Design of Induction Motors With Flat Wires and Copper Rotor for E-Vehicles Traction System

Popescu, Mircea; Leonardo, Lino Di; Fabri, G.; Volpe, Giuseppe; Riviere, Nicolas; Villani, Marco

doi:10.1109/tia.2023.3256391

Cited by 12 publications

(2 citation statements)

References 51 publications

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“…The overload has been investigated by checking the hotspot temperature of the winding. In [31], a 200 kW 370 N.m IM has been designed for an EV with the target of enhancing the performance for mass production. To achieve this goal, suitable materials and manufacturing processes like rotor die-casting, hairpin stator winding, and a specific cooling system have been investigated.…”

Section: Methodsmentioning

confidence: 99%

Design Optimization of Induction Motors with Different Stator Slot Rotor Bar Combinations Considering Drive Cycle

Mahmouditabar,

Baker

2023

Energies

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In this paper, a sequential Taguchi method for design optimization of an induction motor (IM) for an electric vehicle (EV) is presented. First, a series of empirical and mathematical relationships is systematically applied to reduce the number of possible stator slot rotor bar (SSRB) combinations. Then, the admissible optimal combinations are investigated and compared using finite element (FE) simulation over the NEDC driving cycle, and the three best combinations are selected for further analysis. Each topology is optimized over the driving cycle using the k-means clustering method to calculate the representative working points over the NEDC, US06, WLTP Class 3, and EUDC driving cycles. Then, using the Design of Experiment (DOE)-based Taguchi method, a multi-objective optimization is carried out. Finally, the performance of the optimized machines in terms of robustness against manufacturing tolerances, magnetic flux density distribution, mechanical stress analysis, nominal envelope curve and efficiency map is carried out to select the best stator slot rotor bar combination. It is also found that the K-means clustering method is not completely robust for the design of electric machines for electric vehicle traction motors. The method focuses on regions with high-density working points, and it is possible to miss the compliant with the required envelope curve.

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Section: Methodsmentioning

confidence: 99%

Design Optimization of Induction Motors with Different Stator Slot Rotor Bar Combinations Considering Drive Cycle

Mahmouditabar,

Baker

2023

Energies

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show abstract

“…Then, the admissible optimal combinations are optimized over the driving cycle. In [15], a 200 kW 370 N.m IM has been designed with the target of enhancing the performance for mass production. To achieve this goal, suitable materials and manufacturing processes like rotor die-casting, hairpin stator winding, and a specific cooling system have been investigated.…”

Section: Introductionmentioning

confidence: 99%

Robust Design of Induction Machines for High-Speed Electric Freight Locomotive Applications

Mahmouditabar,

Baker

2024

IEEE Access

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This paper showcases a systematic procedure to design the most efficient re design of a commercially available induction machine to be used as a traction motor in an Electric Freight Locomotive for the rail journey from Tehran to Mashhad. Using Taguchi optimization, copper and aluminium wound versions of the machine are optimized for an 1870-ton load locomotive with a peak power of 1203kW. The driving cycle is summarized using the K-means clustering method to obtain representative points. Full details of the drive cycle and guiding rail adhesion modelling are given and subsequently used in a sequential multiphysics and multi-operation mode robust procedure which optimizes the geometry and cooling parameters whilst taking manufacturing tolerances into account. The paper thus presents a thorough comparative study of aluminium-based and copper-based designs to meet a realistic Electric Freight Locomotive specification. Results indicated that the proposed approach is effective in optimum and robust design of conventional and aluminium induction machines and can be applied to other machine types operating on other rail journeys. Switching to aluminium is one way of improving the recyclability of motors, but in the scenario considered here, results in a 1.1% reduction in efficiency over the driving cycle.

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Circularity potential of electric motors in e-mobility: methods, technologies, challenges

Di Gerlando,

Gobbi,

Magnanini

et al. 2024

Jnl Remanufactur

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The imperative shift toward sustainable development mandates a revolutionary transformation in the transportation sector. While the transition from internal combustion engines to electric motors represents a pivotal step, its ecological impact may fall short of expectations. This undertaking is motivated by the recognition that a truly impactful transition necessitates intricate strategies, addressing resource consumption during manufacturing and minimizing post-use waste. This literature review is dedicated to enhancing the framework of circular strategies within the realm of electric motors, with a specific focus on remanufacturing. The objective is to cultivate a conscientious approach to product development, primarily centered on the four key pillars of circularity: reuse, remanufacture, upgrade, and recycle. The primary goal is to furnish a comprehensive overview of the myriad possibilities associated with reusing products, either in parts or as a whole. Upon introducing the circular approach, this review underscores pivotal enabling technologies essential for a successful transition. These include inspection, disassembly, rewinding, and demagnetization. The ensuing discussion delves into the technological challenges faced and presents cutting-edge solutions poised to redefine the landscape. The concluding section extends the perspective to the future, introducing innovative studies and solutions still in their developmental stages. This review is tailored for decision-makers, policymakers, and researchers, providing them with a valuable overview and facilitating discussions to propel our society toward a sustainable and responsible future in electric motor technology.

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Design of Induction Motors With Flat Wires and Copper Rotor for E-Vehicles Traction System

Cited by 12 publications

References 51 publications

Design Optimization of Induction Motors with Different Stator Slot Rotor Bar Combinations Considering Drive Cycle

Design Optimization of Induction Motors with Different Stator Slot Rotor Bar Combinations Considering Drive Cycle

Robust Design of Induction Machines for High-Speed Electric Freight Locomotive Applications

Circularity potential of electric motors in e-mobility: methods, technologies, challenges

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