Increase in Torque Density of High-Efficiency Electric Motors Considering their Suitability for Highly Automated Mass Production

During the first funding period, the general aim of the project "Increase in Torque Density" was to develop a simulation package for parameter-based and quick simulation of electric drives used in vehicles. Thermal and electromagnetic problems posed by the special requirements of electromobility can be quantified with the developed methods and procedures within periods of time that are suitable for industrial applications. The newly developed calculation modules are already being used by many member companies of the project-accompanying committee. Some of these companies are now able to dimension the treated machine types with a higher design accuracy.

Aim of the second funding period is to validate the calculation methods obtained so far by means of measurements, to enhance them and to improve the quality of results. For this purpose, two demonstrator machines suitable for large-scale mass production, an induction machine and a permanent magnet synchronous machine, shall be designed, optimised and constructed in cooperation with an industrial partner and tested on a test bench at IAL. New conclusions obtained from the test and measurement results will contribute through appropriate enhancements to improved calculation methods for the machine types under investigation. With the dimensioning, construction and manufacturing of two demonstrators oriented towards suitability for mass production, SMEs can make use of well documented function patterns and numerous further alternative designs as a starting point for own designs and strategies.