Cross section of the electromagnetic design (top), images of the wound stator (bottom left) and the rotor being lowered on (bottom right).
Image of all the parts of the motor during some point in the assembly process
Basic testing setup of the motor to validate the FEA models
Video showing the motor spining
Project Overview
Project statement:
Design, analyze and implement a passive method to reduce the effects of a short circuit event (called a fault) in a permanent magnet electric motor
Short circuit faults can be very severe and can cripple the motors performance. In applications like aerospace or electric vehicles, continued operation in the event of a fault is critical.
Main objectives:
Create a detailed electromagnetic FEA model in Ansys Maxwell to perform design optimization and performance simulations
Develop the mechanical design of the motor
3D print parts where possible and create drawings for other parts for machining
Iterate on the mechanical design
Design a feasible winding solution and supporting jigs
Characterize the performance under healthy and faulted conditions via dynamometer tests
Challenges:
Mechanical design was difficult due to the weight of the steel parts
Outer rotor topologies are harder to design by nature
Windings were diffuclt to do by hand
Large magnetic forces made assembly difficult
Results:
FEA model was successfully developed (and later validated via prototype results)
Design features like angle of the magnets on the rotor and placement of the integrated chokes was optimized
Over many iterations the mechanical design was implemented
Winding was completed
Dynamometer tests were run
Fault current was reduced by up to 96% as compared to traditional windings
Less than 1% increase in copper losses due to the new winding configuration
The full results of this project have been published and can be accessed via IEEE Xplore or directly.
