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Composition of a domestic brand new energy vehicle electric drive system

High-speed bearings are 100% imported;

Control chip 100% import;

High-end motor composite shafts to be imported;

Electromagnetic wire is resistant to 100% import of corona insulation raw materials;

100% import of high-precision gear processing, grinding and testing equipment;

High-speed motor dynamic test equipment, vibration noise tester 100% import;

Electromagnetic compatibility test equipment, chip wafer and sheet production equipment, motor stator automatic line equipment to be imported...

In the view of veterans of electric vehicles in the field of new energy vehicles, materials and basic manufacturing industries are weak, and some core components and basic manufacturing equipment are heavily dependent on imports, which has become a major problem restricting the healthy development of China's new energy automobile industry.

In other words, leaving the import and relying on domestic production alone cannot support the new energy automobile industry in China today.

In 2018, the sales volume of China's narrow-minded new energy vehicles has exceeded half of the global total, making it a veritable new energy vehicle production and sales country. However, under the huge industrial chain, many parts and components enterprises suffer from the dilemma of “completely blank without spare tires”, “quality of domestic components and high prices of imported components”, and are still at any time likely to be stuck in the neck by foreign companies. "The hidden worry."

Although the gap is directly reflected in the application end of the three-electric system and the whole vehicle, the root cause is in the field of basic industrial materials and basic manufacturing processes that cannot be avoided by new energy vehicles and even the traditional fuel vehicle industry chain. If the basic discipline research is not solid and the basic manufacturing industry is not strong, China's new energy auto industry will be difficult to change the big but not strong situation.

So, what are the materials, components, technologies and equipment that may be “card neck”? What is the impact of the relatively weak basic manufacturing industry on China's new energy auto parts companies?

In order to answer these questions, "Electric Vehicle Observer" will launch a series of reports, from the electric drive system, power battery, hydrogen fuel, vehicle and other fields, to find the gap between China's new energy vehicle infrastructure manufacturing and foreign advanced level. This article will explore the many aspects of the electric drive system being "card necked".

1

Poor consistency:

"No qualified domestic motor shaft supplier can be found in 2 years"

Poor consistency is the biggest problem for domestically produced vehicles (including traditional fuel vehicles and new energy vehicles). Almost exclusively rely on imported parts, the consistency of domestic products is much lower than imported products.

A senior motor company executives introduced to the "Electric Vehicle Observer" that the defective rate of finished products for key components in the automotive industry is usually measured in PPM, which is a few parts per million, while the defective rate of finished products of domestic motor complex shafts is generally high, even if it is Relatively reliable products, the yield rate is not even 90%.

In order to reduce costs, the company used to spend two years in the country to find suppliers of self-manufactured motor gear shafts, but they still rely on imports because of the unsatisfactory quality of the finished products.

The customers of the motor enterprises are distributed at home and abroad, and the imported motor shafts have caused a great burden to the industry. On the one hand, the high cost of importing the core parts of the electric drive system from abroad has led to an increase in cost; on the other hand, some of the finished motor products have been greatly reduced in cost due to round-trip logistics and customs duties.

If it is exported to the United States, it may be subject to high tariffs in both directions due to Sino-US trade disputes, and beating on both sides will result in the loss of the technical and cost advantages of Tier 1 suppliers.

An international brand electric vehicle motor, inverter

Domestic high-speed bearings, temperature and position sensors are difficult to compete with imported products, but China's motor parts are subject to a small part of people. Silicon steel sheets, which account for a high proportion of permanent magnet synchronous motors, also have long-standing problems such as the consistency of domestic products. R&D personnel of a well-known international electric vehicle company have complained that under the same design and manufacturing process conditions, the vibration noise of the motor made with Nippon Steel Silicon Steel Sheet is significantly lower than that of the motor made of Chinese famous brand silicon steel sheet.

According to the above-mentioned seniors, unlike industrial motors, the temperature, vibration, speed and impact of automotive motors are much more severe. This requires not only good magnetic properties of silicon steel sheets, but also high mechanical properties such as strength. On this basis, it is as thin as possible to meet the needs of high-speed, low-iron motors.

At present, the domestically produced silicon steel sheet has a general thickness of 0.30-0.35 mm, while the Tesla Model 3 motor silicon steel sheet has a thickness of about 0.25 mm, and the Porsche motor uses a 0.2 mm silicon steel sheet. International high-level suppliers have already controlled the thickness of silicon steel sheets to within 0.15 mm.

High-end silicon steel sheets and motor shafts test the national basic industrial manufacturing level, the dependence of thin film capacitor film materials, corona-resistant magnet wire materials, and power semiconductor raw materials on imports, reflecting China's basic industrial materials and components, The weak state of the component process.

2

Lack of materials, lack of technology:

Most afraid of foreign supply

"We can make materials, but we can't make materials." An industry insider described the external dependence of Chinese automotive electrical materials.

Taking the film capacitors used in new energy vehicles as an example, in recent years, domestic film capacitors have made great progress, and the report of the electric vehicle system industry chain research "Electric drive system industry chain research - next-generation vehicle industry chain research" shows that Chinese company Farah Electronics is one of the few film capacitor manufacturers in the world that can mature to produce 2.5μm medium.

Source: "Electrical Drive System Industry Chain Research - Next Generation Automotive Industry Chain Research"

However, according to the industry insiders, Chinese companies can do film capacitors, but there are few manufacturers that can make high-quality films. The film materials are basically imported. Once the supply of foreign companies is insufficient, the domestic film capacitor manufacturers are very nervous, and they can only seize the time to stock up.

Moreover, there are only a handful of companies that can produce film capacitors, and their production capacity is difficult to meet the needs of the diversified electronic control market of domestic new energy vehicles.

Similarly, all of the production materials are imported from high-speed bearings and corona-resistant magnet wires.

The above-mentioned veterans said that domestically produced bearings can meet the demand of some commercial vehicles, but all high-speed bearings in China still rely entirely on imports. At its root, there is no domestic company that has the ability to make wide temperature-change greases that meet the operating temperature of -40 ° C to 150 ° C. Although some enterprises have begun to tackle high-speed bearing technology, they have not yet reached the stage of mass production verification.

In terms of electromagnetic wire materials, China can produce copper wire, but the raw materials of the corona-resistant insulating paint film coated on the surface are all from abroad.

What is scarce for domestic companies is not only materials, but also advanced processing techniques.

Permanent magnets account for about 15%-25% of the cost of permanent magnet synchronous motors, which is an important part of motor products. However, the yield of domestic permanent magnets can only be 70%, while the yield of Japanese permanent magnet manufacturers can reach 85%.

In addition, as an important permanent magnet material, the surface of NdFeB needs to seep and bleed, and the amount of heavy rare earth is reduced while increasing the coercive force (the ability of the magnet to be demagnetized). Although China accounts for 30%-40% of the world's rare earth reserves and about 85% of the market supply, in the face of seepage and seepage, domestic suppliers only stay in the sample test stage, and rarely do batches. produce.

3

The power chip broke the monopoly,

The control chip is completely backward

If the motor parts are made in China, the problem of "good or bad" is solved. If the electronic control parts are made in China, it is necessary to solve the problem of "having no". The above-mentioned veterans even described that the electronic control device of a new energy vehicle was opened, and there was no domestically produced device.

The chip part of the motor control system can be roughly divided into a power chip and a control chip. According to the above-mentioned industry insiders, in the field of power chips, Zhuzhou CSR Times Electric, BYD and Jiaxing Star have begun to produce domestic IGBT devices, but their safety, reliability, durability and other test certifications are still on the way to iteration.

The book "New Energy Vehicle Electric Drive Industry Development Report (2019)" also clearly states that the design, manufacturing and technical standards of IGBT devices are basically in the hands of a few foreign power electronic device manufacturers such as Infineon, Fuji, Mitsubishi, I&R and so on. In the hands, IGBT modules rely on imports, which seriously restricts the development of China's industry.

2016 global power module market ranking TOP 10

Source: IHSMarket 2017 Report

In any case, the domestic IGBT has a zero breakthrough, but the control chip is still monopolized by foreign companies.

The above-mentioned industry believes that car-level chips and proprietary integrated circuits rely on imports from development, testing, product manufacturing, and manufacturing test equipment. This is not a new problem encountered by the new energy automobile industry, but a historical issue arising from the era of traditional fuel vehicles, and also a challenge for the entire Chinese industry.

He pointed out that before the rise of the new energy automobile industry, Infineon and other established control chip companies have cooperated with domestic mainstream car companies for several decades, and set up the automotive electronics division to develop a variety of vehicle-level control. chip. With the high technical barriers, many of the domestic manufacturers that have just started are kept out of the door.

“This is a historical continuation issue and is not directly related to new energy vehicles. However, with the development of the new energy automobile industry, such problems have become more and more prominent, affecting technological innovation and China’s global competitiveness.” He commented Road.

Similar to the control chip, the "car neck" problem that is transmitted from the traditional fuel car to the new energy car, including the gearbox, clutch, hydraulic module, high speed gear, planetary gear and so on. For example, the above-mentioned seniors said that in recent years, the domestic drive motor housing has not improved much, but the materials and reliability are still insufficient. Some products have problems such as water leakage, oil leakage, leakage and sealing.

4

device:

One tens of millions, even tens of millions,

How many people can afford it?

High-priced manufacturing equipment and testing equipment, instrumentation, etc., are unbearable for many small and medium-sized parts companies.

The above-mentioned veterans told the "Electric Vehicle Observer" that the high-end equipment manufacturing of automobiles is quite profitable. Taking gears as an example, gear manufacturing is a traditional weakness in China's industrial sector. Gear processing and testing equipment is 100% dependent on imports. For example, a high-precision gear grinding machine costs tens of millions of yuan, and few single companies bear Can afford.

Swiss Reishauer Les Hall RZ60 gear grinding machine

In addition, new energy vehicles have high performance requirements for motors. The speed of high-end motors can generally reach 16,000 rpm or more, even up to 20,000 rpm, while domestic manufacturers can only produce motor dynamic tests below 10,000 rpm. Equipment, equipment above 10,000 rpm depends on imports.

In addition, precision measuring instruments such as torque measuring instruments, vibration and noise testers, high-end power analyzers, and even incubators have very limited domestic capabilities.

5

How to gradually get rid of dependence?

In the face of so many materials, components/components, technology and equipment that are "card necked", what should China do?

Some people believe that the acquisition, "digging people" is the most direct and the fastest way to get rid of monopoly. However, the above-mentioned insiders retorted that "the problem that money can solve is not a problem. The industrial base and technology involved in the entire industrial chain can never be obtained by saving money. The power of one country may not be realized."

In his view, technologies with relatively low technological content or poor market profits may be acquired through acquisition. However, high-tech, high-profit monopoly components, such as functional chips, precision processing and test equipment, the road to acquisition is impossible.

How to do?

The above veterans believe that, first of all, the national level should be directed to support technological innovation projects in the field of new energy vehicles, especially basic research, rather than directly subsidizing end products as in the past. For enterprises with relevant technology research and development, tax reduction and subsidy support can be given, allowing enterprises to try and test and encourage enterprises to carry out projects that are related to manufacturing base and innovative technologies, but are difficult to make profits in the short term.

Second, the new energy automobile industry should strengthen exchanges, with particular emphasis on the transformation of research and development results in universities and research institutes. This also depends on the strategic vision of policy makers, focusing on the basic research of materials, experiments, basic components and other applications away from the application side, and maximizing the supporting role of basic research and development on the entire industrial chain.

Third, respect talents, protect intellectual property rights, and improve the academic environment and rising channels of university and enterprise basic R&D personnel.

The source said that a certain university laboratory in China is the name of Taiwan's Foxconn. The phased results of its carbon nanotube research were tested on the LG power battery in South Korea, but the domestic enterprises that should have been near the water for the first time did not get ahead. This also reflects the status quo of Chinese enterprises' lack of innovation and sense of backwardness in research and development. Another university professor is studying the composite nanotube-copper project, the goal is to achieve the current, thermal conductivity, temperature resistance and strength of the "composite super copper" material to several times the copper. Similar projects in the United States were included in the R&D project of the key development of new energy vehicle motor systems by the Ministry of Energy. Such projects and projects that are far from application and profitability should be equally valued by the Chinese government and industry, academia and research.

"Now, there is no district journal of Electrical Engineering in China. The research results of R&D personnel can only be published in international journals such as the United States, and used by foreign institutions and enterprises. President Xi Jinping called on researchers to write papers in the motherland. On the earth, our institutions of higher learning and research institutes use the articles published in the journals to evaluate professors and experts. This may be one of the reasons why the foundation and innovation are far from the world. This person analyzed. "Basic technology and industrial chain should be valued as well as applied science. Key technologies and core component innovations should be funded like subsidized vehicles. China's new energy vehicles will be globally competitive." He is full of China's auto industry.