Due to the societal and political demand for environmental-friendly and sustainable automotive technology, the industry is facing requests to develop new powertrain concepts. Many of the powertrain concepts are based on a drive system with electric motors. The reduction of the power loss of the electric motor is one major focus of the development activities. The power loss has straight impact to the compliance with the CO2-emission regulations, the operating range of the electric vehicle, the cost and weight of the battery, the cost and size of the power electronics and the cooling power demand of the system. For this reason the entire types of power losses have to be investigated fundamentally, power loss reduction potentials have to be identified and improvements have to be established and implemented. The described investigations of this document are addressing the impact of manufacturing processes on the eddy current losses of a hybrid electric motor with a stator in single tooth design. The main focus of the investigations was the manufacturing processes stamping of the laminations, stacking of the laminations and the assembly of the stacks into the housing. The application of the manufacturing processes creates an electrical connection of the initially insulated laminations and therefore leads to additional eddy current losses. Based on the results of this study, the qualitative and quantitative impact of various manufacturing processes on the eddy current losses could be identified. With the help of an introduced approach, a fast and reliable estimation of the additional losses can be made already during the design phase of an electric motor. A specific selection of the manufacturing processes and a more detailed definition of the loss models of electric motors can then be established. However, further investigations with the focus on the loss measurements of entire electric motors in operation are strongly recommended. Based on the results, a more reliable quantification of the impact of the manufacturing processes in consideration of the magnetic flux direction in adjacent teeth, the cross flux due to rotor movement and the non-sinusoidal characteristic of the flux can be made. A potential intention of following studies could then be a further validation and improvement of the introduced calculation models.
Der Einfluss der Fertigungsverfahren auf die Wirbelstromverluste von Stator-Einzelzahnblechpaketen für den Einsatz in Hybrid- und Elektrofahrzeugen
Fertigungstechnik Erlangen ; 247 ; 1-148
2014
148 Seiten, Bilder, Tabellen, 80 Quellen
Theses
German
Verringerung der Wirbelstromverluste in Mittelfrequenzspulen durch Einsatz permeabler Schirme
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