The total power components of Audi e-tron are front drive and rear drive. The front drive power is 125KW and the rear drive power is 140kW. This is marked in the video. The difference is that the front drive adopts parallel axis electric drive axle and the rear drive adopts coaxial electric drive axle. As shown in the figure below, Audi shows the front drive and rear drive assembly. There are some differences in the water channels of the front and rear drives.

Explain the electronic control part of Audi e-tron in detail

Explain the electronic control part of Audi e-tron in detail

The overall structure is as follows. This is the precursor 3D graphics, electronic control. The same electronic control publicity can be found on Hitachi’s official website. Now there is no data to confirm whether the electronic control part is provided by Hitachi.

Explain the electronic control part of Audi e-tron in detail

(1) It is a three-phase wiring compartment, which can be opened for three-phase wiring between motor and controller, (2) it is a bus wiring compartment, which can be connected on both left and right sides, (3) it is a vent valve, (4) it is an inlet and outlet, and the inlet and outlet of front drive and rear drive are different.

Explain the electronic control part of Audi e-tron in detail

Remove the three-phase wiring compartment cover. The 3D drawing above is the front drive diagram, and the physical object below is the rear drive. The wiring mode is the same.

Explain the electronic control part of Audi e-tron in detail

The rear drive water inlet and outlet are obviously different from the 3D drawing. This drawing is a picture of the rear drive coaxial bridge.

Explain the electronic control part of Audi e-tron in detail

Today, we mainly introduce the electric control part. The pictures of the electric control are as follows. From the appearance, it is actually very special, like a shovel and a fly swatter. This prominent piece has two wiring holes. These two wiring holes are the wiring place of the high-voltage bus. The design here takes into account different outgoing methods, which can be connected on both sides, increasing the flexibility of loading. Next, let’s take a look at the explosion diagram. All parts in the exploded view can be seen. Let’s explain each part next.

Explain the electronic control part of Audi e-tron in detail

Explain the electronic control part of Audi e-tron in detail

Remove the cover and pull out the whole electronic components as a whole. It can be seen that there is a flexible cable at the bottom of the box. Here is the externally connected low-voltage wiring terminal. According to the analysis of 3D diagram, the soft and hard connection board (1) is adopted, which is mainly used for low-voltage power supply, communication and other low-voltage wire numbers; The drive board is connected with the control board (4). From the 3D diagram, it is also connected through the flexible cable, but the flexible cable runs on the upper side of the three-phase line, which is theoretically unfavorable to EMC. The two white lines in the figure are the harness (3) of bus hall and three-phase hall. The three-phase hall adopts the hall sensor of integrated telephone design. There is an elliptical magnetic ring near the bus interface, which is the EMC magnetic ring (2) and (5) is the bus hall.

Explain the electronic control part of Audi e-tron in detail

As shown in the figure below, (1) water outlet, (2) water inlet.

Explain the electronic control part of Audi e-tron in detail

Open the chassis cover, (1) is the bus direction, (2) bus hall, (3) this place is supposed to be open cover protection.

Explain the electronic control part of Audi e-tron in detail

Take the whole electronic unit out of the cabinet, (1) it is a bus copper bar, which uses a laminated bus bar. There are two more terminals on the bus bar, and it is not guessed what to do. The bus copper bar is divided into three sections, one section is added to the junction box with magnetic ring, one section is led from the magnetic ring to the bus capacitance, and the bus capacitance is another section. See (6) for the second and third sections; (2) It is the drive transformer, (3) it is the IGBT signal connector, (4) it is the connector between the drive board and the control board. The drive chip is not seen on the drive board. It should be on the back of the drive board, (5) it leads the bus to the two terminals of the drive board. It is speculated that it is the bus voltage sampling,. Hitachi’s logo can be clearly seen on the drive board. It can be determined that the controller is provided by Hitachi for Audi.

Explain the electronic control part of Audi e-tron in detail

(1) It is the inlet of the water channel. In addition to flowing to the IGBT water channel (4), it is also a section of inflow (3), (3) this section is next to the bus capacitor, which is supposed to be water-cooled, (2) it is the water outlet of the water channel, which flows to the motor.

Explain the electronic control part of Audi e-tron in detail

The following picture is a little messy. This is all the components of the explosion diagram: (1) drive board, (2) drive board support, (3) high voltage bus sampling harness, (4) three-phase output laminated copper bar, (5) three-phase copper bar, (6) bus integrated hall, (7) Hitachi double-sided water-cooled IGBT module, (8) laminated bus bar, (9) water outlet cover plate, (10) IGBT cooling water channel, (11) Bus capacitance, (12) positive (or negative) bus, I don’t know which is positive or negative, (13) water inlet cover plate, (14) control board, (15) capacitor pin welding point, (16) IGBT middle four pin welding point, (17) IGBT thick pin welding point, (18) cover plate at the other end of IGBT water channel.

It can be seen from the whole explosion diagram that the water channel is very complex, especially the waterproof part, (7) (9) (10) (13) (18) need to be waterproof, and they are all inside the chassis; The drive board has obvious Hitachi logo. The IGBT module is also Hitachi’s IGBT. It is speculated that the two in one double-sided water cooling module has five thick pins in the middle, of which four thinner pins should be positive and negative inputs, and the largest one is three-phase output. Whether it is positive and negative laminated bus or three-phase laminated bus, the process is relatively complex; The practice of bus capacitance can be used for reference. The capacitance of a single four pin is about half cheaper than the customized modular capacitance. However, how to reduce the parasitic parameters needs everyone’s imagination, and the capacitance is also designed for water cooling.

Explain the electronic control part of Audi e-tron in detail

In the water channel design, the water channel first flows through the controller and then through the motor, and the water flows in the motor and through the motor wall and the interior of the rotor at the same time. The approximate direction can be judged by the video and heat conduction direction. The water flows from the inlet, first through the capacitor side wall, and then into the electronic rotor through three IGBTs. After the motor rotor comes out, it flows through the motor casing and then flows out.

Explain the electronic control part of Audi e-tron in detail

The figure above shows the front drive water channel, and the figure on the right of the figure below shows the heat conduction diagram of the rear drive water channel. After the rear drive water flows through the IGBT, it enters the motor, first flows through the motor casing, then flows into the rotor, and then flows out. The difference between first flowing into the casing and first flowing into the rotor is unclear.

Explain the electronic control part of Audi e-tron in detail

Responsible editor: GT

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