Spray-Formed Hybrid-Field Traction Motor

Paper #:
  • 2017-01-1225

Published:
  • 2017-03-28
Abstract:
An advanced electric motor with hybrid-field topology has been developed for automotive traction applications. Departing from the conventional radial- and axial-field designs, the hybrid-field motor features three-dimensional magnetic flux paths in a geometry that maximizes the effective volume for magnetic flux flow. The three-dimensional flux paths are enabled by an isotropic soft magnetic material, which has been engineered to replace conventional laminated winding cores with solid isotropic components. The material is produced by a novel additive-manufacturing process based on spray forming. The paper introduces the spray-forming process for motor stator components and presents a conceptual design of the traction motor developed around them, including the motor topology, stator construction and rotor construction. The stator features a spray-formed core with three-dimensional magnetic flux paths, high-density windings and direct liquid cooling. The rotor employs permanent magnets and iron teeth for added reluctance torque. The performance characteristics of the motor are discussed, including the torque-speed curves and efficiency maps. The motor offers an unprecedented combination of high power output, compact size, low weight and energy efficiency. It achieves more than two times higher power density than state-of-the-art high-performance traction motors. In automotive applications, this translates to a more compact and lighter drivetrain, improved dynamics of hybrid and electric vehicles, and increased range for electric vehicles. In addition, the applications of the hybrid-field motor technology extend beyond the electric drivetrain, including electric supercharging and various drive-by-wire systems, such as steering and brakes.
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