武漢理工通宇新源動力純電動系統說明書
武漢理工通宇新源動力有限公司
2017年8月28日
地址：武漢市東湖開發區大學園路理工大科技園
郵編：430000
電話：027-87922915
傳真：027-87859189
目錄
目錄 1
警告及注意事項 3
第一章 純電動系統構成與功能 4
1系統結構示意圖 4
2純電動系統部件清單 4
3 EMT系統介紹 4
第二章 純電動系統各部件性能及參數 5
1 EMT動力總成 5
2五合一控制器 7
3整車控制器 11
4換擋控制面板 12
第三章 純電動系統介紹 13
1純電動動力總成 13
1.1 基本結構 13
1.2電機注意事項 14
1.3變速器注意事項 15
1.4氣動換擋執行機構特點及安裝要求 19
2電機控制器注意事項 20
2.1五合一控制器外形安裝尺寸 20
2.2五合一控制器使用條件 21
3動力系統控制器注意事項 22
3.1動力系統控制器外形安裝尺寸 22
3.2動力系統控制器使用條件 22
4換擋控制面板注意事項 23
4.1換擋控制面板外形安裝尺寸與接口定義 24
4.2換擋面板使用條件 24
第四章EMT動力系統基本故障判斷處理 24
1儀表部分顯示故障 24
2車輛行駛問題 25
3預充不能完成 26
4換擋故障 27
第五章 純電動客車維護 29
1定期維護 29
2一級維護 29
3二級維護 31
版本變更 34
警告及注意事項
此說明書所訴內容僅限于當前版本。
武漢理工通宇新源動力有限公司在未經預告的情況下有權終止或者修改程序、模型、產品規格等。
應按照此說明書中的推薦使用相關品牌的工具和材料，但不包含在承諾書中。
警告：
1）系統上的高壓組件務必確保有警示或者危險標志，高壓線一般有紅色絕緣管包裹或者纏繞。
2）所有的高壓直流和交流電纜接線端的末端比較顯眼的地方都必須貼有警告標簽，并且在產品的整個生命周期內都必須保持完好。
3）務必對于EMT系統、高壓配電柜等設備使用CO2干粉滅火器。
4）不得切斷高壓電纜。
5）不得切斷、打開或者移動逆變器。
6）高壓電纜連接末端在不用的情況下禁止裸露在外面。
第一章 純電動系統構成與功能
1整車結構示意圖
圖1.1 純電動EMT驅動系統結構示意圖
2純電動系統部件清單
WUT EPower Co., Ltd.
Pure Electric System Manual
WUT EPower Co., Ltd.
Aug 28th, 2017
Address: Polytechnic University Science & Technology Park, Daxueyuan Rd, Donghu New & High Technology Development Zone, Wuhan,
Post Code: 430000
Tel: 027-8722915
Fax: 027-87859189
Content
Catalog 1
Warning and precautions 3
Chapter I Structure and Function of Pure Electric System 4
1 System Structure Diagram 4
2 List of Pure Electric System Components 4
Introduction to EMT System 4
Chapter II Performance and Parameters of Pure Electric System Components 5
1 EMT Powertrain 5
2 5-in-1 Controller 7
3 Vehicle Controller 11
4 Gearshift Control Panel 12
Chapter III Introduction to Pure Electric System 13
1 Pure Electric Powertrain 13
1.1 Basic Structure 13
1.2 Motor Precautions 14
1.3 Transmission Precautions 15
1.4 Characteristics and Installation Requirements of Pneumatic Gearshift Actuator 19
2 Motor Controller Precautions 20
2.1 Installation Dimension of 5-in-1 Controller 20
2.2 Service Condition of 5-in-1 Controller 21
3 Power System Controller Precautions 22
3.1 Installation Dimension for Power System Controller 22
3.2 Service Condition for Power System Controller 22
4 Gearshift Control Panel Precautions 23
4.1 Gearshift Control Panel Installation Dimension & Interface Definition 24
4.2 Service Conditions for Gearshift Panel 24
Chapter IV Basic Fault Diagnosis Processing for EMT Power System 24
1 Display Fault of Instrument Part 24
2 Vehicle Travelling Problems 25
3 Pre-charge Failure 26
4 Gearshift Failure 27
Chapter V Maintenance of Pure Electric Bus 29
1 Regular Maintenance 29
2 Level 1 Maintenance 29
3 Level 2 Maintenance 31
Version Change 34
Warning and Precautions
The contents of this document are limited to the current version.
WUT EPower Co., Ltd. reserves the right to terminate or modify programs, models, and product specifications at any time without previous notice.
The use of tools and materials shall comply with the recommended brand in this manual, but not included under the commitment.
Warning:
1) High-voltage assembly of this facility shall be labeled with warning or danger sign, and high voltage cables shall be wrapped or coiled with red insulated tube sets.
2) All high-voltage DC and AC cable terminals must be labeled with warning tags and keep intact throughout the product's life cycle.
3) It is required to use CO2 dry powder fire extinguisher for equipment such as EMT system and high voltage distribution cabinet.
4) Do not cut off high voltage cables.
5) Do not cut, open or remove the inverter.
6) High-voltage cable connection ends are prohibited from being exposed to the outside when not in use.
Chapter I Structure and Function of Pure Electric System
1 System Structure Diagram
Figure 1.1 Schematic diagram of pure electric EMT drive system
2 System Structure Diagram
No. Part Name Specification & Model Unit Remarks
1 EMT Powertrain WTEM80-40-2/T4 Set
2 5-in-1 Controller V6-H-4D90G-TYM09 Pic
3 Vehicle Controller WTPCU2C-3 Pic
4 Gearshift Control Panel WTSNK050A-1 Pic
5 Radiator Assembly WTCSCWB2-4 Set
6 Electric Water Pump Assembly P900124E25 Set
3 Introduction to EMT System
Electric-drive Mechanical Transmission (EMT). Utilizing the electrically driven active synchronization to replace the conventional synchronizer friction, The EMT eliminates the clutch between motor and transmission, and eliminates the mechanical synchronizer in the transmission. Electric-drive Mechanical Transmission has the following advantages over conventional automatic transmissions: high efficiency and low cost as AMT(Automated Manual Transmission), low cost, and interruption time of DCT power (0.2s-0.8s).
Besides, the system applies the integrated design in motor and transmission structure. Following the concept of powertrain, Electric-drive Mechanical Transmission integrates the system in accordance with the assembly arrangement, which reduces the connection and positioning error brought by the components of the dispersion design. In the mean time, Electric-drive Mechanical Transmission also significantly reduces the system's vertical dimension, and effectively optimizes the power of the assembly layout while relieving the system weight.
Chapter II Performance and Parameters of Pure Electric System Components
1 EMT Powertrain
Pure electric system motor applies liquid cooling method. The motor is characterized with small size, light weight, high energy density, and good environmental applicability, which can ensure a safe and reliable operation of motor.
The main parameters of the motor are as follows:
Description Parameter
Motor model WTEM80-40-2
Motor type Synchronous motor
Rated power KW 80
Rated torque N.m 477
Rated speed r / min 1600
Maximum power KW 160
Peak torque N.m 1000
Peak speed r / min 3200
AC voltage 380
Insulation level H
Cooling method Liquid cooling
Figure 2.1 WTEM80-40-2
Main parameters of electromechanical mechanical automatic transmission are as follows:
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2021.11.16