿during￿the￿charging￿procedure no￿valid￿pilot￿signal￿is￿identified￿by￿the￿LIM,￿the￿LIM￿must￿open￿the￿DC￿switch￿contactors￿within 200 ms. The￿direct￿current￿voltage￿applied￿at￿the￿charging￿socket￿is￿measured￿by￿the￿KLE.￿The￿measured￿value is￿then￿sent￿to￿the￿LIM￿as￿an￿analog￿signal.￿The￿LIM￿then￿sends￿the￿calculated￿value￿via￿PT-CAN￿to other￿control￿units. Emergency￿charging If￿both￿the￿high-voltage￿and￿the￿12 V￿battery￿are￿discharged,￿the￿emergency￿charging￿of￿the￿12 V battery￿is￿automatically￿started￿when￿the￿charging￿cable￿is￿connected.￿As￿the￿two￿batteries￿are discharged,￿there￿is￿also￿no￿voltage￿supply￿of￿the￿12 V￿vehicle￿electrical￿system￿and￿the￿LIM￿is￿in￿this case￿initially￿not￿working.￿So￿that￿the￿LIM￿can￿start￿communication￿with￿the￿charging￿station￿and￿thus also￿the￿charging￿procedures,￿a￿special￿voltage￿supply￿of￿the￿LIM￿is￿required.￿The￿voltage￿supply￿for the￿LIM￿is￿effected￿in￿this￿case￿by￿the￿pilot￿line.￿The￿energy￿used￿by￿the￿pilot￿line￿is￿so￿low￿that￿the voltage￿evaluation￿for￿the￿EVSE￿is￿not￿affected. In￿order￿to￿identify￿emergency￿charging￿the￿voltage￿value￿of￿terminal￿30F￿is￿evaluated.￿The￿evaluation circuit￿is￿located￿in￿the￿LIM.￿If￿the￿voltage￿value￿of￿terminal￿30F￿falls￿below￿6 V￿and￿the￿pilot￿line￿is correctly￿connected,￿the￿evaluation￿circuit￿drags￿the￿voltage￿value￿on￿the￿pilot￿line￿to￿a￿value￿of￿6 V. This￿voltage￿value￿corresponds￿to￿the￿message￿at￿the￿charging￿station￿that￿the￿vehicle￿is￿ready￿for charging.￿The￿charging￿station￿is￿thus￿prompted￿to￿apply￿the￿vehicle￿voltage. 6.4.4.￿Convenience￿charging￿electronics￿(KLE) Convenience￿charging￿electronics￿for￿combo￿charging￿at￿7.4 kW￿AC￿charging￿power The￿KLE￿version￿installed￿for￿combo￿charging￿at￿7.4 kW￿AC￿charging￿power￿is￿responsible￿for￿the contact￿of￿all￿HV￿connections￿and￿the￿housing￿of￿the￿two￿DC￿switch￿contactors. In￿this￿case￿the￿KLE￿has￿no￿rectifier￿switching￿for￿the￿conversion￿of￿AC￿voltage￿to￿direct￿current voltage.￿The￿conversion￿of￿the￿AC￿voltage￿to￿direct￿current￿voltage￿takes￿place￿in￿the￿charging￿station. The￿full￿power￿of￿the￿AC￿network￿is￿used￿(all￿three￿phases).￿If￿all￿prerequisites￿for￿charging￿the￿high- voltage￿battery￿are￿satisfied,￿the￿LIM￿switches￿on￿the￿two￿switch￿contactors￿in￿the￿KLE.￿The￿charging station￿then￿provides￿the￿direct￿current￿voltage￿at￿the￿output￿for￿charging￿the￿high-voltage￿battery.￿The direct￿current￿voltage￿reaches￿the￿KLE￿via￿the￿charging￿socket￿and￿the￿high-voltage￿cables.￿The￿direct current￿voltage￿is￿directed￿via￿the￿high-voltage￿cables￿to￿the￿EME￿and￿then￿finally￿to￿the￿high-voltage battery.￿The￿high-voltage￿cables￿and￿the￿switch￿contactors￿are￿designed￿for￿an￿electrical￿power￿of￿up to￿50 kW.
  • Page 134 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery Convenience￿charging￿electronics￿for￿combo￿charging￿at￿7.4 kW￿AC￿charging￿power Index Explanation High-voltage￿cable￿(AC)￿from￿the￿charging￿socket High-voltage￿cable￿(DC)￿to￿the￿electrical￿machine￿electronics Low-voltage￿lines￿(for￿switching￿the￿switch￿contactors) Coolant￿line￿(supply) Low-voltage￿lines￿(signal￿connector) High-voltage￿cable￿(AC)￿from￿KLE￿to￿EME KLE￿mounting￿(potential￿compensation￿contact) High-voltage￿cable￿(DC)￿from￿REME Coolant￿line￿(return) High-voltage￿cable￿(DC)￿from￿the￿charging￿socket￿to￿the￿KLE Convenience￿charging￿electronics￿(KLE) With￿the￿combo￿charging￿at￿7.4 kW￿AC￿charging￿power￿the￿convenience￿charging￿electronics￿can convert￿both￿the￿single-phase￿AC￿voltage￿of￿the￿AC￿charging￿station￿to￿direct￿current￿voltage,￿and￿shift through￿the￿direct￿current￿voltage￿of￿the￿DC￿charging￿station￿for￿the￿electrical￿machine￿electronics and￿high-voltage￿battery￿using￿the￿DC￿switch￿contactors.￿The￿conversion￿of￿the￿AC￿voltage￿to￿the direct￿current￿voltage￿required￿for￿charging￿the￿high-voltage￿battery￿is￿done￿by￿the￿AC/DC￿converter at￿a￿maximum￿power￿of￿3.7 kW.￿The￿properties￿and￿function￿of￿the￿AC/DC￿converter￿were￿already...
  • Page 135 I01￿High-voltage￿Components 6.￿Charging￿the￿High-voltage￿Battery described￿in￿the￿previous￿chapter.￿Together￿with￿the￿standard￿AC/DC￿converter￿in￿the￿EME,￿which￿also provides￿an￿output￿power￿of￿3.7 kW,￿charging￿the￿high-voltage￿battery￿in￿the￿I01￿via￿the￿single-phase alternating￿current￿at￿7.4 kW￿is￿also￿possible. In￿this￿version￿of￿the￿convenience￿charging￿electronics￿two￿further￿switch￿contactors￿are￿housed￿which can￿shift￿through￿the￿direct￿current￿voltage￿of￿a￿DC￿charging￿station￿via￿the￿EME￿to￿the￿high-voltage battery.￿The￿function￿and￿activation￿of￿the￿switch￿contactors￿are￿described￿in￿the￿previous￿subchapter. At￿full￿performance￿of￿the￿AC/DC￿converter￿active￿cooling￿is￿required.￿The￿convenience￿charging electronics￿is￿therefore￿integrated￿in￿the￿cooling￿circuit￿of￿the￿electric￿motor.

  • Page 136: Ekk

    I01￿High-voltage￿Components 7.￿EKK Very￿high￿requirements￿are￿made￿of￿the￿heating￿and￿air-conditioning￿functions￿in￿the￿I01.￿On￿the￿one hand,￿the￿passenger￿compartment￿must￿always￿be￿at￿a￿pleasant￿temperature￿for￿the￿customer.￿On the￿other￿hand,￿in￿order￿to￿prolong￿the￿service￿life￿of￿the￿high-voltage￿battery,￿the￿high-voltage￿battery must￿be￿cooled￿at￿high￿temperatures. An￿EKK￿is￿used￿in￿the￿I01. The￿EKK￿is￿a￿high-voltage￿component￿ Only￿Service￿employees￿who￿satisfy￿all￿the￿prerequisites￿are￿permitted￿to￿work￿on￿the￿designated high-voltage￿components:￿suitable￿qualifications,￿compliance￿with￿the￿safety￿rules,￿procedure following￿the￿repair￿instructions￿to￿the￿letter. The￿diagnosis￿and￿repair￿of￿the￿high-voltage￿components￿is￿only￿allowed￿in￿a￿retail￿service center￿that￿has￿qualified￿and￿certified￿service￿technicians.￿These￿technicians￿must￿have completed￿the￿ST1403b￿I01￿High￿Voltage￿Battery￿and￿Maintenance￿instructor￿led￿course￿and successfully￿passed￿the￿hands￿on￿certification. 7.1.￿Location￿and￿connections The￿EKK￿is￿installed￿at￿the￿housing￿of￿the￿electrical￿machine. Installation￿location￿of￿EKK￿in￿the￿I01 Index Explanation Electrical￿machine High-voltage￿battery...
  • Page 137 I01￿High-voltage￿Components 7.￿EKK Mounting￿of￿the￿EKK￿at￿the￿electrical￿machine Index Explanation Screws Housing￿of￿the￿electrical￿machine The￿EKK￿is￿secured￿to￿the￿housing￿of￿the￿electrical￿machine￿using￿three￿screws. The￿housing￿of￿the￿EKK￿is￿mechanically￿disconnected￿from￿the￿housing￿of￿the￿electrical￿machine,￿thus improving￿the￿acoustic￿behavior.￿As￿the￿two￿housings￿are￿not￿connected,￿there￿is￿a￿separate￿potential compensation￿line￿of￿the￿housing￿of￿the￿EKK￿for￿the￿rear￿axle￿module￿(not￿shown￿in￿the￿graphic￿below).
  • Page 138 I01￿High-voltage￿Components 7.￿EKK Connections￿of￿the￿EKK￿in￿the￿I01￿(view￿from￿above) Index Explanation Low-voltage￿connector High-voltage￿connector Connection￿for￿intake￿pipe Silencer Connection￿for￿pressure￿line In￿the￿eight-pin￿signal￿connector￿the￿connections￿for￿local￿interconnect￿network￿bus,￿ground￿and￿the 12 V￿voltage￿supply￿(terminal￿30)￿are￿integrated. Special￿silencing￿in￿the￿pressure￿line￿provides￿for￿further￿acoustic￿comfort.￿The￿heating￿and￿air- conditioning￿is￿barely￿audible￿even￿when￿the￿vehicle￿is￿at￿a￿standstill.￿The￿mechanical￿disconnection￿of the￿EKK￿from￿the￿electrical￿machine￿also￿improves￿the￿acoustic￿behavior. 7.2.￿Structure￿of￿the￿electric￿A/C￿compressor When￿one￿talks￿about￿the￿EKK,￿the￿entire￿component￿is￿meant.￿The￿EKK￿comprises￿the￿following components:...
  • Page 139 I01￿High-voltage￿Components 7.￿EKK • Housing • EKK￿control￿unit • Three-phase￿current￿synchronous￿motor • AC￿inverter • Air￿conditioning￿compressor. These￿individual￿components￿are￿never￿replaced￿separately￿￿The￿entire￿EKK￿is￿always￿replaced.￿At￿this stage￿the￿tasks￿of￿some￿components￿are￿explained￿in￿order￿to￿better￿explain￿the￿function￿of￿the￿EKK. 7.2.1.￿EKK￿control￿unit The￿EKK￿control￿unit￿controls￿the￿engine￿speed￿of￿the￿three-phase￿motor￿in￿the￿EKK￿based￿on￿the requests￿of￿the￿IHKA￿and￿reports￿the￿operating￿status￿back￿to￿the￿IHKA￿control￿unit.￿The￿EKK￿control unit￿communicates￿with￿the￿IHKA￿via￿the￿LIN￿bus.￿The￿IHKA￿is￿the￿master￿control￿unit￿for￿the￿EKK. 7.2.2.￿Three-phase￿current￿synchronous￿motor A￿three-phase￿synchronous￿motor￿is￿used￿as￿the￿drive￿for￿the￿EKK.￿The￿energy￿is￿taken￿from￿the high-voltage￿battery.￿The￿necessary￿three-phase￿current￿is￿converted￿in￿the￿EKK￿using￿an￿AC￿inverter (DC/AC￿converter).￿The￿three-phase￿synchronous￿motor￿is￿operated￿in￿the￿engine￿speed￿range between￿860￿and￿8600 rpm￿and￿is￿infinitely￿variable.￿It￿uses￿an￿electrical￿power￿of￿up￿to￿4.5 kW.￿The maximum￿power￿is￿required,￿for￿example,￿at￿high￿ambient￿temperatures,￿high￿interior￿temperatures, high￿temperatures￿of￿the￿high-voltage￿battery￿and￿low￿air￿flow￿of￿the￿cooling￿module. 7.2.3.￿AC￿inverter The￿DC/AC￿converter￿converts￿the￿direct￿current￿voltage￿into￿the￿three-phase￿alternating￿current that￿is￿required￿to￿operate￿the￿three-phase￿synchronous￿motor.￿The￿EKK￿control￿unit￿and￿the￿DC/ AC￿converter￿are￿integrated￿in￿the￿aluminium￿housing￿of￿the￿EKK￿and￿are￿cooled￿by￿the￿gaseous refrigerant￿flowing￿past.￿If￿the￿temperature￿of￿the￿DC/AC￿converter￿exceeds￿125 °C,￿the￿high-voltage supply￿is￿shut￿off￿by￿the￿EKK￿control￿unit.￿The￿attempt￿is￿made￿through￿different￿measures￿such￿as speed￿increase￿for￿cooling￿initially￿not￿to￿allow￿the￿temperature￿to￿rise￿so￿high.￿The￿temperature￿is monitored￿by￿the￿electric￿A/C￿compressor￿control￿unit.￿If￿the￿temperature￿drops￿below￿112 °C,￿the EKK￿continues￿to￿run. The￿supply￿voltage￿for￿EKK￿has￿a￿voltage￿range￿of￿about￿200 V￿to￿410 V.￿The￿power￿is￿reduced￿above and￿below￿this￿voltage￿range￿or￿the￿EKK￿is￿switched￿off. 7.2.4.￿Air￿conditioning￿compressor To￿compress￿the￿refrigerant,￿the￿spiral￿compressor￿(also￿known￿as￿the￿scroll￿compressor)￿is￿used. R134a￿refrigerant￿is￿used￿for￿the￿US￿market.
  • Page 140 I01￿High-voltage￿Components 7.￿EKK Discs￿with￿spiral￿profile Index Explanation Shaft Inner￿disc￿with￿spiral￿profile Outer￿disc￿with￿spiral￿profile The￿inner￿disc￿with￿spiral￿profile￿is￿driven￿via￿a￿shaft￿by￿the￿three-phase￿current￿synchronous￿motor and￿rotates￿eccentrically.￿The￿gaseous￿refrigerant￿at￿low￿temperature￿and￿low￿pressure￿is￿drawn￿in through￿two￿openings￿in￿the￿fixed￿outer￿disc￿with￿spiral￿profile￿and￿compressed￿and￿heated￿by￿the movement￿of￿the￿two￿discs￿with￿spiral￿profiles. Principle￿of￿refrigerant￿compression After￿three￿revolutions,￿the￿refrigerant￿drawn￿in￿is￿compressed￿and￿heated￿and￿can￿escape￿in￿a gaseous￿state￿through￿an￿opening￿in￿the￿center￿of￿the￿outer￿disc.￿From￿here,￿gaseous￿refrigerant with￿high￿temperature￿and￿high￿pressure￿escapes￿via￿an￿oil￿separator￿at￿the￿connection￿of￿the￿A/C compressor￿towards￿the￿condenser.￿The￿EKK￿is￿operated￿at￿maximum￿8600 rpm￿and￿generates￿a maximum￿operating￿pressure￿of￿about￿30 bar. 7.3.￿High-voltage￿safety...
  • Page 141 I01￿High-voltage￿Components 7.￿EKK Functional￿wiring￿diagram￿for￿the￿EKK Index Explanation Low-voltage￿connector EKK￿(EKK￿control￿unit) High-voltage￿battery Electrical￿machine￿electronics Bidirectional￿AC/DC￿converter￿in￿the￿EME Electrical￿machine High-voltage￿connector￿at￿EKK Unidirectional￿inverter￿DC/AC￿converter￿in￿the￿EKK Three-phase￿current￿synchronous￿motor Temperature￿sensor Pressure￿sensor The￿high-voltage￿contacts￿of￿the￿round￿high-voltage￿connector￿for￿the￿EKK￿are￿protected￿against contact. The￿high-voltage￿connector￿of￿the￿EKK￿is￿not￿part￿of￿the￿circuit￿of￿the￿high-voltage￿interlock￿loop. The￿electrical￿capacity￿in￿the￿EKK￿is￿less￿than￿100￿µF.￿This￿capacity￿is￿discharged￿via￿a￿passive￿resistor in￿the￿EKK.￿After￿the￿EKK￿is￿shut￿down￿the￿voltage￿falls￿to￿below￿60 V￿in￿less￿than￿5￿seconds.
  • Page 142 I01￿High-voltage￿Components 8.￿Electric￿Heating Due￿to￿the￿high￿efficiency￿considerably￿less￿heat￿is￿emitted￿from￿the￿electrical￿machine￿than￿from combustion￿engines.￿The￿heat￿from￿the￿electrical￿machine￿can￿therefore￿not￿be￿used￿for￿heating.￿In order￿to￿be￿able￿to￿control￿the￿interior￿temperature￿of￿the￿passenger￿compartment,￿electric￿heating￿is installed￿in￿the￿I01. The￿electric￿heating￿is￿a￿high-voltage￿component￿ Only￿Service￿employees￿who￿satisfy￿all￿the￿prerequisites￿are￿permitted￿to￿work￿on￿the￿designated high-voltage￿components:￿suitable￿qualifications,￿compliance￿with￿the￿safety￿rules,￿procedure following￿the￿repair￿instructions￿to￿the￿letter. The￿diagnosis￿and￿repair￿of￿the￿high-voltage￿components￿is￿only￿allowed￿in￿a￿retail￿service center￿that￿has￿qualified￿and￿certified￿service￿technicians.￿These￿technicians￿must￿have completed￿the￿ST1403b￿I01￿High￿Voltage￿Battery￿and￿Maintenance￿instructor￿led￿course￿and successfully￿passed￿the￿hands￿on￿certification. 8.1.￿Location￿and￿connections The￿installation￿location￿of￿the￿electric￿heating￿is￿in￿the￿space￿below￿the￿engine￿compartment￿lid. Installation￿location￿of￿the￿electric￿heating Index Explanation Electric￿heating Coolant￿expansion￿tank...
  • Page 143 I01￿High-voltage￿Components 8.￿Electric￿Heating Connections￿at￿the￿electric￿heating Index Explanation Connection￿for￿coolant￿return Sensor￿for￿temperature￿of￿the￿coolant￿at￿the￿output￿of￿the￿electric￿heating Connection￿for￿potential￿compensation￿line Signal￿connector￿(low-voltage￿connector) Connection￿for￿sensor Connection￿for￿high-voltage￿connector Housing￿of￿the￿electric￿heating Connection￿for￿coolant￿return...
  • Page 144 I01￿High-voltage￿Components 8.￿Electric￿Heating 8.2.￿Operating￿principle Heating￿for￿the￿passenger￿compartment￿in￿the￿standard￿equipment Index Explanation Heat￿exchanger￿in￿the￿passenger￿compartment Electric￿heating Electric￿coolant￿pump￿(12 V) Coolant￿expansion￿tank The￿coolant￿is￿heated￿up￿in￿the￿electric￿heating￿and￿circulated￿by￿an￿electric￿coolant￿pump￿(20 W). The￿warm￿coolant￿flows￿through￿the￿heat￿exchanger￿in￿the￿passenger￿compartment￿and￿emits￿the heat.￿The￿warm￿air￿finally￿reaches￿the￿passenger￿compartment￿by￿means￿of￿a￿blower.￿The￿refrigerant￿is conveyed￿from￿the￿heat￿exchanger￿to￿the￿coolant￿expansion￿tank. A￿mixture￿of￿water￿and￿a￿new￿coolant￿concentrate￿called￿"coolant￿concentrate￿i3"￿is￿used￿as￿a￿coolant. The￿water￿and￿coolant￿concentrate￿are￿mixed￿in￿the￿ratio￿50:50.
  • Page 145 I01￿High-voltage￿Components 8.￿Electric￿Heating Index Explanation Connection￿for￿coolant￿supply￿from￿the￿electrical￿12 V￿coolant￿pump￿or￿with corresponding￿optional￿equipment￿from￿the￿heat￿pump￿capacitor Connection￿for￿coolant￿return￿(to￿the￿heat￿exchanger￿for￿the￿passenger compartment) Sensor￿for￿temperature￿of￿the￿coolant￿at￿the￿output￿of￿the￿electric￿heating High-voltage￿connection Three￿heater￿coils The￿maximum￿electrical￿power￿of￿the￿electric￿heating￿is￿5.5 kW￿(280 V￿x￿20 A).￿The￿electric￿heating￿is done￿by￿three￿heater￿coils,￿each￿with￿a￿power￿of￿about￿0.75 kW,￿1.5 kW￿and￿2.25 kW.￿The￿switching of￿the￿heater￿coils￿(individually￿or￿together)￿is￿effected￿within￿the￿electric￿heating￿using￿an￿electronic switch￿(Power￿MOSFET).
  • Page 146 I01￿High-voltage￿Components 8.￿Electric￿Heating Functional￿wiring￿diagram￿for￿the￿electric￿heating Index Explanation Low-voltage￿connector Sensor￿for￿temperature￿of￿the￿printed￿circuit￿board￿of￿the￿control￿unit￿for electric￿heating Sensor￿for￿temperature￿of￿the￿return￿coolant Electric￿heating￿(control￿unit) High-voltage￿battery Electrical￿machine￿electronics Bidirectional￿AC/DC￿converter￿in￿the￿EME Electrical￿machine High-voltage￿connector￿at￿electric￿heating Hardware￿shutdown￿in￿the￿event￿of￿excessive￿current￿in￿heater￿coil￿3 Hardware￿shutdown￿in￿the￿event￿of￿excessive￿current￿in￿heater￿coil￿2 Hardware￿shutdown￿in￿the￿event￿of￿excessive￿current￿in￿heater￿coil￿1 Electronic￿switch￿(Power￿MOSFET)￿for￿heater￿coil￿1 Electronic￿switch￿(Power￿MOSFET)￿for￿heater￿coil￿2...
  • Page 147 I01￿High-voltage￿Components 8.￿Electric￿Heating Index Explanation Electronic￿switch￿(Power￿MOSFET)￿for￿heater￿coil￿3 Heater￿coil￿1 Heater￿coil￿2 Heater￿coil￿3 The￿current￿through￿the￿individual￿strands￿is￿measured￿and￿controlled￿by￿the￿electric￿heating￿control unit.￿A￿current￿of￿maximum￿20￿A￿flows￿in￿a￿voltage￿range￿of￿250 V￿to￿400 V.￿The￿power￿is￿reduced above￿and￿below￿this￿voltage￿range.￿At￿increased￿power￿consumption￿the￿energy￿supply￿by￿the hardware￿switching￿is￿interrupted.￿This￿switching￿is￿designed￿so￿that￿even￿in￿the￿event￿of￿a￿fault￿in￿the control￿unit￿a￿power￿cut￿is￿effected￿safely. The￿temperature￿of￿the￿coolant￿is￿measured￿using￿a￿sensor￿at￿the￿output￿of￿the￿electric￿heating. Inside￿the￿electric￿heating￿a￿galvanic￿separation￿was￿installed￿between￿the￿high-voltage￿circuit￿and￿the low-voltage￿circuit. The￿connections￿for￿local￿interconnect￿network￿bus￿and￿voltage￿supply￿(terminal￿30B)￿are￿located￿at the￿low-voltage￿connector. A￿bridge￿is￿integrated￿in￿the￿high-voltage￿connector￿beside￿the￿contacts￿for￿the￿high￿voltage.￿The contacts￿of￿the￿bridge￿in￿the￿high-voltage￿connector￿are￿designed￿as￿leading￿contacts.￿This￿means when￿removing￿the￿high-voltage￿connector￿the￿contacts￿of￿the￿high-voltage￿bridge￿are￿separated￿first. As￿a￿result,￿the￿voltage￿supply￿of￿the￿control￿unit￿(EH)￿is￿interrupted.￿This￿also￿means￿the￿high-voltage supply￿is￿interrupted￿before￿the￿high-voltage￿connector￿is￿pulled￿out￿fully.￿No￿electric￿arc￿thus￿arises on￿the￿high-voltage￿contacts.￿The￿high-voltage￿contacts￿are￿protected￿from￿contact.￿The￿high-voltage connector￿of￿the￿electric￿heating￿is￿not￿part￿of￿the￿circuit￿of￿the￿high-voltage￿interlock￿loop. 8.3.￿Control￿system Six￿heating￿stages￿can￿be￿set￿through￿separate￿or￿combined￿activation￿of￿the￿individual￿heater￿coils. The￿request￿for￿switching￿on￿the￿heating￿comes￿from￿the￿IHKA￿control￿unit￿via￿local￿interconnect network￿bus. Heater￿coil Heating￿stage 1￿+￿3 2￿+￿3 1￿+￿2￿+￿3 When￿the￿maximum￿temperature￿is￿reached￿or￿if￿the￿maximum￿permissible￿current￿level￿is￿exceeded, the￿heater￿output￿is￿automatically￿restricted￿by￿the￿electric￿heating￿control￿unit. The￿electric￿heating￿is￿switched￿off￿in￿the￿event￿of￿system￿faults. The￿electric￿heating￿is￿maintenance-free.

  • Page 148: Introduction

    I01￿High-voltage￿Components 9.￿Range￿Extender￿Electrical￿Machine 9.1.￿Introduction The￿high-voltage￿components￿examined￿up￿to￿now￿pave￿the￿way￿for￿a￿pure￿electric￿driving￿of￿the I01.￿The￿electrical￿machine￿receives￿the￿energy￿required￿for￿the￿electric￿motor￿from￿the￿high-voltage battery.￿The￿EME￿converts￿the￿direct￿current￿voltage￿from￿the￿high-voltage￿battery￿into￿3-phase￿AC voltage. The￿I01￿with￿a￿pure￿electric￿driving￿is￿designed￿so￿that￿a￿distance￿of￿about￿150 km￿/￿93￿mi￿(115￿mi using￿efficiency￿mode)￿can￿be￿covered￿before￿the￿high-voltage￿battery￿must￿be￿charged￿up￿again.￿The high-voltage￿battery￿can￿also￿be￿charged￿at￿an￿earlier￿stage. A￿I01￿which￿is￿equipped￿with￿a￿range￿extender￿can￿cover￿a￿distance￿of￿about￿300 km￿/￿186￿mi￿(200 mi￿using￿efficiency￿mode)￿before￿the￿high-voltage￿battery￿has￿to￿be￿charged￿or￿the￿tank￿has￿to￿be refuelled.￿This￿means￿a￿I01￿with￿range￿extender￿offers￿double￿the￿range￿in￿comparison￿to￿a￿I01￿with￿a purely￿electric￿motor. Also￿in￿the￿I01￿with￿range￿extender￿the￿electric￿motor￿with￿energy￿from￿the￿high-voltage￿battery￿is￿used as￿a￿primary￿drive￿type.￿The￿range￿extender￿system￿is￿only￿activated￿when￿the￿state￿of￿charge￿of￿the high-voltage￿battery￿falls￿below￿a￿certain￿value. The￿range￿extender￿system￿consists￿of￿the￿following￿components: • W20￿Combustion￿engine • Range￿extender￿electrical￿machine • Range￿Extender￿Electrical￿Machine￿Electronics • Range￿Extender￿Digital￿Engine￿Electronics. The￿W20￿combustion￿engine￿is￿a￿2-cylinder￿engine.￿It￿is￿a￿small,￿very￿smooth-running￿and￿quiet gasoline￿engine,￿which￿is￿connected￿mechanically￿to￿the￿range￿extender￿electrical￿machine￿via￿a geared￿shaft.￿At￿a￿low￿state￿of￿charge￿of￿the￿high-voltage￿battery￿the￿W20￿engine￿is￿started￿using￿the range￿extender￿electrical￿machine.￿In￿this￿case￿the￿range￿extender￿electrical￿machine￿works￿in￿engine mode.￿The￿electrical￿energy￿for￿starting￿the￿W20￿engine￿comes￿from￿the￿high-voltage￿battery.￿As￿soon as￿the￿W20￿has￿been￿started,￿the￿range￿extender￿electrical￿machine￿changes￿from￿engine￿to￿alternator mode￿and￿generates￿electrical￿energy￿which￿is￿used￿for￿the￿electric￿motor￿of￿the￿vehicle￿via￿the￿(main) electrical￿machine.￿The￿W20￿engine￿is￿not￿connected￿mechanically￿to￿the￿sprockets.￿The￿mechanical energy￿of￿the￿W20￿engine￿is￿converted￿by￿the￿range￿extender￿electrical￿machine￿solely￿into￿electrical energy.￿The￿(main)￿electrical￿machine￿uses￿this￿electrical￿energy￿and￿converts￿it￿to￿mechanical￿energy to￿drive￿the￿rear￿wheels.￿The￿layout￿of￿these￿components￿corresponds￿to￿a￿serial￿hybrid￿car. In￿this￿chapter￿the￿range￿extender￿electrical￿machine￿is￿described￿and￿in￿the￿next￿chapter￿details￿are provided￿on￿the￿range￿extender￿electrical￿machine￿electronics. The￿W20￿engine￿and￿the￿engine￿control￿of￿the￿range￿extender￿digital￿engine￿electronics￿are￿described in￿the￿product￿information￿bulletin￿"W20￿Engine".
  • Page 149 I01￿High-voltage￿Components 9.￿Range￿Extender￿Electrical￿Machine Size Value Nominal￿voltage 250 V Continuous￿power,￿electrical about￿23.3 kW￿electrical￿DC￿power￿at￿4300 rpm and￿330 V￿DC Efficiency about￿94% Outer￿diameter about￿300 mm Length about￿115 mm Weight about￿26 kg The￿range￿extender￿electrical￿machine￿is￿supplied￿by￿Valeo. Installation￿location￿of￿the￿range￿extender￿electrical￿machine Index Explanation Rear￿axle￿module Range￿extender￿electrical￿machine Range￿extender￿(W20￿engine)

  • Page 150: Design

    I01￿High-voltage￿Components 9.￿Range￿Extender￿Electrical￿Machine The￿range￿extender￿electrical￿machine￿is￿installed￿in￿the￿rear￿of￿the￿I01. 9.3.￿Design The￿range￿extender￿electrical￿machine￿in￿the￿I01￿is￿a￿synchronous￿machine.￿Its￿general￿structure￿and operating￿principle￿correspond￿to￿those￿of￿a￿permanently￿excited￿synchronous￿machine￿with￿internal rotor:￿The￿rotor￿is￿located￿inside￿and￿is￿equipped￿with￿permanent￿magnets.￿The￿stator￿is￿ring-shaped and￿located￿outside￿around￿the￿rotor.￿It￿is￿shaped￿with￿iron￿cores￿through￿the￿3-phase￿coils.￿If￿a￿3- phase￿AC￿voltage￿is￿applied￿to￿the￿stator￿coils,￿they￿generate￿a￿rotating￿magnetic￿field,￿which￿"pulls" the￿magnets￿in￿the￿rotor￿(in￿engine￿operation). 9.3.1.￿Cooling Connections￿for￿coolant￿lines Index Explanation Range￿extender￿electrical￿machine Connection￿for￿coolant￿line￿(supply) Connection￿for￿coolant￿line￿(return) Retaining￿springs￿for￿the￿coating Ventilation...

  • Page 151: Sensors

    I01￿High-voltage￿Components 9.￿Range￿Extender￿Electrical￿Machine The￿electrical￿machine￿is￿designed￿for￿a￿large￿temperature￿range.￿The￿coolant￿can￿reach￿a￿temperature of￿up￿to￿70 °C￿(158￿°F)￿at￿the￿input￿(supply)￿at￿a￿flow￿of￿six￿liters￿per￿minute.￿The￿temperature￿at the￿input￿is￿time-restricted￿and￿can￿rise￿up￿to￿85 °C￿(185￿°F).￿And￿although￿the￿electrical￿machine demonstrates￿less￿losses￿during￿energy￿conversion￿than￿a￿combustion￿engine,￿its￿housing￿can￿absorb a￿temperature￿of￿up￿to￿100 °C￿(212￿°F). The￿two￿connections￿for￿the￿coolant￿lines￿integrate￿the￿range￿extender￿electrical￿machine￿in￿the cooling￿circuit￿of￿the￿electric￿motor.￿This￿is￿described￿in￿the￿chapter￿"Cooling￿of￿electric￿motor components".￿The￿graphics￿in￿this￿chapter￿show￿the￿range￿extender￿electrical￿machine￿and￿the￿W20 engine￿without￿coating.￿In￿the￿production￿vehicle￿sometimes￿these￿components￿are￿still￿covered￿by￿a foam￿part.￿This￿serves￿for￿the￿acoustic￿encapsulation￿of￿the￿range￿extender￿components￿and￿absorbs noises￿which￿the￿customer￿may￿find￿irritating. The￿housing￿of￿the￿range￿extender￿electrical￿machine￿is￿airtight￿and￿waterproof.￿A￿vent￿line￿is￿required to￿prevent￿water￿(resulting￿from￿temperature￿changes￿and￿thus￿possible￿condensation￿of￿air￿humidity) collecting￿inside￿the￿range￿extender￿electrical￿machine. 9.3.2.￿Sensors Temperature￿sensor In￿order￿to￿avoid￿damage￿to￿the￿components￿due￿to￿the￿high￿temperature,￿there￿is￿a￿temperature sensor￿in￿the￿range￿extender￿electrical￿machine￿of￿the￿I01.￿The￿temperature￿sensor￿is￿a￿temperature- dependent￿resistor￿and￿is￿located￿in￿the￿coils￿of￿the￿stator.￿The￿temperature￿of￿the￿rotor￿is￿not measured￿directly,￿but￿can￿be￿determined￿from￿the￿measured￿values￿of￿the￿temperature￿sensors￿in the￿stator.￿The￿signal￿is￿read￿in￿and￿evaluated￿analogously￿by￿the￿range￿extender￿electrical￿machine electronics. Rotor￿position￿sensor The￿rotor￿position￿sensor￿cannot￿be￿replaced￿in￿Service￿...
  • Page 152 I01￿High-voltage￿Components 9.￿Range￿Extender￿Electrical￿Machine Rotor￿position￿sensor￿in￿range￿extender￿electrical￿machine Index Explanation Rotor￿position￿sensor￿in￿the￿range￿extender￿electrical￿machine Connection￿for￿rotor￿position￿sensor Connection￿for￿temperature￿sensor So￿that￿the￿voltages￿for￿the￿coils￿in￿the￿stator￿can￿be￿correctly￿calculated￿and￿generated￿by￿the￿range extender￿electrical￿machine￿electronics￿in￿terms￿of￿amplitude￿and￿phase￿layer,￿the￿precise￿angle setting￿of￿the￿rotor￿must￿be￿known.￿This￿is￿why￿there￿is￿also￿a￿rotor￿position￿sensor￿in￿the￿range extender￿electrical￿machine. The￿rotor￿position￿sensor￿is￿secured￿at￿the￿stator￿of￿the￿range￿extender￿electrical￿machine￿and￿works according￿to￿the￿tilt￿sensor￿principle.￿There￿are￿three￿coils￿in￿the￿rotor￿position￿sensor.￿A￿defined AC￿voltage￿is￿fed￿to￿one￿of￿the￿coils.￿The￿other￿two￿coils￿are￿each￿moved￿90°.￿The￿voltages￿induced in￿these￿coils￿provide￿information￿about￿the￿angle￿setting￿of￿the￿rotor.￿The￿rotor￿position￿sensor￿is mounted￿by￿the￿manufacturer￿of￿the￿range￿extender￿electrical￿machine￿at￿the￿corresponding￿alignment so￿that￿it￿is￿already￿correctly￿adjusted.
  • Page 153 I01￿High-voltage￿Components 9.￿Range￿Extender￿Electrical￿Machine 9.4.￿External￿characteristics￿and￿interfaces 9.4.1.￿Mechanical￿interfaces Mounting￿of￿the￿range￿extender￿electrical￿machine Index Explanation W20￿Combustion￿engine Mounting￿bolts￿for￿range￿extender￿electrical￿machine￿(x6) Range￿extender￿electrical￿machine Cover￿over￿the￿rotor￿position￿sensor The￿range￿extender￿electrical￿machine￿is￿secured￿at￿the￿crankcase￿of￿the￿W20￿engine￿using￿six screws. The￿power￿transmission￿between￿the￿crankshaft￿of￿the￿combustion￿engine￿and￿the￿range￿extender electrical￿machine￿is￿effected￿via￿a￿geared￿shaft.
  • Page 154 I01￿High-voltage￿Components 9.￿Range￿Extender￿Electrical￿Machine The￿cover￿over￿the￿rotor￿position￿sensor￿cannot￿be￿removed￿ Geared￿shaft￿for￿the￿power￿transmission Index Explanation Range￿extender￿electrical￿machine O-ring￿seal Grooved￿ball￿bearing Sealing￿ring Geared￿shaft The￿range￿extender￿electrical￿machine￿can￿be￿removed￿separately￿from￿the￿W20￿engine￿using￿a separate￿tool. Please￿refer￿to￿the￿repair￿instructions￿for￿the￿exact￿procedure.
  • Page 155 I01￿High-voltage￿Components 9.￿Range￿Extender￿Electrical￿Machine 9.4.2.￿Electrical￿interfaces There￿are￿both￿connections￿for￿the￿two￿sensors￿and￿also￿a￿high-voltage￿connection￿at￿the￿range extender￿electrical￿machine.￿The￿connections￿for￿the￿temperature￿sensor￿and￿the￿rotor￿position￿sensor were￿shown￿and￿described￿in￿the￿previous￿section. High-voltage￿connection￿at￿the￿range￿extender￿electrical￿machine Index Explanation Range￿extender￿electrical￿machine High-voltage￿connection￿at￿the￿range￿extender￿electrical￿machine Screws￿for￿mounting￿the￿high-voltage￿connection High-voltage￿connector￿and￿line￿to￿the￿REME 9.4.3.￿Coolant￿connections The￿two￿connections￿for￿the￿coolant￿lines￿integrate￿the￿range￿extender￿electrical￿machine￿in￿the cooling￿circuit￿of￿the￿electric￿motor.￿This￿is￿described￿in￿the￿chapter￿"Cooling￿of￿electric￿motor components".

  • Page 156: Reme

    I01￿High-voltage￿Components 10.￿REME 10.1.￿Introduction The￿main￿task￿of￿the￿range￿extender￿electrical￿machine￿electronics￿is￿to￿control￿the￿range￿extender electrical￿machine.￿It￿converts￿the￿direct￿current￿voltage￿from￿the￿high-voltage￿battery￿into￿a￿three- phase￿AC￿voltage￿(up￿to￿about￿420 V￿AC)￿for￿the￿activation￿of￿the￿range￿extender￿electrical￿machine￿as an￿engine.￿Currents￿of￿up￿to￿200￿A￿can￿flow.￿Vice￿versa,￿when￿the￿range￿extender￿electrical￿machine works￿as￿an￿alternator,￿the￿range￿extender￿electrical￿machine￿electronics￿converts￿the￿three-phase￿AC voltage￿of￿the￿range￿extender￿electrical￿machine￿to￿a￿direct￿current￿voltage￿and￿can￿thus￿supply￿the energy￿for￿the￿electric￿motor￿of￿the￿I01.￿The￿continuous￿phase￿currents￿of￿about￿130￿A￿flow.￿For￿these two￿operating￿modes￿a￿bidirectional￿DC/AC￿converter￿is￿necessary￿which￿can￿work￿as￿both￿an￿inverter and￿a￿rectifier. The￿entire￿range￿extender￿electrical￿machine￿electronics￿of￿the￿I01￿is￿located￿in￿an￿aluminium￿housing. This￿housing￿accommodates￿the￿control￿unit￿and￿the￿bidirectional￿DC/AC. The￿range￿extender￿electrical￿machine￿electronics￿is￿a￿high-voltage￿component￿ Only￿Service￿employees￿who￿satisfy￿all￿the￿prerequisites￿are￿permitted￿to￿work￿on￿the￿designated high-voltage￿components:￿suitable￿qualifications,￿compliance￿with￿the￿safety￿rules,￿procedure following￿the￿repair￿instructions￿to￿the￿letter. The￿diagnosis￿and￿repair￿of￿the￿high-voltage￿components￿is￿only￿allowed￿in￿a￿retail￿service center￿that￿has￿qualified￿and￿certified￿service￿technicians.￿These￿technicians￿must￿have completed￿the￿ST1403b￿I01￿High￿Voltage￿Battery￿and￿Maintenance￿instructor￿led￿course￿and successfully￿passed￿the￿hands￿on￿certification. The￿housing￿of￿the￿range￿extender￿electrical￿machine￿electronics￿cannot￿be￿opened￿in￿Service. The￿range￿extender￿electrical￿machine￿electronics￿of￿the￿I01￿was￿developed￿and￿supplied￿by￿Bosch. The￿efficiency￿of￿the￿REME￿is￿96%.￿The￿weight￿of￿the￿REME￿is￿about￿6 kg. 10.2.￿Installation￿location￿and￿mounting The￿range￿extender￿electrical￿machine￿electronics￿is￿installed￿in￿the￿rear￿of￿the￿I01,￿in￿an￿area separated￿from￿the￿luggage￿compartment.
  • Page 157 I01￿High-voltage￿Components 10.￿REME Installation￿location￿of￿the￿REME The￿REME￿is￿secured￿at￿the￿rear￿axle￿module￿on￿the￿right￿using￿three￿screws. REME￿at￿rear￿axle￿module...
  • Page 158 I01￿High-voltage￿Components 10.￿REME Index Explanation Rear￿axle￿module Screws￿for￿mounting￿the￿heat￿shield Screws￿for￿mounting￿the￿REME￿at￿the￿rear￿axle￿module REME Heat￿shield￿for￿REME The￿heating￿of￿the￿REME￿by￿the￿combustion￿engine￿is￿reduced￿by￿a￿heat￿shield.￿The￿heat￿shield￿is secured￿to￿the￿REME￿using￿three￿screws.￿In￿order￿to￿remove￿the￿flat￿high-voltage￿connector￿and￿the signal￿connector￿from￿the￿REME,￿this￿heat￿shield￿has￿to￿be￿removed. 10.3.￿Connections￿at￿REME The￿following￿graphics￿show￿all￿the￿connections￿of￿the￿range￿extender￿electrical￿machine￿electronics. Details￿of￿the￿individual￿categories￿are￿provided￿in￿the￿following￿chapters.
  • Page 159 I01￿High-voltage￿Components 10.￿REME Connections￿at￿REME￿with￿lines Index Explanation Coolant￿line￿(return) Coolant￿line￿(supply) Signal￿line￿from￿the￿vehicle￿electrical￿system Potential￿compensation￿line Screw￿connection￿of￿the￿potential￿compensation￿screw￿at￿the￿rear￿axle￿module Screw￿connection￿of￿the￿potential￿compensation￿screw￿at￿the￿REME Range￿Extender￿Electrical￿Machine￿Electronics Signal￿connector 3-phase￿high-voltage￿cable￿to￿the￿range￿extender￿electrical￿machine Signal￿line￿from￿the￿range￿extender￿electrical￿machine Two-phase￿high-voltage￿cable￿to￿the￿EME￿or￿KLE...
  • Page 160 I01￿High-voltage￿Components 10.￿REME For￿a￿better￿overview￿the￿connections￿at￿the￿REME￿are￿shown￿without￿lines. Connections￿at￿the￿REME￿without￿connected￿lines Index Explanation Coolant￿connection￿(return) Coolant￿connection￿(supply) Potential￿compensation￿line Screw￿connection￿of￿the￿potential￿compensation￿screw￿at￿the￿REME Range￿Extender￿Electrical￿Machine￿Electronics Connection￿for￿signal￿connector Connection￿for￿three-phase￿high-voltage￿cable￿from￿the￿range￿extender electrical￿machine Connection￿for￿the￿two-pin￿high-voltage￿cable￿from￿the￿EME￿or￿KLE The￿connections￿at￿the￿range￿extender￿electrical￿machine￿electronics￿can￿be￿divided￿into￿four categories:...
  • Page 161 I01￿High-voltage￿Components 10.￿REME • Low-voltage￿connections • High-voltage￿connections • Connection￿for￿potential￿compensation￿line • Connections￿for￿coolant￿lines. 10.3.1.￿Low-voltage￿connections In￿the￿multipolar￿low-voltage￿connector￿at￿the￿range￿extender￿electrical￿machine￿electronics￿two￿multi- core￿lines￿with￿the￿following￿signals￿are￿combined: • Voltage￿supply￿for￿the￿REME￿control￿unit￿(terminal￿30B￿and￿ground￿connection) • PT-CAN￿2 • Two￿lines￿from￿the￿ACSM￿for￿the￿signal￿for￿the￿quick￿shutdown￿of￿the￿high-voltage￿system￿in the￿event￿of￿an￿accident￿of￿corresponding￿severity • Wake-up￿line • Input￿and￿output￿of￿the￿circuit￿of￿the￿high-voltage￿interlock￿loop￿(REME￿control￿unit￿does￿not evaluate￿the￿signal) • Rotor￿position￿sensor￿of￿the￿electrical￿machine￿(supply￿and￿sensor￿signals) • Signal￿of￿the￿temperature￿sensor￿in￿the￿stator￿coils￿of￿the￿electrical￿machine. These￿lines￿and￿signals￿have￿relatively￿low￿current￿levels. 10.3.2.￿High-voltage￿connections Two￿high-voltage￿cables￿are￿connected￿at￿the￿REME: • 3-phase￿high-voltage￿cable￿from￿the￿range￿extender￿electrical￿machine • Two-pin￿high-voltage￿cable￿from￿the￿KLE.
  • Page 162 I01￿High-voltage￿Components 10.￿REME High-voltage￿cables￿at￿the￿REME Index Explanation Range￿Extender￿Electrical￿Machine￿Electronics Flat￿two-pin￿high-voltage￿connector Range￿extender￿electrical￿machine 3-phase￿high-voltage￿connector￿at￿range￿extender￿electrical￿machine 3-phase￿high-voltage￿connector￿at￿range￿extender￿electrical￿machine electronics The￿procedure￿for￿removing￿the￿flat￿high-voltage￿connector￿was￿already￿described￿in￿chapter￿2￿of￿this product￿information￿bulletin. Three￿screws￿must￿be￿slackened￿to￿remove￿the￿3-phase￿high-voltage￿connector￿at￿the￿REME.
  • Page 163 I01￿High-voltage￿Components 10.￿REME 3-phase￿high-voltage￿connector￿at￿the￿REME Index Explanation Range￿Extender￿Electrical￿Machine￿Electronics Bridge￿for￿high-voltage￿interlock￿loop Screw￿for￿securing￿the￿high-voltage￿connector￿at￿the￿REME￿(under￿the￿bridge) Three-phase￿high-voltage￿connector Screws￿for￿securing￿the￿high-voltage￿connector￿at￿the￿REME Two￿of￿the￿three￿screws￿are￿accessible￿and￿can￿be￿easily￿slackened.￿To￿slacken￿the￿third￿screw￿the bridge￿of￿the￿high-voltage￿interlock￿loop￿must￿be￿removed￿first.￿Only￿then￿is￿the￿third￿screw￿visible￿and it￿can￿be￿slackened.￿Separating￿the￿bridge￿of￿the￿high-voltage￿interlock￿loop￿causes￿the￿high-voltage system￿to￿shut￿down. The￿connection￿of￿the￿two-pin￿line￿from￿the￿REME￿is￿dependent￿on￿the￿vehicle￿equipment.
  • Page 164 I01￿High-voltage￿Components 10.￿REME High-voltage￿connections￿at￿the￿REME Index Explanation Range￿extender￿electrical￿machine 3-phase￿high-voltage￿cables￿between￿range￿extender￿electrical￿machine￿and REME Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Electrical￿machine￿electronics￿(EME) Two-pin￿high-voltage￿cable￿between￿KLE Convenience￿charging￿electronics￿KLE Two-pin￿high-voltage￿cable￿between￿KLE￿and￿EME Three-phase￿high-voltage￿cable￿between￿EME￿and￿electrical￿machine Electrical￿machine Two-pin￿high-voltage￿cable￿between￿EME￿and￿high-voltage￿battery High-voltage￿battery...
  • Page 165 I01￿High-voltage￿Components 10.￿REME If￿a￿convenience￿charging￿electronics￿is￿installed￿in￿the￿vehicle,￿the￿REME￿is￿connected￿via￿a￿two-pin HV￿cable￿and￿a￿flat￿HV￿connector￿to￿the￿KLE.￿The￿KLE￿is￿also￿connected￿to￿the￿EME￿via￿a￿two-pin high-voltage￿cable￿and￿a￿flat￿high-voltage￿connector.￿The￿3-phase￿AC￿voltage￿generated￿by￿the￿range extender￿electrical￿machine￿is￿converted￿by￿the￿REME￿to￿direct￿current￿voltage￿and￿fed￿from￿the￿REME via￿the￿KLE￿to￿the￿EME￿via￿the￿high-voltage￿cables.￿The￿energy￿required￿to￿start￿the￿range￿extender combustion￿engine￿is￿provided￿by￿the￿high-voltage￿battery.￿The￿direct￿current￿voltage￿is￿directed￿via the￿EME￿and￿KLE￿to￿the￿REME￿by￿two-pin￿high-voltage￿cables.￿The￿EME￿and￿the￿KLE￿do￿not￿convert this￿direct￿current￿voltage,￿it￿is￿used￿solely￿for￿the￿contact.￿With￿this￿type￿of￿contact￿(via￿KLE)￿only￿one version￿of￿the￿EME￿(irrespective￿of￿the￿equipment)￿has￿to￿be￿installed￿in￿the￿I01. 10.3.3.￿Connections￿for￿coolant￿lines The￿range￿extender￿electrical￿machine￿electronics￿is￿integrated￿in￿the￿cooling￿circuit￿of￿the electric￿motor.￿This￿cooling￿circuit￿is￿described￿in￿detail￿in￿chapter￿11￿"Cooling￿the￿electric￿motor components". 10.3.4.￿Connection￿for￿potential￿compensation￿line The￿housing￿of￿the￿REME￿is￿connected￿to￿the￿rear￿axle￿module￿and￿thus￿ground￿via￿a￿potential compensation￿line.￿The￿potential￿compensation￿line￿is￿secured￿using￿a￿screw￿connection. 10.4.￿Structure￿and￿functions The￿range￿extender￿electrical￿machine￿electronics￿is￿made￿up￿internally￿of￿two￿subcomponents: the￿bidirectional￿DC/AC￿converter￿and￿the￿REME￿control￿unit.￿The￿link￿capacitors￿for￿smoothing￿the voltage￿and￿filtering￿high-frequency￿parts￿are￿also￿an￿element￿of￿the￿power￿electronics￿switching.￿It performs￿the￿following￿functions￿with￿help￿of￿the￿subcomponents￿mentioned: • Control￿of￿the￿electrical￿machine￿(engine￿speed,￿torque)￿using￿DC/AC￿converter • Reading￿and￿evaluation￿of￿the￿temperature￿sensor￿of￿the￿range￿extender￿electrical￿machine • Reading￿and￿evaluation￿of￿the￿rotor￿position￿sensor • Contact￿of￿the￿range￿extender￿electrical￿machine • Contact￿of￿the￿electrical￿machine￿electronics￿or￿the￿convenience￿charging￿electronics • Communication￿with￿other￿control￿units • Active￿and￿passive￿discharging￿of￿the￿link￿capacitors￿to￿voltages￿less￿then￿60 V • Self-test￿and￿diagnostic￿function The￿power￿electronics￿for￿the￿activation￿of￿the￿electrical￿machine￿are￿mainly￿made￿up￿of￿the bidirectional￿DC/AC￿converter.￿It￿is￿a￿pulse￿converter￿(also￿called￿"inverter")￿with￿a￿two-pin￿DC￿voltage...
  • Page 166 I01￿High-voltage￿Components 10.￿REME Input/Output￿of￿REME Index Explanation Body￿Domain￿Controller￿(BDC) Terminal￿status Electrical￿machine￿electronics￿(EME) Setpoint￿value,￿engine￿speed Crash￿Safety￿Module￿(ACSM) Signal￿for￿quick￿shutdown￿of￿the￿high-voltage￿system￿in￿the￿event￿of￿an accident Battery￿management￿electronics￿(SME) Information￿about￿the￿state￿of￿charge￿of￿the￿high-voltage￿battery Rotor￿position￿sensor￿of￿the￿range￿extender￿electrical￿machine Signal￿from￿rotor￿position￿sensor Range￿Extender￿Electrical￿Machine￿Electronics￿(REME)
  • Page 167 I01￿High-voltage￿Components 10.￿REME Index Explanation Temperature￿sensor￿of￿the￿range￿extender￿electrical￿machine Signal￿from￿temperature￿sensor Range￿extender￿electrical￿machine Bidirectional￿energy￿flow￿between￿REME￿and￿range￿extender￿electrical machine High-voltage￿battery Bidirectional￿energy￿flow￿between￿REME￿and￿high-voltage￿battery The￿operating￿mode￿of￿the￿DC/AC￿converter￿is￿defined￿by￿the￿REME￿control￿unit.￿The￿REME￿control unit￿receives￿the￿setpoint￿value￿as￿an￿important￿input￿variable￿from￿the￿EME￿control￿unit.￿From￿this setpoint￿value￿and￿the￿current￿operating￿condition￿of￿the￿range￿extender￿electrical￿machine￿(engine speed￿and￿torque)￿the￿REME￿control￿unit￿determines￿the￿operating￿mode￿of￿the￿DC/AC￿converter,￿as well￿as￿the￿amplitude￿and￿frequency￿of￿the￿phase￿voltages￿for￿the￿range￿extender￿electrical￿machine. According￿to￿these￿specifications,￿the￿power￿semiconductors￿of￿the￿DC/AC￿converter￿are￿activated￿in sync. In￿addition￿to￿the￿DC/AC￿converter,￿the￿power￿electronics￿also￿contains￿current￿sensors￿in￿all￿three phases￿on￿the￿AC￿voltage￿side￿of￿the￿DC/AC￿converter.￿Using￿the￿signals￿from￿the￿current￿sensors,￿the REME￿control￿unit￿monitors￿the￿electrical￿power￿which￿is￿used￿in￿the￿power￿electronics￿and￿the￿range extender￿electrical￿machine￿and￿what￿torque￿the￿range￿extender￿electrical￿machine￿generates.￿The control￿loop￿of￿the￿range￿extender￿electrical￿machine￿electronics￿is￿closed￿by￿the￿signals￿of￿the￿current sensors￿and￿the￿rotor￿position￿sensor￿in￿the￿range￿extender￿electrical￿machine. The￿performance￿data￿of￿the￿range￿extender￿electrical￿machine￿electronics￿and￿the￿range￿extender electrical￿machine￿are￿coordinated￿in￿development.￿The￿range￿extender￿electrical￿machine￿electronics is￿thus￿able￿to￿permanently￿provide￿an￿electrical￿power￿of￿about￿23.3 kW￿(DC￿power￿at￿4300 rpm).￿In order￿to￿avoid￿overloading￿the￿power￿electronics,￿there￿is￿also￿another￿temperature￿sensor￿at￿the￿DC/ AC￿converter.￿If￿an￿excessive￿temperature￿of￿the￿power￿semiconductor￿is￿identified￿using￿this￿signal, the￿REME￿control￿unit￿reduces￿the￿power￿delivered￿to￿the￿range￿extender￿electrical￿machine￿or￿used by￿the￿range￿extender￿electrical￿machine￿in￿order￿to￿protect￿the￿power￿electronics.￿The￿customer￿is informed￿via￿a￿Check￿Control￿message￿in￿the￿case￿of￿a￿noticeable￿power￿reduction.￿The￿customer receives￿the￿same￿error￿response￿(power￿reduction)￿and￿the￿same￿Check￿Control￿message￿if￿the temperature￿of￿the￿range￿extender￿electrical￿machine￿exceeds￿the￿permissible￿range.
  • Page 168 I01￿High-voltage￿Components 11.￿Cooling￿the￿Electrical￿Machine Components Due￿to￿the￿high￿efficiency￿considerably￿less￿heat￿is￿emitted￿from￿the￿electrical￿machines￿and￿the power￿electronics￿than￿from￿combustion￿engines.￿Nevertheless,￿in￿order￿to￿ensure￿fault-free￿operation at￿all￿temperature￿conditions,￿a￿cooling￿system￿for￿cooling￿the￿electric￿motor￿components￿is￿necessary in￿the￿I01.￿To￿provide￿a￿complete￿overview￿the￿cooling￿system￿is￿shown￿below￿with￿the￿maximum equipment.￿For￿vehicles￿with￿less￿equipment,￿e.g.￿no￿range￿extender￿or￿no￿convenience￿charging electronics,￿the￿scope￿of￿the￿components￿of￿the￿cooling￿system￿is￿reduced. All￿circuits￿are￿colored￿for￿better￿representation.￿The￿blue￿colors￿should￿indicate￿a￿lower￿temperature. The￿red￿colors￿indicate￿a￿high￿temperature￿of￿the￿coolant.￿The￿different￿red￿colors￿highlight￿the different￿high￿temperatures.
  • Page 169 I01￿High-voltage￿Components 11.￿Cooling￿the￿Electrical￿Machine Components 11.1.￿System￿overview System￿overview￿for￿cooling￿the￿drive￿components￿in￿the￿I01￿(maximum￿equipment)
  • Page 170 I01￿High-voltage￿Components 11.￿Cooling￿the￿Electrical￿Machine Components Index Explanation Radiator Electric￿coolant￿pump￿(80 W) Electrical￿machine￿electronics￿(EME) Electrical￿machine Convenience￿charging￿electronics￿(KLE) Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Range￿extender￿electrical￿machine Mechanical￿coolant￿pump Additional￿electric￿fan￿for￿range￿extender￿cooling￿unit￿(coolant-refrigerant￿heat exchanger) Engine￿oil-to-coolant￿heat￿exchanger Range￿extender￿for￿W20￿engine Coolant￿temperature￿sensor Expansion￿tank￿in￿the￿cooling￿circuit￿of￿the￿combustion￿engine Thermostat Coolant-refrigerant￿heat￿exchanger￿for￿range￿extender Scope￿is￿only￿installed￿for￿equipment￿with￿range￿extender Expansion￿tank￿in￿the￿cooling￿circuit￿of￿the￿electric￿motor￿components Electric￿fan￿for￿the￿radiator The￿components￿to￿be￿cooled￿are￿switched￿in￿the￿cooling￿circuit￿so￿that￿the￿maximum￿temperature levels￿required￿are￿observed.￿A￿lower￿temperature￿is￿required￿for￿the￿electrical￿machine￿electronics than￿for￿the￿electrical￿machine,￿which￿is￿why￿the￿series￿connection￿in￿this￿sequence￿was￿chosen.￿As the￿electric￿motor￿and￿the￿convenience￿charging￿electronics￿are￿not￿operated￿at￿the￿same￿time,￿the parallel￿circuit￿was￿chosen.￿The￿range￿extender￿electrical￿machine￿and￿the￿range￿extender￿electrical machine￿electronics￿are￿switched￿initially￿in￿series.￿As￿these￿two￿components￿are￿operated￿at￿the same￿time￿as￿the￿convenience￿charging￿electronics￿and￿the￿electrical￿machine￿electronics,￿they￿were switched￿in￿parallel￿to￿these.￿In￿addition,￿the￿cooling￿system￿is￿therefore￿not￿designed￿for￿the￿sum￿of￿all heat￿outputs,￿because￿in￿reality￿heat￿only￿has￿to￿be￿discharged￿in￿one￿or￿two￿of￿the￿parallel￿branches. If￿the￿vehicle￿is￿equipped￿with￿a￿range￿extender,￿in￿the￿cooling￿circuit￿there￿is￿a￿coolant-coolant￿heat exchanger￿for￿cooling￿the￿W20￿engine.

  • Page 171: Components

    I01￿High-voltage￿Components 11.￿Cooling￿the￿Electrical￿Machine Components 11.2.￿Components Cooling￿of￿electric￿motor￿components￿—￿Installation￿locations Index Explanation Expansion￿tank￿in￿the￿cooling￿circuit￿of￿the￿electric￿motor￿components Radiator Electric￿fan￿for￿the￿radiator Electrical￿Digital￿Motor￿Electronics Feed￿line Electric￿coolant￿pump￿(80 W) Range￿extender￿electrical￿machine Expansion￿tank￿in￿the￿cooling￿circuit￿of￿the￿combustion￿engine Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Electrical￿machine￿electronics￿(EME) Convenience￿charging￿electronics￿(KLE) Electrical￿machine Return￿line The￿cooling￿module￿at￿the￿front￿of￿vehicle￿is￿made￿up￿of￿the￿coolant-air￿heat￿exchanger,￿the￿electric￿fan and￿optional￿active￿air￿cooling￿flaps.
  • Page 172 I01￿High-voltage￿Components 11.￿Cooling￿the￿Electrical￿Machine Components The￿electric￿coolant￿pump￿has￿a￿power￿of￿80 W￿(Manufacturer:￿Bosch).￿The￿coolant￿pump￿is￿activated by￿the￿EDME￿control￿unit.￿For￿this￿purpose,￿the￿coolant￿pump￿and￿the￿EDME￿control￿unit￿are connected￿via￿a￿direct￿line.￿The￿electric￿coolant￿pump￿can￿be￿activated￿at￿varying￿power￿by￿pulse- width￿modulated￿signals.￿The￿voltage￿supply￿of￿the￿coolant￿pump￿is￿effected￿via￿terminal￿30B.￿The installation￿location￿of￿the￿coolant￿pump￿is￿at￿the￿rear￿right. The￿expansion￿tank￿is￿located￿in￿the￿space￿below￿the￿engine￿compartment￿lid￿on￿the￿left.￿There￿is no￿electrical￿level￿sensor￿installed￿in￿the￿expansion￿tank.￿But￿there￿is￿the￿following￿special￿feature to￿be￿noted￿for￿Service:￿A￿loss￿of￿coolant,￿for￿example￿due￿to￿a￿leak,￿in￿the￿cooling￿system￿is￿not identified￿directly￿due￿to￿the￿lack￿of￿an￿electrical￿level￿sensor.￿Instead,￿in￿the￿event￿of￿coolant￿loss the￿temperature￿of￿the￿cooled￿components￿(electrical￿machine,￿electrical￿machine￿electronics, convenience￿charging￿electronics,￿range￿extender￿and￿the￿range￿extender￿electrical￿machine electronics)￿rises￿above￿the￿normal￿operating￿range.￿In￿this￿case￿the￿power￿of￿the￿electric￿motor￿is reduced￿and￿a￿corresponding￿Check￿Control￿message￿is￿issued.￿The￿Service￿employee￿must￿check the￿following￿fault￿causes￿during￿troubleshooting: • Loss￿of￿coolant,￿e.g.￿by￿a￿leak • Coolant-air￿heat￿exchanger￿blocked • Electric￿fan￿does￿not￿work￿or￿is￿restricted • Coolant￿pump￿does￿not￿work • Coolant￿lines￿or￿connections￿damaged • Components￿to￿be￿cooled￿faulty￿(electrical￿machine,￿electrical￿machine￿electronics, convenience￿charging￿electronics,￿range￿extender￿electrical￿machine,￿range￿extender￿electrical machine￿electronics). If￿excess￿temperature￿is￿displayed￿in￿the￿cooling￿system￿of￿the￿electric￿motor,￿then￿this￿may￿have several￿causes,￿including￿also￿the￿loss￿of￿coolant.￿Therefore,￿during￿troubleshooting￿all￿components￿of the￿cooling￿system￿must￿be￿checked￿systematically. The￿familiar￿mixture￿of￿water￿and￿antifreeze￿and￿corrosion￿inhibitors￿in￿BMW￿vehicles￿is￿used￿as￿a coolant. When￿filling￿the￿cooling￿circuit￿of￿the￿electric￿motor￿use￿the￿special￿tool￿for￿vacuum￿filling￿according￿to the￿repair￿instructions. Perform￿a￿bleeding￿after￿filling￿the￿cooling￿circuit,￿as￿well￿as￿after￿replacing￿components￿in￿the￿cooling circuit.

  • Page 173: Function

    I01￿High-voltage￿Components 11.￿Cooling￿the￿Electrical￿Machine Components Switch￿on￿light Actuate￿the￿parking￿brake Activate￿the￿parking￿lock Adjust￿heating￿control￿to￿maximum￿temperature Press￿and￿hold￿down￿brake￿pedal￿at￿the￿same￿time Press￿the￿accelerator￿pedal￿for￿less￿than￿10￿seconds￿(fully) The￿bleeding￿procedure￿is￿started.￿The￿bleeding￿procedure￿takes￿about￿12￿minutes. Before￿the￿high-voltage￿battery￿is￿charged￿or￿the￿I01￿is￿driven,￿the￿cooling￿system￿of￿the￿electric￿motor is￿filled￿with￿coolant￿and￿bled.￿Otherwise,￿damage￿may￿occur￿to￿the￿convenience￿charging￿electronics, the￿electrical￿machine,￿the￿electrical￿machine￿electronics,￿the￿range￿extender￿electrical￿machine￿or￿the range￿extender￿electrical￿machine￿electronics. 11.3.￿Function The￿coolant￿in￿the￿cooling￿circuit￿of￿the￿electric￿motor￿components￿is￿pumped￿by￿an￿electric￿coolant pump￿(80 W)￿through￿the￿five￿electric￿motor￿components￿and￿if￿necessary￿the￿coolant-coolant￿heat exchanger. If￿the￿air￿stream￿is￿insufficient￿for￿cooling￿the￿coolant￿in￿the￿radiator,￿the￿electric￿fan￿is￿also￿switched￿on by￿the￿EDME.￿The￿electric￿fan￿has￿a￿power￿rating￿of￿400 W. There￿is￿only￿one￿version￿of￿this￿cooling￿system,￿which￿is￿used￿in￿both￿the￿European￿and￿US￿version￿of the￿vehicle.￿A￿variant￿for￿cold￿and￿hot￿countries￿is￿not￿offered.
  • Page 174 I01￿High-voltage￿Components 11.￿Cooling￿the￿Electrical￿Machine Components Input/Output￿for￿cooling￿of￿electric￿motor￿components Index Explanation Body￿Domain￿Controller￿(BDC) Signal,￿terminal￿status Temperature￿sensor￿in￿the￿electrical￿machine￿electronics Signal,￿temperature￿of￿the￿power￿electronics￿in￿the￿electrical￿machine electronics Temperature￿sensor￿in￿the￿electrical￿machine...
  • Page 175 I01￿High-voltage￿Components 11.￿Cooling￿the￿Electrical￿Machine Components Index Explanation Signal,￿temperature￿in￿the￿electrical￿machine Temperature￿sensor￿in￿the￿convenience￿charging￿electronics Signal,￿temperature￿in￿the￿convenience￿charging￿electronics Dynamic￿Stability￿Control Vehicle￿speed Temperature￿sensor￿of￿the￿range￿extender￿electrical￿machine Signal,￿temperature￿in￿the￿range￿extender￿electrical￿machine Electrical￿Digital￿Motor￿Electronics Temperature￿sensor￿in￿the￿range￿extender￿electrical￿machine￿electronics Signal,￿temperature￿in￿the￿range￿extender￿electrical￿machine￿electronics Electric￿coolant￿pump Power￿requirement￿at￿electric￿coolant￿pump Electric￿fan Speed￿requirement,￿electric￿fan Similar￿to￿the￿cooling￿systems￿of￿current￿BMW￿vehicles￿with￿combustion￿engines,￿the￿control￿in￿the I01￿is￿also￿effected￿depending￿on￿the￿cooling￿power￿requirement.￿This￿control￿is￿integrated￿in￿the Electrical￿Digital￿Motor￿Electronics￿(EDME). The￿following￿input￿signals￿are￿used￿for￿the￿control: • Component￿temperature￿of￿electrical￿machine • Component￿temperature￿of￿electrical￿machine￿electronics • Component￿temperature￿of￿convenience￿charging￿electronics • Component￿temperature￿of￿range￿extender￿electrical￿machine￿electronics • Component￿temperature￿of￿range￿extender￿electrical￿machine • Current￿power￿used￿in￿the￿electric￿motor￿or￿convenience￿charging￿electronics • Driving￿speed. In￿comparison￿to￿the￿familiar￿cooling￿systems￿of￿conventional￿vehicles,￿the￿coolant￿temperature￿is￿not used￿as￿an￿input￿variable￿for￿the￿control.￿Accordingly,￿there￿is￿no￿coolant￿temperature￿sensor￿in￿the cooling￿system￿for￿the￿electric￿motor￿of￿the￿I01.￿Instead,￿the￿electric￿coolant￿pump￿and￿the￿electric fan￿are￿activated￿according￿to￿the￿listed￿input￿variables￿and￿also￿the￿current￿cooling￿requirement.￿The...
  • Page 176 I01￿High-voltage￿Components 11.￿Cooling￿the￿Electrical￿Machine Components • Terminal￿15￿switched￿on,￿driving￿readiness • Terminal￿15￿switched￿on,￿no￿driving￿readiness • High-voltage￿battery￿is￿charged. The￿power￿electronics￿switching￿of￿the￿electrical￿machine￿electronics￿are￿already￿working￿when terminal￿15￿is￿switched￿on.￿Both￿the￿high-voltage￿electrical￿system￿(EKK￿and￿electric￿heating)￿and￿the 12 V￿vehicle￿electrical￿system￿are￿supplied￿with￿energy￿by￿the￿DC/DC￿converter.￿If￿due￿to￿the￿arising heat￿a￿cooling￿requirement￿is￿identified,￿the￿coolant￿pump￿is￿switched￿on,￿and￿if￿required￿also￿the electric￿fan. When￿terminal￿15￿is￿switched￿the￿coolant￿pump￿and￿electric￿fan￿can￿be￿switched￿on￿automatically. For￿work￿with￿an￿open￿engine￿compartment￿lid￿or￿at￿the￿cooling￿module￿it￿is￿imperative￿terminal￿15￿is switched￿off. While￿the￿high-voltage￿battery￿is￿being￿charged,￿the￿power￿electronics￿in￿the￿electrical￿machine electronics￿and￿in￿the￿convenience￿charging￿electronics￿are￿working.￿Due￿to￿the￿high￿electrical power,￿which￿is￿generated￿in￿the￿electrical￿machine￿electronics￿and￿the￿convenience￿charging electronics,￿heat￿also￿develops.￿This￿must￿be￿dissipated￿using￿the￿cooling￿circuit￿described￿here. For￿this￿reason,￿the￿electric￿coolant￿pump￿and￿the￿electric￿fan￿are￿also￿switched￿on￿during￿charging with￿a￿correspondingly￿high￿temperature￿in￿the￿electrical￿machine￿electronics￿and￿in￿the￿convenience charging￿electronics. The￿coolant￿pump￿and￿the￿electric￿fan￿can￿be￿switched￿on￿automatically￿when￿charging￿the high-voltage￿battery.￿The￿high-voltage￿battery￿cannot￿be￿charged￿when￿working￿with￿the￿engine compartment￿lid￿open￿or￿at￿the￿cooling￿module.
  • Page 177 I01￿High-voltage￿Components 12.￿Technical￿Safety￿Precautions 12.1.￿High￿voltage￿interlock￿loop The￿high-voltage￿interlock￿loop￿is￿used￿to￿protect￿individuals￿when￿working￿on￿or￿at￿the￿high-voltage components.￿Via￿the￿high-voltage￿interlock￿loop￿it￿is￿identified￿whether￿one￿or￿several￿high-voltage plug￿connections￿have￿been￿disconnected.￿If￿a￿high-voltage￿plug￿connection￿has￿been￿disconnected, the￿entire￿high-voltage￿system￿is￿shut￿down￿automatically.￿A￿square￿wave￿signal￿with￿alternating current￿direction￿is￿sent￿through￿the￿line￿of￿the￿high-voltage￿interlock￿loop￿by￿the￿battery￿management electronics￿SME.￿The￿SME￿and￿the￿electrical￿machine￿electronics￿EME￿evaluate￿this￿signal. The￿line￿of￿the￿high-voltage￿interlock￿loop￿runs￿through￿each￿connector/plug￿of￿the￿high-voltage components,￿which￿are￿able￿to￿generate￿high￿voltage.
  • Page 178 I01￿High-voltage￿Components 12.￿Technical￿Safety￿Precautions Main￿wiring￿diagram￿for￿high￿voltage￿interlock￿loop...

  • Page 179: Starting

    I01￿High-voltage￿Components 12.￿Technical￿Safety￿Precautions Index Explanation High-voltage￿safety￿connector￿("Service-Disconnect") Fuse￿block,￿front Safety￿battery￿terminal￿(SBK) 12 V￿battery Intelligent￿battery￿sensor￿(IBS) Crash￿Safety￿Module￿(ACSM) High-voltage￿battery￿unit Battery￿management￿electronics￿(SME) Signal￿generator￿for￿test￿signal￿of￿the￿high-voltage￿interlock￿loop￿in￿the￿battery management￿electronics Evaluation￿circuit￿for￿test￿signal￿of￿the￿high-voltage￿interlock￿loop￿in￿the￿battery management￿electronics Cells￿of￿the￿high-voltage￿battery Switch￿contactor,￿fuse￿and￿series￿resistor￿in￿the￿high-voltage￿battery Convenience￿charging￿electronics￿(KLE) Range￿extender￿electrical￿machine Range￿Extender￿Electrical￿Machine￿Electronics￿(REME) Evaluation￿circuit￿for￿test￿signal￿of￿the￿high-voltage￿interlock￿loop￿in￿the electrical￿machine￿electronics Electrical￿machine￿electronics￿(EME) 12.2.￿Starting￿and￿shutting￿down￿the￿high-voltage￿system The￿master￿control￿unit￿for￿the￿control￿of￿the￿high-voltage￿system￿is￿the￿electrical￿machine￿electronics. 12.2.1.￿Starting The￿sequence￿for￿starting￿the￿high-voltage￿system￿is￿always￿the￿same￿irrespective￿of￿which￿of￿the following￿events￿was￿the￿trigger: • Terminal￿15￿is￿switched￿on￿or￿driving￿readiness￿is￿established • Charging￿the￿high-voltage￿battery￿should￿start • "Preparation"￿of￿the￿vehicle￿for￿the￿journey￿(climate￿control￿of￿the￿high-voltage￿battery￿or￿the passenger￿compartment). The￿individual￿steps￿for￿starting￿the￿high-voltage￿system￿are: EME￿control￿unit￿requests￿starting￿via￿bus￿signal￿at￿the￿PT-CAN￿and￿PT-CAN2 The￿high-voltage￿electrical￿system￿is￿checked￿using￿self-diagnosis￿functions...
  • Page 180 I01￿High-voltage￿Components 12.￿Technical￿Safety￿Precautions The￿voltage￿in￿the￿high-voltage￿circuit￿is￿increased￿continuously The￿contacts￿of￿the￿switch￿contactors￿are￿fully￿closed. The￿high-voltage￿electrical￿system￿is￿mainly￿checked￿by￿the￿EME￿control￿unit￿and￿the￿SME￿control unit.￿Criteria￿relevant￿for￿safety,￿for￿example￿the￿circuit￿of￿the￿high-voltage￿interlock￿loop￿or￿the￿isolation resistance,￿are￿checked.￿Functional￿preconditions￿such￿as￿the￿operating￿readiness￿of￿all￿subsystems must￿also￿be￿fulfilled￿for￿starting. As￿the￿high-voltage￿circuit￿capacitors￿have￿high￿capacity￿values￿(link￿capacitors￿in￿the￿power electronics),￿the￿contacts￿of￿the￿electromechanical￿switch￿contactors￿cannot￿be￿easily￿closed. Extremely￿high￿current￿pulses￿would￿damage￿both￿the￿high-voltage￿battery￿and￿the￿link￿capacitors and￿the￿contacts￿of￿the￿switch￿contactors.￿First￿of￿all,￿the￿switch￿contactor￿of￿the￿ground￿cable￿in￿the high-voltage￿battery￿is￿closed.￿In￿order￿to￿restrict￿the￿switch-on￿current,￿there￿is￿a￿current￿path￿with resistance￿in￿the￿positive￿wire￿(connected￿parallel￿to￿the￿switch￿contactor).￿This￿is￿now￿activated￿and a￿switch-on￿current￿restricted￿by￿the￿resistance￿charges￿the￿link￿capacitors.￿If￿the￿voltage￿of￿the￿link capacitors￿has￿reached￿the￿approximate￿value￿of￿the￿battery￿voltage,￿the￿last￿contact￿of￿the￿switch contactor￿at￿the￿positive￿terminal￿of￿the￿high-voltage￿battery￿unit￿is￿closed.￿The￿high-voltage￿system￿is now￿fully￿operational. If￿there￿is￿no￿fault￿in￿the￿high-voltage￿system,￿the￿entire￿starting￿of￿the￿high-voltage￿system￿is completed￿in￿about￿0.5￿seconds.￿There￿is￿thus￿no￿disadvantage￿for￿the￿customer￿in￿comparison￿to vehicles￿with￿a￿conventional￿engine. The￿SME￿control￿unit￿communicates￿successful￿starting￿via￿the￿PT-CAN2￿to￿the￿EME￿control￿unit. Fault￿statuses￿are￿also￿communicated￿in￿the￿same￿way,￿if,￿for￿example,￿a￿contact￿of￿a￿switch￿contactor was￿unable￿to￿be￿closed. 12.2.2.￿Shutting￿off￿the￿high-voltage￿system When￿it￿comes￿to￿shutting￿off￿the￿high-voltage￿system￿a￿distinction￿is￿made￿between￿regular￿shut- off￿and￿fast￿shut-off.￿The￿regular￿shutdown￿described￿here￿protects￿all￿respective￿components￿on￿the one￿hand,￿and,￿on￿the￿other￿hand,￿includes￿the￿monitoring￿of￿components￿of￿the￿high-voltage￿system which￿are￿relevant￿for￿safety. Regular￿shutdown If￿the￿following￿preconditions￿or￿criteria￿are￿present,￿the￿high-voltage￿system￿is￿shutdown￿in￿the￿regular manner: • Terminal￿15￿is￿switched￿off￿by￿the￿driver￿and￿the￿after-running￿period￿is￿expired￿(controlled￿by EME) • End￿of￿the￿functions￿"stationary￿cooling",￿"auxiliary￿heater"￿or￿"conditioning￿of￿the￿high- voltage￿battery" • End￿of￿the￿charging￿procedure￿for￿the￿high-voltage￿battery.
  • Page 181 I01￿High-voltage￿Components 12.￿Technical￿Safety￿Precautions The￿systems￿at￿the￿high-voltage￿electrical￿system￿(EME,￿REME,￿KLE,￿EKK,￿EH)￿reduce￿the currents￿in￿the￿high-voltage￿electrical￿system￿to￿zero Opening￿the￿switch￿contactors￿in￿the￿high-voltage￿battery￿unit￿(controlled￿by￿SME) Discharging￿the￿high-voltage￿circuit,￿i.e.￿active￿discharging￿of￿the￿link￿capacitors￿(EME,￿REME￿and KLE),￿short-circuit￿of￿the￿coils￿of￿the￿electrical￿machine￿(EME￿and￿REME),￿short-circuit￿of￿the￿coils of￿the￿EKK Checking￿the￿high-voltage￿system,￿e.g.￿as￿to￿whether￿the￿contacts￿of￿the￿electromechanical switch￿contactors￿were￿correctly￿opened. Both￿the￿after-running￿period￿after￿switching￿off￿terminal￿15￿and￿the￿shutdown￿itself￿can￿last￿a￿few minutes.￿The￿automatic￿monitoring￿functions￿are￿a￿reason￿for￿this,￿for￿example.￿The￿regular￿shutdown is￿interrupted￿if￿in￿the￿meantime￿either￿a￿request￿for￿a￿renewed￿start-up￿is￿made￿or￿a￿condition￿has arisen￿to￿request￿a￿quick￿shutdown. Quick￿shutdown The￿overriding￿aim￿here￿is￿to￿shut￿down￿the￿high-voltage￿system￿as￿quickly￿as￿possible.￿This￿quick shutdown￿is￿then￿always￿carried￿out￿if￿for￿safety￿reasons￿the￿voltage￿in￿the￿high-voltage￿system￿has￿to be￿reduced￿to￿a￿safe￿value￿as￿quickly￿as￿possible.￿The￿following￿list￿describes￿the￿triggering￿conditions and￿the￿functional￿chain￿leading￿to￿the￿quick￿shutdown. Accident: • ACSM￿identifies￿an￿accident.￿Depending￿on￿the￿severity￿of￿the￿accident￿the￿shutdown￿of￿the high-voltage￿system￿is￿requested￿via￿bus￿signals.￿The￿SME￿triggers￿the￿separation￿of￿the switch￿contactors￿in￿the￿high-voltage￿battery.￿In￿the￿case￿where￿communication￿via￿a￿data￿bus is￿faulty￿or￿not￿possible,￿the￿switch-off￿of￿the￿switch￿contactors￿is￿forced￿(hard￿opening).￿The switch￿contactors￿are￿supplied￿with￿voltage￿by￿terminal￿30C.￿Through￿the￿separation￿of￿the safety￿battery￿terminal￿from￿the￿positive￿terminal￿of￿the￿12 V￿battery,￿the￿voltage￿supply￿of￿the switch￿contactors￿is￿also￿interrupted￿and￿their￿contacts￿open￿automatically. The￿EME￿and￿the￿REME￿also￿receive￿bus￿signals￿for￿switching￿off￿the￿high-voltage￿system. Both￿control￿units￿immediately￿trigger￿the￿active￿short￿circuit￿of￿the￿electrical￿machines￿(short- circuit￿of￿the￿coils￿of￿the￿corresponding￿electrical￿machine￿via￿the￿power￿semiconductor￿of￿the AC/DC￿converter)￿and￿the￿active￿link￿capacitors￿are￿discharged.￿If￿communication￿via￿the￿data bus￿is￿not￿possible,￿the￿shutdown￿request￿is￿sent￿via￿the￿separate￿lines￿between￿ASCM￿and EME,￿as￿well￿as￿between￿ACSM￿and￿REME. Overload￿current￿monitoring: • With￿help￿of￿current￿sensors￿in￿the￿high-voltage￿battery￿unit￿the￿current￿level￿in￿the￿high- voltage￿electrical￿system￿is￿monitored.￿If￿too￿high￿a￿current￿level￿is￿identified,￿the￿SME￿control unit￿causes￿a￿hard￿opening￿of￿the￿electromechanical￿switch￿contactors.￿Considerable￿wear occurs￿to￿the￿contacts￿of￿the￿switch￿contactors￿as￿a￿result￿of￿this￿opening￿under￿a￿high current,￿which￿must￿be￿accepted￿to￿protect￿the￿other￿components￿from￿damage.
  • Page 182 I01￿High-voltage￿Components 12.￿Technical￿Safety￿Precautions If￿a￿cell￿supervision￿circuit￿identifies￿extreme￿under-voltage,￿over-voltage￿or￿excess temperature￿at￿a￿battery￿cell,￿this￿also￿leads￿to￿a￿hard￿opening￿of￿the￿electromechanical￿switch contactors￿-￿controlled￿by￿the￿SME￿control￿unit.￿Although￿this￿may￿lead￿again￿to￿increased wear￿at￿the￿contacts,￿this￿quick￿shutdown￿is￿necessary￿to￿prevent￿destroying￿the￿respective battery￿cells. Malfunction￿of￿the￿12 V￿voltage￿supply￿of￿the￿high-voltage￿battery￿unit: • In￿this￿case￿the￿battery￿management￿electronics￿control￿unit￿no￿longer￿works￿and￿it is￿no￿longer￿possible￿to￿monitor￿the￿battery￿cells.￿For￿this￿reason￿the￿contacts￿of￿the electromechanical￿switch￿contactors￿also￿open￿here￿automatically. 12.2.3.￿Charging￿the￿high-voltage￿battery The￿SME￿control￿unit￿also￿plays￿an￿important￿role￿in￿the￿charging￿of￿the￿high-voltage￿battery￿with energy￿supply￿from￿an￿external￿power￿network.￿Using￿the￿state￿of￿charge￿and￿the￿temperature￿of the￿battery￿cells,￿the￿SME￿control￿unit￿defines￿the￿maximum￿electrical￿power￿which￿the￿high-voltage battery￿can￿currently￿use.￿This￿value￿is￿transmitted￿in￿the￿form￿of￿a￿bus￿signal￿via￿the￿PT-CAN2￿to￿the EME￿control￿unit.￿The￿"High-voltage￿power￿management"￿function￿coordinates￿the￿individual￿power requirements￿and￿forwards￿the￿total￿value￿to￿the￿electrical￿machine￿electronics￿(and￿from￿there￿to￿the convenience￿charging￿electronics). During￿charging￿the￿SME￿control￿unit￿constantly￿identifies￿the￿state￿of￿charge￿already￿reached￿and monitors￿all￿sensor￿signals￿of￿the￿high-voltage￿battery.￿In￿order￿to￿ensure￿optimal￿progress￿of￿the charging￿procedure,￿the￿SME￿control￿unit￿constantly￿calculates￿current￿values￿for￿the￿maximum charging￿power￿based￿on￿these￿values￿and￿communicates￿these￿to￿the￿EME￿control￿unit.￿The￿heating/ cooling￿system￿of￿the￿high-voltage￿battery￿is￿also￿continuously￿controlled￿by￿the￿SME￿control￿unit during￿the￿charging￿procedure￿which￿contributes￿to￿a￿quick￿and￿efficient￿charging￿procedure. 12.3.￿Pinpointing￿isolation￿faults The￿SME￿control￿unit￿reliably￿identifies￿when￿the￿isolation￿resistance￿in￿the￿high-voltage￿electrical system￿drops￿below￿the￿specified￿values.￿A￿fault￿code￿entry,￿a￿Check￿Control￿message￿and,￿if￿required, the￿shutdown￿of￿the￿high-voltage￿system,￿are￿automatically￿effected.￿The￿isolation￿monitoring￿in￿the SME￿control￿unit￿alone￿cannot￿determine￿the￿actual￿location￿of￿the￿fault￿in￿the￿high-voltage￿electrical system.￿Instead,￿an￿isolation￿fault￿must￿be￿pinpointed￿by￿using￿a￿test￿schedule￿in￿the￿diagnosis￿system. Several￿systematic￿test￿steps￿are￿required￿in￿order￿to￿determine￿the￿components￿or￿the￿high-voltage cable￿causing￿the￿isolation￿fault. 12.4.￿Start-up￿of￿the￿high-voltage￿system If￿in￿the￿event￿of￿a￿repair￿high-voltage￿components￿are￿removed￿or￿replaced,￿it￿is￿imperative￿to￿ensure that • all￿high-voltage￿connectors •...
  • Page 183 I01￿High-voltage￿Components 12.￿Technical￿Safety￿Precautions The￿cooling￿or￿refrigerant￿system￿must￿also￿be￿filled￿with￿coolant￿or￿refrigerant. If￿the￿above-mentioned￿preconditions￿are￿not￿satisfied,￿the￿high-voltage￿system￿cannot￿be￿operated.
  • Page 184 I01￿High-voltage￿Components 13.￿Operating￿Strategy The￿operating￿strategy￿has￿the￿task￿of￿maximizing￿the￿service￿life￿of￿the￿high-voltage￿battery￿and protecting￿it￿against￿damage￿during￿operation.￿All￿customer￿requirements￿when￿driving￿and￿during charging￿should￿also￿be￿fulfilled.￿The￿behavior￿of￿the￿electric￿motor￿in￿the￿event￿of￿a￿fault￿is￿also￿an element￿of￿the￿operating￿strategy.￿The￿EDME￿is￿the￿master￿control￿unit￿for￿the￿operating￿strategy. 13.1.￿Operating￿strategy￿with￿pure￿electric￿drive The￿I01￿is￿designed￿as￿a￿vehicle￿with￿a￿pure￿electric￿drive￿for￿urban￿mobility.￿The￿high-voltage￿battery and￿the￿electrical￿machine￿deliver￿impressive￿vehicle￿performances: • Range￿>￿160 km￿(at￿20 °C)￿/￿100￿mi￿(at￿68 °F) • Maximum￿speed￿150 km/h/￿93￿mph￿(short-term,￿3￿minutes)￿or￿120 km/h/74.5￿mph (continuous) • Acceleration￿from￿0-100 km/h￿in￿7.2￿s Before￿a￿drive￿torque￿is￿applied,￿the￿EDME￿must￿check￿whether￿the￿driving￿readiness￿is￿established. The￿EDME￿also￿queries￿whether￿all￿subsystems￿of￿the￿electrical￿drive￿train￿are￿functioning￿trouble- free,￿which￿is￿also￿a￿prerequisite￿for￿the￿provision￿of￿a￿drive￿torque.￿Finally,￿the￿EDME￿still￿has￿to consider￿the￿available￿electrical￿power￿for￿the￿electric￿motor￿which￿is￿primarily￿determined￿by￿the condition￿of￿the￿high-voltage￿battery.￿The￿SME￿control￿unit￿communicates￿this￿condition￿to￿the￿EDME control￿unit￿via￿corresponding￿bus￿signals.￿As￿a￿result￿of￿these￿checks￿the￿EDME￿identifies￿whether and￿in￿what￿scope￿the￿drive￿torque￿can￿be￿provided.￿In￿the￿case￿of￿fault￿statuses￿or￿in￿the￿event￿of limited￿availability,￿the￿EDME￿issues￿an￿appropriate￿Check￿Control￿message￿via￿the￿instrument￿cluster. The￿statuses￿of￿the￿operating￿strategy￿relevant￿for￿the￿customer￿and￿the￿Service￿employee￿are￿listed below￿and￿described￿briefly.
  • Page 185 I01￿High-voltage￿Components 13.￿Operating￿Strategy Status Features Reason/ Displays Precondition Driving￿without The￿full￿power￿of State￿of￿charge￿of￿the Normal￿functional restrictions the￿electric￿motor high-voltage￿battery￿in displays￿such￿as is￿available￿for optimal￿range. state￿of￿charge￿of acceleration. Temperature￿of￿the the￿high-voltage Full￿scope￿of￿brake high-voltage￿battery￿in battery,￿drive￿power energy optimal￿range during￿acceleration￿or regeneration￿is deceleration possible. Full￿scope￿of￿all climate￿control functions￿are available. Driving￿with￿restricted The￿drive￿power￿is State￿of￿charge￿of￿the driving￿power reduced￿to￿protect high-voltage￿battery components.￿Full...
  • Page 186 I01￿High-voltage￿Components 13.￿Operating￿Strategy Diagram￿for￿the￿BEV￿operating￿strategy Index Explanation Range￿in￿which￿driving￿without￿restrictions￿is￿possible Range￿in￿which￿driving￿with￿restricted￿drive￿power￿takes￿place Range￿in￿which￿driving￿is￿not￿possible Calculated￿state￿of￿charge￿of￿the￿high-voltage￿battery￿(State￿of￿Charge￿=￿SOC) Warning￿for￿range￿of￿20 km Warning￿for￿range￿of￿10 km Warning￿for￿range￿of￿less￿than￿1 km Axis￿for￿relative￿SOC￿values Axis￿for￿absolute￿SOC￿values SOC￿of￿the￿high-voltage￿battery￿0%￿absolute SOC￿of￿the￿high-voltage￿battery￿10%￿absolute,￿or￿0%￿relative SOC￿of￿the￿high-voltage￿battery￿14.2%￿absolute,￿or￿4.9%￿relative SOC￿of￿the￿high-voltage￿battery￿100%￿relative In￿the￿diagram￿the￿relative￿and￿the￿absolute￿state￿of￿charge￿values￿(SOC￿values)￿of￿the￿high-voltage battery￿are￿shown.￿The￿absolute￿values￿correspond￿to￿the￿actual￿state￿of￿charge￿of￿the￿high-voltage battery.￿The￿relative￿SOC￿values￿are￿the￿values￿which￿are￿displayed￿to￿the￿driver￿in￿the￿instrument cluster￿or￿in￿the￿central￿information￿display.￿In￿range￿"A"￿driving￿without￿power￿restriction￿and￿full functionality￿of￿the￿convenience￿functions￿are￿available.￿If￿the￿SOC￿value￿of￿the￿high-voltage￿battery approaches￿about￿5%,￿the￿Check￿Control￿messages￿for￿ranges￿between￿20 km￿and￿10 km￿are￿issued. In￿range￿"B"￿the￿performance￿of￿the￿drive￿train￿is￿reduced￿due￿to￿the￿low￿state￿of￿charge￿of￿the￿high- voltage￿battery.￿The￿heating￿and￿air-conditioning￿system￿is￿switched￿off￿here. If￿the￿absolute￿SOC￿value￿falls￿below￿10%,￿driving￿the￿vehicle￿is￿no￿longer￿possible.￿The￿reserve￿of 10%￿is￿required￿to￿give￿the￿customer￿adequate￿time￿to￿charge￿the￿high-voltage￿battery￿and￿prevent deep￿discharge. The￿driver￿has￿the￿option￿to￿extend￿the￿range￿by￿activating￿ECO￿PRO￿or￿ECO￿PRO￿+￿mode.￿Here￿the power￿of￿some￿electrical￿consumers￿is￿reduced￿or￿the￿consumers￿are￿switched￿off￿completely.￿In￿ECO PRO￿mode￿the￿maximum￿speed￿is￿130 km/h￿(can￿be￿adjusted￿in￿ECO￿PRO￿menu￿from￿80 km/h￿to 130 km/h).￿In￿ECO￿PRO￿+￿mode￿the￿maximum￿driving￿speed￿is￿restricted￿to￿90 km/h.
  • Page 187 I01￿High-voltage￿Components 13.￿Operating￿Strategy Comfort ECO￿PRO ECO￿PRO￿+ Range￿potential up￿to￿20%￿more￿than up￿to￿30%￿more￿than in￿Comfort￿mode in￿Comfort￿mode Restriction￿of￿the none 80 km/h￿to￿130 km/h 90￿km/h maximum￿driving (adjustable) speed￿(can￿be breached) Mirror￿heating No￿reduction -￿25% -￿25%￿and￿after￿10 minutes￿off,￿if￿wiper Heated￿rear￿window No￿reduction Shorter￿heating￿and Shorter￿heating￿and cycle￿times cycle￿times Dim￿low-beam headlight Heated￿seats No￿reduction Maximum￿Stage￿2 Deactivated Cooling￿in￿passenger Balance￿comfort/ More￿economical Climate￿control compartment range program￿with￿reduced...
  • Page 188 I01￿High-voltage￿Components 13.￿Operating￿Strategy Index Explanation Range￿in￿which￿driving￿without￿restrictions￿is￿possible Range￿in￿which￿driving￿without￿restrictions￿is￿possible￿and￿automatic￿engine start-stop￿function￿is￿active Range￿in￿which￿driving￿without￿restrictions￿is￿possible￿and￿automatic￿engine start-stop￿function￿is￿not￿active￿(REX￿is￿permanently￿on) Range￿in￿which￿driving￿with￿restricted￿drive￿power￿takes￿place Range￿with￿safety￿reserve￿for￿REX￿start Range￿in￿which￿driving￿is￿not￿possible Calculated￿state￿of￿charge￿of￿the￿high-voltage￿battery￿(State￿of￿Charge￿=￿SOC) First￿automatic￿REX￿start Warning￿for￿range￿of￿less￿than￿1 km Axis￿for￿relative￿SOC￿values Axis￿for￿absolute￿SOC￿values SOC￿of￿the￿high-voltage￿battery￿0%￿absolute SOC￿of￿the￿high-voltage￿battery￿0.4%￿relative SOC￿of￿the￿high-voltage￿battery￿1.9%￿relative SOC￿of￿the￿high-voltage￿battery￿3.5%￿relative SOC￿of￿the￿high-voltage￿battery￿6.5%￿relative,￿or￿15.7%￿absolute SOC￿of￿the￿high-voltage￿battery￿75%￿relative SOC￿of￿the￿high-voltage￿battery￿100%￿relative Up￿to￿a￿state￿of￿charge￿of￿the￿high-voltage￿battery￿of￿6.5%￿relative￿(displayed￿SOC)￿a￿I01￿with￿REX behaves￿in￿exactly￿the￿same￿way￿as￿a￿I01￿with￿a￿pure￿electric￿motor. If￿the￿state￿of￿charge￿of￿the￿high-voltage￿battery￿drops￿below￿6.5%￿relative,￿the￿REX￿combustion engine￿is￿started￿automatically.￿The￿automatic￿engine￿start-stop￿function￿is￿active￿up￿to￿a￿state￿of charge￿of￿3.5%.￿Driving￿without￿restrictions￿is￿possible￿for￿the￿state￿of￿charge￿between￿3.5%￿and 1.9%,￿but￿without￿automatic￿engine￿start-stop￿function.￿Only￿when￿the￿state￿of￿charge￿of￿the￿high- voltage￿battery￿falls￿below￿1.9%,￿does￿the￿driving￿with￿restricted￿drive￿power￿takes￿effect.￿At￿a￿state￿of charge￿of￿0.4%￿a￿warning￿message￿with￿range￿of￿one￿kilometer￿is￿issued.￿Driving￿is￿no￿longer￿possible below￿this￿SOC￿value.￿In￿the￿high-voltage￿battery￿there￿is￿an￿energy￿reserve￿so￿that￿it￿is￿possible￿to restart￿the￿REX￿combustion￿engine￿or￿so￿that￿the￿high-voltage￿battery￿does￿not￿discharge￿fully￿over￿an extended￿period. After￿refueling￿the￿I01￿with￿REX￿driving￿without￿restrictions￿is￿again￿possible.
  • Page 190 Bayerische￿Motorenwerke￿Aktiengesellschaft Qualifizierung￿und￿Training Röntgenstraße￿7 85716￿Unterschleißheim,￿Germany...

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