Modeling and Simulation of Electric Motors Using Lightweight Materials

Boopathi, Nikita Gobichettipalayam; Muthuraman, Manoj Shrivatsaan; Pałka, Ryszard; Wardach, Marcin; Prajzendanc, Paweł; Gundabattini, Edison; Singh, R. Raja; Solomon, Darius Gnanaraj

doi:10.3390/en15145183

Cited by 8 publications

(12 citation statements)

References 29 publications

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“…In Figure 3a, a kind of lightweight material, i.e., PA6GF30 30% glass fiber-reinforced polymer, is explored in the motor casing to reduce motor weight and remain compatible with the water-cooling system [11]. Compared to the aluminum casing, the cooling efficiency of the motor using composite materials is slightly reduced, i.e., the winding maximum temperature increases from 127 • C to 131 • C, while its weight is greatly reduced by 20.27%.…”

Section: Composite Materialsmentioning

confidence: 99%

“…Composite materials [11,16,31] Glass fiber-reinforced polymer, Carbon-reinforced plastic, Advanced plastic, etc.…”

Section: Materials Common Materials Extended Performance Boundaries L...mentioning

confidence: 99%

“…Several approaches have been employed with favorable outcomes in the pursuit of achieving lightweight motor construction [11][12][13]. As depicted in Figure 1, typical methods for motor lightweight design can be classified into two categories: the utilization of lightweight materials [10] and the implementation of structural lightweight design [14,15].…”

Section: Introductionmentioning

confidence: 99%

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State-of-the-Art Lightweight Implementation Methods in Electrical Machines

Zhao,

Li,

Zhang

et al. 2024

Machines

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The demand for high-power density motors has been increasing due to their remarkable output capability and compact construction. To achieve a significant improvement in motor power density, lightweight design methods have been recognized as an effective enabler. Therefore, extensive investigations have been conducted to reduce motor mass and achieve lightweight configurations through the exploration of lightweight materials, structures and manufacturing techniques. This article provides a comprehensive review and summary of state-of-the-art lightweight implementation methods for electrical machines, including the utilization of lightweight materials, structural lightweight design, and incorporation of advanced manufacturing technologies, such as additive manufacturing techniques. The advantages and limitations of each approach are also discussed in this paper. Furthermore, some comments and forecasts on potential future methodologies for motor lightweighting are also provided.

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Section: Composite Materialsmentioning

confidence: 99%

“…Composite materials [11,16,31] Glass fiber-reinforced polymer, Carbon-reinforced plastic, Advanced plastic, etc.…”

Section: Materials Common Materials Extended Performance Boundaries L...mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

State-of-the-Art Lightweight Implementation Methods in Electrical Machines

Zhao,

Li,

Zhang

et al. 2024

Machines

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“…1 To increase the power density of motors, a high electromagnetic load together with a lightweight structure can be employed while designing the motor. In Fang et al 2 , Boopathi et al 3 four different models were designed to study the lightweight design of stators along with their high-efficient magnetic-alloy-core selection to expand the total power density for the motor.…”

Section: Different Ways Of Reducing Motor Weight and Increasing Effic...mentioning

confidence: 99%

Performance analysis of electric motors, comparing lightweight techniques and cooling methods: A review

Shrivatsaan M,

GB,

Palka

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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The paper gives a comprehensive review of lightweight materials/design of permanent-magnet-synchronous-motors and different temperature-reducing (cooling) techniques. The paper discusses and compares various simulations and performance analyses of different practically implemented solutions. Temperature and performance analyses for cooling systems using phase-changing materials, cooling jackets, and other coolants are investigated, and the use of lightweight materials and composites is compared. A discussion on numerical methods and results (finite element method analysis), in order to get a more-precise thermal mapping model for different machine structures is presented. Finally, the best temperature-reducing-cooling systems methods along with the good lightweight designs which increase the overall efficiency of the motor are discussed and commented on.

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“…Jiang et al 7 optimized the magnesium alloy wheel hub structure by establishing a finite element model of the magnesium alloy wheel, achieving weight reduction and optimizing the dynamic impact performance of the magnesium alloy wheel. Boopathi et al 8 applied lightweight materials such as carbon fiber composites to the casing of automobile motors. Reducing the weight of the motor also reduced energy consumption and improved the lightweight level of automobiles.…”

Section: Introductionmentioning

confidence: 99%

Research on the lightweight design and multilevel optimization method of B‐pillar of hybrid material based on side‐impact safety and multicriteria decision‐making

Zhang,

Lu,

Huang

et al. 2023

Polymer Composites

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This paper designs and optimizes a new structure hybrid material B‐pillar assembly. Establish a finite element analysis model for the side impact test of an electric vehicle to verify the model's accuracy. Construct a finite element model of the hybrid material B‐pillar assembly. Combined with the static performance analysis of the B‐pillar, the laminate design of the carbon fiber composite B‐pillar reinforcement plate and optimization. For the outer and inner panels of the B‐pillar, the surrogate model method and the multiobjective optimization method are combined to set 11 design variables and 13 responses. The optimal Latin hypercube design method was used to randomly sample each design variable and fit the radial basis function (RBF) approximate model. The modified second‐generation non‐dominated sorting genetic algorithm (MNSGA‐II) was used to carry out multiobjective optimization of the mixed material B‐pillar assembly, and the multicriteria decision‐making method was used to obtain the optimal solution for the Pareto solution set. A drop weight impact test was performed on the hybrid material B‐pillar assembly. The results showed that the peak collision force of the hybrid material B‐pillar was reduced by 43.7% compared with the original steel B‐pillar, the specific energy absorption was increased by 17.5%, and the side impact safety performance was better. After optimization, the weight of the mixed material B‐column was reduced by 26.44%. The improvement rates of the intrusion amount at P2 and the intrusion speed at P1 were 23.99% and 0.63%, respectively, and the lightweight effect and side impact safety were significantly improved.Highlights The finite element analysis parameters of carbon fiber composite materials were constructed through experiments, and the basis for simulation analysis under various working conditions of the B‐pillar based on performance‐driven optimization was established. A hybrid material B‐pillar design method is proposed, which consists of a variable‐thickness high‐strength steel B‐pillar outer plate, a variable‐thickness high‐strength steel B‐pillar inner plate, and a carbon fiber composite B‐pillar reinforcement plate. The super layer of the carbon fiber composite B‐pillar reinforcement plate was optimized and the laying plan of the carbon fiber composite B‐pillar reinforcement plate was determined. Performance‐driven optimization is adopted to realize the collaboration of multilevel design and optimization methods such as B‐pillar conceptual design, detailed design, and multiobjective optimization. A modified NSGA‐II algorithm was proposed and combined with the multicriteria decision‐making method and the entropy‐weighted gray relation analysis method to determine the Pareto optimal solution and the optimal design scheme for the mixed material B‐pillar.

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Modeling and Simulation of Electric Motors Using Lightweight Materials

Cited by 8 publications

References 29 publications

State-of-the-Art Lightweight Implementation Methods in Electrical Machines

State-of-the-Art Lightweight Implementation Methods in Electrical Machines

Performance analysis of electric motors, comparing lightweight techniques and cooling methods: A review

Research on the lightweight design and multilevel optimization method of B‐pillar of hybrid material based on side‐impact safety and multicriteria decision‐making

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