Motor Design Ltd will be presenting a virtual tutorial on Sunday 10th October.
Optimised Electrical Machine Designs for E-Mobility Applications – Mircea Popescu (Chief Technology Officer, MDL), Philip Mellor, Nick Simpson, James Goss (CEO, MDL), Melanie Michon (Head of Engineering, MDL) and Jonathan Godbehere (Senior E-Machine Specialist, MDL).
Transport electrification is seen as one of main solutions to reduce global CO2 emissions and increased demand of mechanical energy can be provided by electrical energy. The best energy conversion systems are undoubtedly the combination: electrical machines + power electronics + batteries. The increasing demand of full electric vehicles arises specific challenges in terms of design for manufacturing, low weight, material costs and material supply chain. There is a strong interest to reduce the volume and cost of active materials in propulsion motor technologies beyond their current state-of‐art, with a strong focus on industrial feasibility for mass production. Potential solutions include increased motor speeds and higher pole numbers and/or the adoption of rare earth free typologies such as reluctance (switched and synchronous) and induction machines. As there can be significantly different usage and performance requirements across e-mobility applications adopting a common standard of motor design is unlikely to yield the optimum in terms of overall system efficiency and electric vehicle range. These considerations will be discussed and compared. Advances in fast switching power semiconductor devices and digital control have enabled high frequency operation of electrical machine drives, with fundamental operating frequencies exceeding 1 kHz being proposed. High frequency operation allows for greater mechanical speeds and designs with a larger number of magnetic poles, leading to a more compact electrical machine package for a given output requirement. However, high frequency operation results in a higher volumetric loss in the active components of the electrical machine; primarily as a result of induced circulating eddy currents in the stator laminations, winding conductors and the rotor. The non-uniform heating and reduction in efficiency associated with these AC loss effects represent a major hurdle to the successful development of compact high frequency electrical machine drives. The benefits and challenges associated with high frequency operation of electrical machines for aerospace and automotive applications will be reviewed and the techniques and design choices available to the designer to reduce high frequency loss effects and extract heat will be surveyed.
Cutting-edge sensitivity analysis and multi-objective optimisation techniques will be applied in the design of an electric motor for a PHEV traction application. Each candidate solution will be evaluated in terms of electromagnetic, thermal and mechanical behaviour across the full operating envelope. The optimisation will generate a pareto front which allows efficiency over a drive cycle to be traded off against motor cost. This approach utilises a high performance or cloud computing infrastructure to deliver a truly revolutionary design workflow.
The tutorial will be focussed around various design approaches and aspects for a range of automotive and aerospace applications. The tutorial is structured as follows:
- Elimination/reduction of rare earth magnets in E-mobility
- Holistic design against an operational duty cycle in Electrical Vehicles
- High frequency operation of E-Motors in E-mobility
- Innovative multi-physics designs of E-Motors using multi-objective optimisation.
The tutorial is mainly addressed to Engineers and Technical Professionals who have an interest in Electric Machines for automotive application.
View the ECCE technical program here.