Tribology and Lubrication for E-Mobility

[Pages:16]Tribology and Lubrication for E-Mobility

Conference Program An all-new event exploring the latest technical challenges and commercial opportunities that will impact the future of electric vehicle (EV) technology.

November 3-5, 2021

Southwest Research Institute (SwRI) San Antonio, Texas (USA) A HYBRID EVENT

Society of Tribologists and Lubrication Engineers

840 Busse Highway # Park Ridge, Illinois 60068 (USA) # (847) 825-5536 #

Society of Tribologists and Lubrication Engineers

The Future of E-Mobility

Dear Conference Attendees,

Welcome to those joining us in-person here at the Southwest Research Institute (SwRI) in San Antonio or participating virtually for STLE's inaugural Tribology and Lubrication for E-Mobility Conference. I am very excited about the event and am so pleased we have more than 300 participants that will be attending the three-day hybrid technical conference.

Hopefully you find the conference to be informative and worthwhile as we'll spend the next few days exploring the rapidly changing electric vehicle (EV) technologies that are bringing new opportunities to the tribology and lubrication field. The conference includes more than 20 speakers from leading companies and organizations with an interest in e-mobility that will discuss the latest advancements and outlook for the EV market.

This impressive lineup of presenters will address key topics at the forefront of the evolving EV landscape, including transmission, gear and bearing lubrication issues, recent requirements for lubricant thermal and electrical properties, new operating conditions, and changes in the manufacturing of parts.

In addition to the technical program, we're pleased to offer an education course introducing EV technology featuring expert speakers, representing OEMs, tier-one suppliers, and additive and lubricant companies, covering different

EV platforms such as battery electric vehicles (BEVs) and hybrid technologies and topics including hardware design, lubricant requirements for EVs, EV thermal management, heat transfer fluids in EVs and testing methods.

For your convenience, we will be recording the entire conference. The final recording will include speakers who presented live, as well as pre-recorded presentations. All registered participants will have access to the presentation slides and recordings after the conference concludes, so you can watch again or catch up on any talks you might have missed.

I personally would like to thank my colleagues on the conference planning committee and the STLE staff for the great work in organizing this event. More importantly, special thanks to our speakers, course instructors, and STLE corporate sponsors, especially to SwRI for hosting the conference. If it were not for you, we wouldn't be able to deliver a top-notch technical program without your generous support.

Have an enjoyable and productive conference!

Sincerely,

Bill

William Anderson, Ph.D., Afton Chemical Corporation 2021 EV Conference Planning Committee Chair

Thank You to Our Sponsors

STLE wishes to thank the following sponsors for their generous support of the 2021 Tribology and Lubrication for E-Mobility Conference. Visit evconference for the most up to date sponsors list and signage on-site in San Antonio.

Signature Event Sponsor

Power-Up Sponsors

Current Sponsors

The Society of Tribologists and Lubrication Engineers (STLE) is the premier technical society serving the needs of more than 13,000 industry professionals and 250 organizations that comprise the tribology and lubrication engineering business sector. STLE offers its members industry-specific education and training,

professional resources, technical information, certification programs and career development. STLE is an international organization headquartered at 840 Busse Highway, Park Ridge, Illinois 60068 (USA). Contact us at (847) 825-5536, email: Information@; website: .

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Special Acknowledgments

2021 Tribology and Lubrication for E-Mobility Conference Planning Committee

STLE wishes to thank these individuals for their support and contributions in planning an outstanding technical program.

William Anderson, Ph.D. (Program Chair) Afton Chemical Corporation

Ken Hope, Ph.D. Chevron Phillips Chemical Company

Jun Qu, Ph.D. Oak Ridge National Laboratory

Neil Canter, Ph.D. Chemical Solutions

Peter Lee, Ph.D. Southwest Research Institute

Dairene Uy, Ph.D. Shell Global Solutions (US) Inc.

Michael Duncan, Ph.D. Daubert Chemical Company, Inc.

Hong Liang, Ph.D. Texas A&M University

Paul Hetherington HollyFrontier Lubricants & Specialties

Babak Lotfi, Ph.D. ExxonMobil Chemical Company

Ken Hope, Ph.D., (President) Chevron Phillips Chemical Company

Ryan Evans, Ph.D., (Vice President) The Timken Company

Hong Liang, Ph.D., (Secretary) Texas A&M University

Jack McKenna, (Treasurer) Sea-Land Chemical Company

Paul Hetherington, (Immediate Past President) HollyFrontier Lubricants & Specialties

William Anderson, Ph.D. Afton Chemical Corporation

Nicholas Argibay, Ph.D. Ames National Laboratory

Steffen Bots Lubeserv

2021-2022 STLE Board of Directors

Aaron Greco, Ph.D. Argonne National Laboratory Karen Harrington Fuchs Lubricants Company Brian Holtkamp Nye Lubricants Brian Hovik Viking Engineering Peter Lee, Ph.D. Southwest Research Institute Khalid Malik Ontario Power Generation Mandi McElwain Univar Solutions Kuldeep Kishore Mistry, Ph.D. The Timken Company

Ramoun Mourhatch Chevron Oronite

Angela Pitenis, Ph.D. University of California, Santa Barbara

Farrukh Qureshi, Ph.D. The Lubrizol Corporation

Thomas Scharf, Ph.D. University of North Texas

Raj Shah, Ph.D. Koehler Instrument Company, Inc.

David Turner CITGO Petroleum Corporation

Min Zou, Ph.D. University of Arkansas

Edward P. Salek, CAE Executive Director | STLE Headquarters

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Society of Tribologists and Lubrication Engineers

Program Schedule-at-a-Glance

As of October 25, 2021 # All Times Represent US Central Time (CT)

Please note speakers will be participating either in-person or virtual during the conference. Those participating with a virtual presentation will be noted in the schedule below.

Wednesday, November 3, 2021

8:30 am ? 5 pm | Education Course Program | Introduction to Electric Vehicles

Agenda

7:30 ? 8:30 am Registration and Continental Breakfast

8:30 ? 8:45 am Welcome and Introductions

8:45 ? 9:45 am An Overview of Hybrid, Full Electric and Fuel Cell Vehicles Arup Gangopadhyay, Ph.D., Ford Motor Company

9:45 ? 10 am | Break

10 ? 11 am Hardware Design and Drive Unit: Transmission System, Electric Machine, and Geartrain (Virtual Presentation) Michael Tekletsion Berhan, Ford Motor Company Research and Advanced Engineering

11 ? 11:15 am | Break

11:15 am ? 12:15 pm Lubricant Requirements for Electric Vehicles (including hybrids, gearbox and eMotor) Christopher Cleveland, Afton Chemical Corporation

12:15 ? 1:15 pm | Lunch

1:15 ? 2:15 pm Heat Transfer Fluids and Thermal Management in HEV and EVs (General Overview) Thomas Wellmann, FEV

2:15 ? 2:30 pm | Break

2:30 ? 3:30 pm Thermal Management in EVs ? Sub-system and Components (Virtual Presentation) Andreas Mayer, FEV North America

3:30 ? 3:45 pm | Break

3:45 ? 4:30 pm Test Methods for Evaluation of Electric Vehicles (including tribological, thermal and electrical properties) Rebecca Warden, Southwest Research Institute

4:30 ? 5 pm Q&A and Wrap Up

6 ? 7:30 pm Meet-in-Greet (Grand Hyatt San Antonio River Walk Hotel)

Thursday, November 4, 2021

7:30 ? 8:30 am Registration and Continental Breakfast

8:30 ? 8:45 am Welcome and Introductions

Session 1: Laying the Groundwork

8:45 ? 9:45 am Keynote Address ? Electric Vehicle Tribology and Rolling Element Bearing Challenges Ryan Evans, Ph.D., The Timken Company

9:45 ? 10:15 am Compatibility Study of E-Fluids with Copper and Insulation Materials (Virtual Presentation) Rosemary Ran, Shell (Shanghai) Technology Company, Ltd.

10:15 ? 10:45 am Improving Gear and Thermal Efficiency of Electric Vehicle Transmission Fluids with the Use of New Group V Base Stocks Gareth Moody, Ph.D., Croda Europe Ltd.

10:45 ? 11 am | Break

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Session 2: EV Driveline Fluids

11 ? 11:30 am Profiling Electric Drivetrain Fluid Characteristics ? Presented by SAE International Greg Miiller, Savant Group

11:30 am ? Noon Base Oil Benchmarking for Gear Oils in Electric Vehicle Drivetrains (Virtual Presentation) Steffen Gl?enzer, Ph.D., Clariant

Noon ? 1 pm | Lunch

Session 3: Lubrication for EVs 1 ? Base Oils

1 ? 1:30 pm Base Oils Useful for E-Mobility Ken Hope, Ph.D., Chevron Phillips Chemical Company

1:30 ? 2 pm Extending Drive Range and Enhancing Thermal Management in EVs using Next-Generation PAOs Babak Lotfi, Ph.D., ExxonMobil

2 ? 2:30 pm A Lifecycle Analysis for the Efficiency and Emission of EVs in Comparison to IC Engines Ali Erdemir, Ph.D., Texas A&M University

2:30 ? 3 pm Will Electric Vehicles Break the Grid?(Virtual Presentation) Amro Farid, Ph.D., Dartmouth/MIT

3 ? 3:15 pm | Break

Session 4: Lubrication for EVs 2 ? Additives and Finished Fluids

3:15 ? 3:45 pm New E-Mobility Test Developments and Electric Drivetrain Fluid Technology Yungwan Kwak, Ph.D., Afton Chemical Corporation

3:45 ? 4:15 pm Heat Transfer Performance of Fluids for Electrified Vehicles (Virtual Presentation) Andy Richenderfer, Ph.D., The Lubrizol Corporation

4:15 ? 4:45 pm Ultra-Low Viscosity E-Fluids Enabling a Sustainable Future (Virtual Presentation) Hitesh Thaker, Ph.D., Infineum USA L.P.

4:45 ? 5:15 pm Challenges and Opportunities for Industrial Lubricants as the Automotive Industry Moves to Electric Vehicles Neil Canter, Ph.D., Chemical Solutions

6:30 ? 8 pm Networking Reception (Biga on the Banks) 203 South Mary's at Market, San Antonio, TX

Friday, November 5, 2021

7:30 ? 8:30 am Continental Breakfast

Session 5: Lubricant Testing for EVs

8:30 ? 9 am Characterization of E-Fluids from Laboratory Analysis to the Test Bench (Virtual Presentation) Gunther M?ller, Ph.D., and Rico Pelz, APL

9 ? 9:30 am E-Mobility Fluid Testing for Heavy Truck Transmissions (Virtual Presentation) Mattias Forslund, Ph.D., Scania

9:30 ? 10 am Innovative Design of Lubricants Test Rig for E-Grease and E-Fluid (Virtual Presentation) Deepak H. Veeregowda, Ph.D., Ducom Instruments

10 ? 10:15 am | Break

10:15 ? 10:45 am Dielectric and Electrochemical Properties of Lubricants for Electric Drivetrains and their Influence on the Lubricant-Stator Interface Michael Miller, Ph.D., Southwest Research Institute

10:45 ? 11:15 am Efficiency Performance of Lubricants for Electric Vehicle Powertrains Prof. Dr.-Ing. Karsten Stahl, FZG

11:15 ? 11:30 am | Break

Session 6: EV Hardware Trends ? Stakeholder Perspectives ? Panel Discussion

11:30 am ? 1 pm Needs in Fundamental Understanding of Electric Vehicles, Hong Liang, Ph.D., Texas A&M University

Challenges of Hardware and Fluid Design for Electric Drive Units (Virtual Presentation), Troy Muransky, American Axle & Manufacturing

Fluids for Electrified Vehicles ? Past, Present, and Future, Joe Noles, Infineum USA L.P.

Fluid Implications for Electric Vehicle Drivetrain, Farrukh Qureshi, Ph.D., The Lubrizol Corporation

Topic: TBA, Thomas Wellmann, FEV

Technology Trends in Battery Pack Thermal Management, Ian Smith, Southwest Research Institute

1 ? 3 pm Wrap Up and Tour of SwRI Facility

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Society of Tribologists and Lubrication Engineers

Education Program Schedule

2021 STLE Tribology and Lubrication for E-Mobility Conference

Course instructors will be participating either in-person or virtual during the conference. Those participating with a virtual presentation will be noted in the schedule below.

Wednesday, November 3, 2021

8:30 am ? 5 pm | Education Course Program | Introduction to Electric Vehicles # All Times Represent US Central Time (CT)

Course Agenda (As of October 25, 2021)

7:30 ? 8:30 am Registration and Continental Breakfast

8:30 ? 8:45 am Welcome and Introductions

Program Co-Chairs: Babak Lotfi, Ph.D., ExxonMobil and Neil Canter, Ph.D., Chemical Solutions

8:45 ? 9:45 am An Overview of Hybrid, Full Electric and Fuel Cell Vehicles Arup Gangopadhyay, Ph.D., Ford Motor Company

This presentation will provide an overview of hybrid, battery electric and fuel cell vehicles. The presentation will explain hybridization levels i.e., micro, mild, full, and plug-in, and how they are differentiated by functionalities, battery power requirements, potential fuel economy benefits, and powertrain architectures (series, parallel, series-parallel). Types of engines and driveline systems used in these types of vehicles will also be discussed. These vehicles will be compared against battery electric and fuel cell vehicles including some examples of vehicle name plates related to these technologies available in the market.

Arup Gangopadhyay is a Technical Leader in Powertrain Tribology in Energy, Propulsion and Sustainability organization in Research and Advanced Engineering at Ford Motor Company. Arup has been at Ford for over 30 years and his research focuses on improving fuel economy by reducing frictional losses in powertrain and improving powertrain durability through modifying surfaces of materials, efficient lubrication, and understanding the interaction between lubricant additives and materials. Arup's more recent research includes development of novel lubricants for engines and transmissions and development of coatings for liner-less cylinder bores in engines.

9:45 ? 10 am | Break

10 ? 11 am Hardware Design and Drive Unit: Transmission System, Electric Machine, and Geartrain (Virtual Presentation) Michael Tekletsion Berhan, Ford Motor Company Research and Advanced Engineering

This presentation will review some of the subsystem and component details that were touched on in Module 1 on the vehicle and system levels. Fundamentally, it will focus on the driveline systems of hybrid and full electric units. It will touch on the high-level basics of the transmissions, the electric motor/generators, and the heart of the geartrains, gears and bearings. Along with their mechanical details, we will discuss some of the tribology aspects and what that means in vehicle electric drives.

Michael Tekletsion Berhan is the Powertrain Gears and Bearings Technical Expert at Ford Motor Company Research and Advanced Engineering. Michael has over 25 years in the design, analysis, and integration of gears, bearings, shafts, chains, geartrain systems, and electric motors. He is the chair of the Ford Transmission/ Driveline Patent Committee, the Training Lead for Ford Transmission/Driveline Research, and teaches geartrain systems, components, and CAE. Michael has been a member of the SAE Automatic Transmission Technical Committee for 16 years, sponsoring several standards and recommended practices, and served as Editor and revision author for SAE's AE-29 Design Practices book's Gear, Splines, and Chains chapter. He has also served on the AGMA Electric Drive Committee and taught the AGMA class Integration and Trade-offs in Gear and Bearing Systems.

11 ? 11:15 am | Break

11:15 am ? 12:15 pm Lubricant Requirements for Electric Vehicles (including hybrids, gearbox and eMotor) Christopher Cleveland, Afton Chemical Corporation

This module presents an overview on lubricant requirements for single and multi-speed, direct oil-cooled electric drive unit applications. As traditional lubricant formulation strategies are increasingly restrictive for EV applications, novel lubricant/additive technologies will be needed to meet new requirements and evolving hardware demands. This module will include formulation approach for EV driveline

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fluids development and fluid properties required in electric drive units. The discussion will briefly cover use of grease in EV applications. Finally, we will discuss challenges related to electrical and thermal properties as well as compatibility with copper and other insulation materials.

Christopher Cleveland is R&D Technical Director at Afton Chemical Corporation, where he has worked for 15 years in transmission fluid research and development. Currently, Chris leads the ATF Formulation team, which is responsible for the development of performance additives for the next generation transmission fluids, AT, DCT, CVT, eV, in collaboration with key customers and OEM partners.

12:15 ? 1:15 pm | Lunch

1:15 ? 2:15 pm Heat Transfer Fluids and Thermal Management in HEV and EVs (General Overview) Thomas Wellmann, FEV

This lecture will begin with a layout of propulsion system architectures in electrified vehicles. The architectures will cover the landscape from micro-hybrid vehicles through mild-hybrid, full hybrid, plug-in hybrid electric vehicles (PHEVs), and electric vehicles (EVs). The flow of energy in the driveline of electrified vehicles will be described through the use of case study examples. Typical experimental approaches to gather and analyze the flow of energy will be illustrated. Specifically, the role of thermal management at the vehicle level will be highlighted using specific examples spanning hybrid electric vehicles (HEVs) as well as battery electric vehicles (BEVs). Simulation techniques used for designing the thermal management layout of electrified vehicles will be discussed. The layout of the thermal management systems of typical electrified vehicles (i.e., HEVs and EVs) will be shown using pictures and schematics from real vehicles. Typical battery architectures and associated thermal management strategies will be shown using examples of contemporary EV. Finally, examples of vehicle range testing, as well as methodologies to optimize the range of electric vehicles (via improved thermal management) will be discussed

Thomas Wellmann has been at FEV for more than 20 years in different roles.Thomas started his career in NVH (noise, vibration, harshness), where he was engaged in multiple projects for powertrain and driveling NVH, including conventional and electrified powertrains. Activities include detailed studies such as driveline torsional analysis and isolation, engine start/stop investigations, hybrid system strategy analysis, with focus on fuel economy and driveline NVH, as well as integration of electric drive units. With focus on transmissions and drivelines, his responsibilities grew to oversee all vehicle and component testing in this area, including projects on driveline efficiency, durability, and vehicle fuel economy for conventional, hybrid electric and fully electrified powertrains. He has published several publications on the topics of driveline electrification of propulsions systems.

2:15 ? 2:30 pm | Break

2:30 ? 3:30 pm Thermal Management in EVs ? Sub-system and Components (Virtual Presentation) Andreas Mayer, FEV North America

This lecture will provide a component-specific view of key drivetrain elements of electrified powertrains. Specifically, challenges and solutions from a lubrication and thermal management perspective of electrified drivetrain components will be discussed. Initially, the layout of typical drivetrains for hybrid as well as battery electric vehicles will be described. Examples depicting the integration of electric motors and generators in hybrid transmissions will be shown. Examples of state-of-the-art single-speed and multi-speed electric drive units will be illustrated. Case study examples showing the use of advanced simulation tools to meet the lubrication and heat transfer needs of such drive units will be provided. Similarly, results from typical component level testing showing the influence of fluid properties on drive unit efficiency will be discussed. The future technology path for inverters, electric machines, and drive units, along with associated thermal management challenges and solutions, will be discussed

Andreas Mayer is Chief Engineer ? E-Mobility at FEV North America, with over 20 years in advanced powertrain testing methodologies, calibration and development. His area of expertise includes E-motor and inverter controls and parametrization, project and engineering management. Andreas has held several roles at FEV, including Subject Matter Expert?E-Mobility; Senior Technical Specialist ? Testing Methods; Technical Specialist ? Powertrain Testing; Project Engineer ? Powertrain Testing; Test Engineer ? Base Engineer Calibration; and Test Bench Engineer ? Thermodynamics (FEV EU, Germany). He is a State-certified Engineer (EQF Level 6), BBS Germersheim, Germany (automotive engineering) and Certified Instructor (AEVO) IHK Ludwigshafen, Germany.

3:30 ? 3:45 pm | Break

3:45 ? 4:30 pm Test Methods for Evaluation of Electric Vehicles (including tribological, thermal and electrical properties) Rebecca Warden, Southwest Research Institute

This presentation will discuss some of the current established test methods for evaluating EV lubricants and coolants and assess their ability to perform in the unique environment. This will include discussions on high-speed performance, non-conventional materials compatibility, thermal performance, and others. The module will also include a discussion on evaluation methods that will need to be developed to enable industry to properly formulate and evaluate fluids for EV applications.

Rebecca Warden is the manager of the Fleet and Driveline Fluids Evaluation Section at Southwest Research Institute (SwRI). Her section focuses on lubricant evaluations for electrified vehicles, automatic transmissions, axles, tractor hydraulic systems, and gear/hydraulic systems in industrial applications. She is the co-project manager for the Advanced Fluids for Electrified Vehicles (AFEV) consortium, which exists to better understand the unique interactions of EV lubricants with the rapidly growing and changing EV market. During her 12-year career at SwRI, Rebecca has been involved with projects ranging from test stand design and development, standardized lubricants testing, and next generation research and development.

4:30 ? 5 pm Q&A and Wrap Up

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Society of Tribologists and Lubrication Engineers

Technical Program Schedule

2021 STLE Tribology and Lubrication for E-Mobility Conference

Speakers will be participating either in-person or virtual during the conference. Those participating with a virtual presentation will be noted in the schedule below.

Thursday, November 4, 2021 | All Times Represent US Central Time (CT)

Program Agenda (As of October 25, 2021)

7:30 ? 8:30 am Registration and Continental Breakfast

8:30 ? 8:45 am Welcome and Introductions

Ken Hope (STLE President), Ph.D., Chevron Phillips Chemical Company, and William Anderson (EV Program Chair), Ph.D., Afton Chemical Corporation

Session 1: Laying the Groundwork

Moderator: William Anderson, Ph.D., Afton Chemical Corporation

8:45 ? 9:45 am Keynote Address ? Electric Vehicle Tribology and Rolling Element Bearing Challenges Ryan Evans, Ph.D., The Timken Company

The development and mainstream adoption of electric vehicles presents an exciting landscape for tribological system and component optimization. While the bearings used in internal combustion engine vehicles have known effective designs, the initial bearing selections in new electric vehicle platforms present opportunities for improvement. An introduction to rolling element bearings will be given, followed by a survey of high-level electric vehicle key trends and technology drivers. Two electric vehicle bearing application spaces are discussed in detail, including wheel end bearings and electric axle bearings. Tribological challenges and recommended solutions in each area are offered, along with descriptions of key technology development capabilities needed to accelerate innovation such as high-speed bearing testing and advanced lubricant rheology experimental apparatus.

Ryan Evans is the director of research and development at The Timken Company, currently responsible for leading teams that identify and develop new product, materials, and manufacturing technologies to meet customer needs. He joined Timken in 2002 as a researcher in the field of advanced materials and made significant contributions in the areas of thin film coatings (Timken "Wear-Resistant Bearing" premium product option), lubrication, advanced materials characterization, and tribology within the R&D division. He has authored over 40 refereed technical publications and has 14 patents in these fields.

Ryan is Vice President of the Society of Tribologists and Lubrication Engineers (STLE) for 2021-2022 and has won several STLE publishing awards. In addition to STLE, he is a member of ASM International and ASME.

9:45 ? 10:15 am Compatibility Study of E-Fluids with Copper and Insulation Materials (Virtual Presentation) Rosemary Ran, Shell (Shanghai) Technology Company, Ltd.

With the consensus on reducing greenhouse gas emissions, a typical manifestation of the automotive market is the rapid growth in the number of electric and hybrid electric vehicles. The development of new energy models and the overall acceleration of the electrification of new cars are not only the way forward of the times, but also of extraordinary strategic significance to China. Unlike the drive structure of conventional fuel vehicles, in hybrid vehicles (HEVs and PHEV), more OEMs combine hardware such as motors, gearboxes, clutches and some control units, with motors set up in transmissions and immersed in transmission lubricants to improve the cooling efficiency of motors. Therefore, the direct contact between the E-motor and transmission lubricants poses many challenges to the compatibility of lubricants and motors and puts forward strict requirements for the oil resistance of motor insulation materials.

For the integrated electric drive system, there is no unified standard specification at home and abroad. The standards used by each lubricant company in the market also vary. In December 2019, the China Electrical Industry Association (CELA), launched "Technical Requirements for Insulation Structure of Drive Motors in New Energy Vehicles." The specification is for the requirements of insulation material hardware, but also clearly proposed that for oil-cooled motors, insulation components and insulation structures should also meet the requirements of oil resistance. In this presentation, we conducted fluid compatibility tests at different temperatures, with various E-motor insulation materials to explore the correlation between different chemical additive technology and motor insulation materials. The results show that there are big differences in compatibility between different insulation materials and oil formulations. At the same time, this presentation also shows the possibility of attenuation or decomposition of additives by different water content in oil, thus affecting the insulation of motors. The unique transmission structure design of electric and hybrid vehicles from different OEMs presents many challenges for lubricants. However, lubricants can be tailored to demonstrate outstanding insulation compatibility and excellent high temperature corrosion resistance in the above tests, in line with the special design requirements of EVs and hybrid vehicle transmission systems.

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