EM USER DAYS 2019 Innovative motors for electric mobility: axial - PowerPoint PPT Presentation

EM USER DAYS 2019 Innovative motors for electric mobility: axial flux for high torque density and synchronous reluctance for rare earth free solutions Luigi Rizzi Technical Director at SPIN www.spinmag.it 2019 EM USER DAYS October 22nd — 23rd, 2019 | Stadthalle Sindelfingen, GERMANY

PRICE OF CARS Ford Model T - 1925

AVAILABILITY OF CHARGING STATIONS

AXIAL FLUX MOTORS Michael Faraday

AXIAL FLUX MOTORS Thomas Davenport

AXIAL FLUX MOTORS

AXIAL FLUX MOTORS

AXIAL FLUX MOTORS 𝑈 𝑏𝑦𝑗𝑏𝑚 ∝ 𝑠 3 𝑈 𝑠𝑏𝑒𝑗𝑏𝑚 ∝ 𝑠 2 • Higher power density than Radial-Flux motors • Better ventilation and cooling • Planar airgap best fits the different applications • Ideal to design modular motors for different power and torque requirements • Output power proportional to the square of the outer diameter

COMPRESSORS FOR REFRIGERATORS

COMPRESSORS FOR REFRIGERATORS Joule Iron TORQUE Output SPEED TORQUE Efficiency Losses Losses RIPPLE Power [RPM] [W] [W] [Nm] pk-pk [%] [W] 1400 1,06 1,31 0,181 5,5 26,54 91,8 2400 1,09 2,61 0,182 5,4 45,65 92,5 2400 2,12 2,67 0,258 3,9 64,77 93,1 PEAK EFFICIENCY 4000 5,28 5,75 0,409 2,5 171,4 94,0 AXIAL FLUX

MULTIPHASE TORQUE MOTOR Joule Iron Magnet Output SPEED TORQUE Losses Losses losses Power [RPM] [kW] [kW] [kW] [Nm] [kW] 1400 14.9 0.4 2.3 840 123.1 EDDY CURRENT LOSSES IN MAGNETS

HYDRAULIC PUMP SPEED Torque Power Torque density Power density [RPM] [Nm] [kW] [Nm/kg] [kW/kg] 2500 90 23.5 6.6 1.7 TORQUE DENSITY Joule Iron Magnet TORQU Output SPEED Losses Losses losses E Power [RPM] [kW] [kW] [kW] [Nm] [kW] 2500 14.9 0.4 2.3 90 23.5

SYNC-REL MOTORS CONFIDENTIAL

SYNC-REL MOTORS EFFECT OF ROTOR GEOMETRY ON TORQUE RIPPLE A-A-A-A generates the red curve B-B-B-B generates the blue curve CONFIDENTIAL A-B-A-B TORQUE RIPPLE

SYNC-REL MOTORS IDENTIFICATION OF OPTIMIZATION PARAMETERS CONFIDENTIAL The optimization objectives MIN torque ripple • MAX mean torque •

SYNC-REL MOTORS RESULT OF OPTIMIZATION ON TORQUE RIPPLE SYMMETRIC ASYMMETRIC

SYNC-REL MOTORS RADIAL FORCES ON ASYMMETRIC CONFIGURATION UMBALANCED PULL @ 0.05mm MISALIGNMENT 124.4 N CONFIDENTIAL

SYNC-REL MOTORS RADIAL FORCES ON ASYMMETRIC CONFIGURATION UMBALANCED PULL @ 0.05mm MISALIGNMENT 124.4 N

SYNC-REL MOTORS MOTOR PERFORMANCE SUMMARY SPEED S1 Power Torque Torque S1 POWER RANGE TORQUE density Density Ripple [RPM] [Nm] [kW] [kW/kg] [Nm/kg] [%] 10.000 200 64 1.0 3.1 2.3 POWER DENSITY IN CONTINUOUS OPERATION FINAL TORQUE RIPPLE

CONCLUSION ANALYSIS Prototyping & Electrical / Thermal / Testing Mechanical / System