Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658367
Wilken Wöβner, Johannes T. Stoll, Max Oliveira Flammer, Peter Wurster, Manuel Peter, J. Fleischer
The increasing electrification of vehicles poses new challenges to the automotive industry. Especially in highperformance applications, the drive system is designed for high rotational speeds, best dynamic behaviour and optimal power-to-weight ratio. However, most rotor designs for drivetrain application are commonly designed for negative balancing. In that case, balancing discs are used to enable the subtraction of a small amount of mass, thus balancing the rotor. The excessive mass of the balancing discs must cover all production deviations and leads to massive balancing discs with a weight ratio of up to 10% for the overall rotor system. In order to reduce the weight and the installation space for permanent magnet rotors, this article presents an approach that allows to avoid excessive masses by using a rotor components arrangement with minimized unbalance followed by a positive balancing process. In preliminary investigations, the initial rotor unbalance occurring in a state-of-the-art assembly process was therefore significantly reduced by using an optimized selective assembly. Based on researched state-of-the-art positive balancing concepts, new positive balancing concepts are systematically developed, tested and evaluated for applicability in high-performing motors. It shows that the required balancing quality in high-performance applications (usually
{"title":"Intelligent Rotor Assembly Enabling Positive Balancing Concepts for High-Performance Permanent Magnet Rotors","authors":"Wilken Wöβner, Johannes T. Stoll, Max Oliveira Flammer, Peter Wurster, Manuel Peter, J. Fleischer","doi":"10.1109/EDPC.2018.8658367","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658367","url":null,"abstract":"The increasing electrification of vehicles poses new challenges to the automotive industry. Especially in highperformance applications, the drive system is designed for high rotational speeds, best dynamic behaviour and optimal power-to-weight ratio. However, most rotor designs for drivetrain application are commonly designed for negative balancing. In that case, balancing discs are used to enable the subtraction of a small amount of mass, thus balancing the rotor. The excessive mass of the balancing discs must cover all production deviations and leads to massive balancing discs with a weight ratio of up to 10% for the overall rotor system. In order to reduce the weight and the installation space for permanent magnet rotors, this article presents an approach that allows to avoid excessive masses by using a rotor components arrangement with minimized unbalance followed by a positive balancing process. In preliminary investigations, the initial rotor unbalance occurring in a state-of-the-art assembly process was therefore significantly reduced by using an optimized selective assembly. Based on researched state-of-the-art positive balancing concepts, new positive balancing concepts are systematically developed, tested and evaluated for applicability in high-performing motors. It shows that the required balancing quality in high-performance applications (usually <G2.5) can be achieved with a positive balancing concept. The results are discussed within this article and integrated into improvement measures for the design of permanent magnet rotors.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"54 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124275676","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658329
M. Weigelt, A. Mayr, M. Masuch, Kilian Batz, J. Franke, Peter M. Bican, A. Brem, J. Russer, P. Russer
The spread of electric mobility in Germany lags far behind government's targets. High vehicle and energy prices, the limited vehicle range and obligatory time-consuming conductive charging processes are the main obstacles to mass adoption. Strategic mobility concepts, such as electric vehicles with high performance batteries (BEV), hydrogen technologies (FCEV), or dynamic inductive charging (IPTEV), i.e. a constant energy supply while the vehicle is in motion, can overcome those obstacles in Germany and beyond. Numerous studies investigated the different energy sources and compared potential drive technologies. However, in most prior studies, only partial aspects of a specific technology are considered. The contribution of this study is in providing a comprehensive technology comparison, enabling a thorough analysis and evaluation of various technological alternatives for solving the range problem of electric vehicles. For this purpose, a general framework as well as technology-specific key indicators and aspects are presented. The holistic evaluation of the technologies is carried out on the basis of specially defined evaluation criteria, with the focus on passenger car and commercial vehicle applications. In order to ensure a comparison that is as unbiased and objective as possible, measures are adjusted to avoid bias of key figures. Finally, the consideration of foreseeable macroeconomic and technological developments should ensure that long-term valid statements can also be derived from the results of the investigation.
{"title":"Techno-Economic Evaluation of Strategic Solutions to Extend the Range of Electric Vehicles","authors":"M. Weigelt, A. Mayr, M. Masuch, Kilian Batz, J. Franke, Peter M. Bican, A. Brem, J. Russer, P. Russer","doi":"10.1109/EDPC.2018.8658329","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658329","url":null,"abstract":"The spread of electric mobility in Germany lags far behind government's targets. High vehicle and energy prices, the limited vehicle range and obligatory time-consuming conductive charging processes are the main obstacles to mass adoption. Strategic mobility concepts, such as electric vehicles with high performance batteries (BEV), hydrogen technologies (FCEV), or dynamic inductive charging (IPTEV), i.e. a constant energy supply while the vehicle is in motion, can overcome those obstacles in Germany and beyond. Numerous studies investigated the different energy sources and compared potential drive technologies. However, in most prior studies, only partial aspects of a specific technology are considered. The contribution of this study is in providing a comprehensive technology comparison, enabling a thorough analysis and evaluation of various technological alternatives for solving the range problem of electric vehicles. For this purpose, a general framework as well as technology-specific key indicators and aspects are presented. The holistic evaluation of the technologies is carried out on the basis of specially defined evaluation criteria, with the focus on passenger car and commercial vehicle applications. In order to ensure a comparison that is as unbiased and objective as possible, measures are adjusted to avoid bias of key figures. Finally, the consideration of foreseeable macroeconomic and technological developments should ensure that long-term valid statements can also be derived from the results of the investigation.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"66 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123469171","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658348
N. Urban, A. Kühl, M. Glauche, J. Franke
Additive Manufacturing (AM) process technologies gain increased degree of technical maturity through the implementation of quality control mechanisms, fully automated production systems as well as increasing knowledge about the effects during the build-up processes. Nevertheless, the main focus of current research and development activities is set on the processing of conventional construction materials with sufficient mechanical properties. The implementation of additional, mechatronic features, e.g. optic or magnetic functions, is not well investigated yet. But as already demonstrated with printed electronics, which are decisive for manufacturing antenna structures in modern consumer electronics like smartphones, additional functionality can lift the potentials of AM to a new level. Mechatronic functionalities require a smart combination of different functional materials that are not commercially available for AM processes yet. Within this paper, a survey of the possibilities of printing rare earth permanent magnets with different process technologies is presented. The technology with the highest magnetic performance is presented more in detail and a concept for further increasing the magnetic performance is outlined.
{"title":"Additive Manufacturing of Neodymium-Iran-Boron Permanent Magnets","authors":"N. Urban, A. Kühl, M. Glauche, J. Franke","doi":"10.1109/EDPC.2018.8658348","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658348","url":null,"abstract":"Additive Manufacturing (AM) process technologies gain increased degree of technical maturity through the implementation of quality control mechanisms, fully automated production systems as well as increasing knowledge about the effects during the build-up processes. Nevertheless, the main focus of current research and development activities is set on the processing of conventional construction materials with sufficient mechanical properties. The implementation of additional, mechatronic features, e.g. optic or magnetic functions, is not well investigated yet. But as already demonstrated with printed electronics, which are decisive for manufacturing antenna structures in modern consumer electronics like smartphones, additional functionality can lift the potentials of AM to a new level. Mechatronic functionalities require a smart combination of different functional materials that are not commercially available for AM processes yet. Within this paper, a survey of the possibilities of printing rare earth permanent magnets with different process technologies is presented. The technology with the highest magnetic performance is presented more in detail and a concept for further increasing the magnetic performance is outlined.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"58 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129572405","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658282
A. Meyer, Johannes von Lindenfels, A. Mayr, J. Franke
In the production of electric motors, various manufacturing imperfections occur. These production-related deviations influence the product characteristics concerning power output, efficiency, vibration, noise and lifetime. However, measures to minimize manufacturing deviations are involved with several challenges such as additional measurements, advanced process control and above all costs. Thus, the benefit of possible improvement measures has to be carefully evaluated since not every production-related deviation has a significant impact on the product quality. Consequently, research is proceeding in this direction to quantify the actual influence of the various manufacturing imperfections on the motor characteristics as well as the whole drive system. To support the evaluation process, this paper gives a concise overview of the manufacturing imperfections in the production of permanent magnet synchronous motors (PMSM). A special focus is set on Halbach array rotors since these are particularly sensitive to magnetic deviations. As follows from first experiments, considerable deviations in magnitude and direction of the magnetization of the single magnets occur. The effects of these deviations are simulated on a specially developed Halbach test motor. Based on this, further effects will be investigated and practically tested using different motor configurations.
{"title":"Manufacturing Imperfections in Electric Motor Production with Focus on Halbach Array Permanent Magnet Rotor Assembly","authors":"A. Meyer, Johannes von Lindenfels, A. Mayr, J. Franke","doi":"10.1109/EDPC.2018.8658282","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658282","url":null,"abstract":"In the production of electric motors, various manufacturing imperfections occur. These production-related deviations influence the product characteristics concerning power output, efficiency, vibration, noise and lifetime. However, measures to minimize manufacturing deviations are involved with several challenges such as additional measurements, advanced process control and above all costs. Thus, the benefit of possible improvement measures has to be carefully evaluated since not every production-related deviation has a significant impact on the product quality. Consequently, research is proceeding in this direction to quantify the actual influence of the various manufacturing imperfections on the motor characteristics as well as the whole drive system. To support the evaluation process, this paper gives a concise overview of the manufacturing imperfections in the production of permanent magnet synchronous motors (PMSM). A special focus is set on Halbach array rotors since these are particularly sensitive to magnetic deviations. As follows from first experiments, considerable deviations in magnitude and direction of the magnetization of the single magnets occur. The effects of these deviations are simulated on a specially developed Halbach test motor. Based on this, further effects will be investigated and practically tested using different motor configurations.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"51 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121086496","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658293
Dominik Kißkalt, A. Mayr, Johannes von Lindenfels, J. Franke
The market volume of electric drives for industrial applications and electric mobility is increasing steadily. Thus, efficient ways for monitoring and optimizing the production of electric drives are gaining importance. Besides winding, joining or impregnation processes, machining operations have a high share in the production chain. However, developing a process monitoring system for machining centers can be a cost-intense matter due to the need of addressing a manifold and dynamic error-space. Therefore, this paper examines potentials of cost-efficient data-driven approaches for process monitoring of machining operations on the example of electric drive production. In this context, a flexible approach for detecting current operational states by means of supervised machine learning is proposed. Since labor-intense modeling of process models based on a priori knowledge and first principles gets dispensable, the basis for self-adapting monitoring solutions is laid. Diverse process parameters such as structure-borne sound or cutting forces are suitable to train process and behavioral models. By realizing a system for operational state detection without necessary access to control-internal data, a cost-efficient process monitoring of the often heterogeneous machinery in electric drive production is enabled.
{"title":"Towards a Data-Driven Process Monitoring for Machining Operations Using the Example of Electric Drive Production","authors":"Dominik Kißkalt, A. Mayr, Johannes von Lindenfels, J. Franke","doi":"10.1109/EDPC.2018.8658293","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658293","url":null,"abstract":"The market volume of electric drives for industrial applications and electric mobility is increasing steadily. Thus, efficient ways for monitoring and optimizing the production of electric drives are gaining importance. Besides winding, joining or impregnation processes, machining operations have a high share in the production chain. However, developing a process monitoring system for machining centers can be a cost-intense matter due to the need of addressing a manifold and dynamic error-space. Therefore, this paper examines potentials of cost-efficient data-driven approaches for process monitoring of machining operations on the example of electric drive production. In this context, a flexible approach for detecting current operational states by means of supervised machine learning is proposed. Since labor-intense modeling of process models based on a priori knowledge and first principles gets dispensable, the basis for self-adapting monitoring solutions is laid. Diverse process parameters such as structure-borne sound or cutting forces are suitable to train process and behavioral models. By realizing a system for operational state detection without necessary access to control-internal data, a cost-efficient process monitoring of the often heterogeneous machinery in electric drive production is enabled.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"11 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123867076","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658359
A. Kampker, K. Kreisköther, M. Büning, Tom Möller, Sven Windau
Within the context of Industry 4.0, data is being recorded and collected at an increasing rate in the production environment of electric drives. On the one hand, the data serves the producer as a backup against potential failure induced returns. On the other hand, some of the recorded data is used specifically for data analytics methods with the expectation to generate additional information and thus knowledge through intelligent data aggregation and processing. In the latter case, i.e. the use of data analytics methods, there are several possibilities to identify use cases and to implement them in a later step. Use cases can be discovered and identified on the basis of actual problems, so they can be considered as problem-driven. Problems and challenges in current electric drive production are taken here as a possible starting point for the identification of use cases. It is also conceivable that future problems can be anticipated by, for example, expert knowledge. Therefore, actual problems can be prevented prematurely with data analytics. A completely different approach is to analyze the currently available data bases and develop possible use cases based on the existing data. Currently, there is no systematical approach to cover the use case implementation for electric drives holistically. Therefore, in this paper, the possible fields of tension of the use case identification, evaluation and implementation will be presented. In the second step, based on the findings, a systematical approach to identify, evaluate and eventually implement use cases will be derived. The approach will then be applied to the generic production process chain of electric motors. Within the application of the approach, the whole drive production process chain was systematically analyzed. Out of the variety of process steps, a total of three use cases were selected due to the availability of data or due to identified process instabilities. For each of these three process steps, a use case was identified by conducting interviews with experts and the process-related operators. Out of the three developed use cases, one is being implemented, following the systematic approach presented within this paper
{"title":"Exhaustive Data- and Problem-Driven use Case Identification and Implementation for Electric Drive Production","authors":"A. Kampker, K. Kreisköther, M. Büning, Tom Möller, Sven Windau","doi":"10.1109/EDPC.2018.8658359","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658359","url":null,"abstract":"Within the context of Industry 4.0, data is being recorded and collected at an increasing rate in the production environment of electric drives. On the one hand, the data serves the producer as a backup against potential failure induced returns. On the other hand, some of the recorded data is used specifically for data analytics methods with the expectation to generate additional information and thus knowledge through intelligent data aggregation and processing. In the latter case, i.e. the use of data analytics methods, there are several possibilities to identify use cases and to implement them in a later step. Use cases can be discovered and identified on the basis of actual problems, so they can be considered as problem-driven. Problems and challenges in current electric drive production are taken here as a possible starting point for the identification of use cases. It is also conceivable that future problems can be anticipated by, for example, expert knowledge. Therefore, actual problems can be prevented prematurely with data analytics. A completely different approach is to analyze the currently available data bases and develop possible use cases based on the existing data. Currently, there is no systematical approach to cover the use case implementation for electric drives holistically. Therefore, in this paper, the possible fields of tension of the use case identification, evaluation and implementation will be presented. In the second step, based on the findings, a systematical approach to identify, evaluate and eventually implement use cases will be derived. The approach will then be applied to the generic production process chain of electric motors. Within the application of the approach, the whole drive production process chain was systematically analyzed. Out of the variety of process steps, a total of three use cases were selected due to the availability of data or due to identified process instabilities. For each of these three process steps, a use case was identified by conducting interviews with experts and the process-related operators. Out of the three developed use cases, one is being implemented, following the systematic approach presented within this paper","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"32 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115813966","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658365
J. Niemann, Christoph Eckermann, A. Schlegel, T. Büttner, J. Stoldt, M. Putz
Electro mobility represents a key concept in response to current trends in the mobility sector. Yet, strong uncertainties regarding future demand of electric vehicles pose major challenges for capacity planning and procurement. Current forecasts predict a total market share of electric vehicles between 3 % and 24 % in 2025. This paper presents a study that aims to shed light on the challenges of capacity planning. We provide insights on the requirements of volume flexibility and changeability in the production and purchasing of electrified powertrains. The study relies on expert interviews in the field of production and procurement. We interviewed 13 managers from three leading, premium German carmakers. The interviews were conducted using a semi-structured guide that addresses six hypotheses concerning market development, long-term capacity planning, identification and definition of courses of action, interdependencies between the production and the supplier, specifics of the production system for electrified powertrains, and access to resources. The study's results show that demand volatility of electrified vehicles is expected to persist for the next 5 years. Consequently, existing demand uncertainties lead to a high number of different planning scenarios. This challenges capacity planners to provide enough capacity by relying on flexibility or changeability measures. Differences in supplier structures further require automotive OEM to change their mindset and to implement new processes. Despite those substantial changes, however, the task of purchasing remains vital to prevent quality losses or significant cost increases. Lastly, we show the importance of integrating supplier and purchasing department capacity planning process. Our main results indicate the need for developing a decision support system. It supports supply chain capacity planning of electric drive trains in order to enable fast and efficient reactions to volatile volumes.
{"title":"Requirements for Volume Flexibility and Changeability in the Production of Electrified Powertrains","authors":"J. Niemann, Christoph Eckermann, A. Schlegel, T. Büttner, J. Stoldt, M. Putz","doi":"10.1109/EDPC.2018.8658365","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658365","url":null,"abstract":"Electro mobility represents a key concept in response to current trends in the mobility sector. Yet, strong uncertainties regarding future demand of electric vehicles pose major challenges for capacity planning and procurement. Current forecasts predict a total market share of electric vehicles between 3 % and 24 % in 2025. This paper presents a study that aims to shed light on the challenges of capacity planning. We provide insights on the requirements of volume flexibility and changeability in the production and purchasing of electrified powertrains. The study relies on expert interviews in the field of production and procurement. We interviewed 13 managers from three leading, premium German carmakers. The interviews were conducted using a semi-structured guide that addresses six hypotheses concerning market development, long-term capacity planning, identification and definition of courses of action, interdependencies between the production and the supplier, specifics of the production system for electrified powertrains, and access to resources. The study's results show that demand volatility of electrified vehicles is expected to persist for the next 5 years. Consequently, existing demand uncertainties lead to a high number of different planning scenarios. This challenges capacity planners to provide enough capacity by relying on flexibility or changeability measures. Differences in supplier structures further require automotive OEM to change their mindset and to implement new processes. Despite those substantial changes, however, the task of purchasing remains vital to prevent quality losses or significant cost increases. Lastly, we show the importance of integrating supplier and purchasing department capacity planning process. Our main results indicate the need for developing a decision support system. It supports supply chain capacity planning of electric drive trains in order to enable fast and efficient reactions to volatile volumes.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133754660","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658341
A. Kampker, Patrick Treichel, K. Kreisköther, R. Pandey, M. Büning, Till Backes
Axial flux permanent magnet (AFPM) motors, also known as disc type or pancake motors, offer many advantageous characteristics like high power density, compact design and diverse possibilities of motor design. Although distinctly better in few aspects compared to radial flux motors, there are definite reasons why axial flux motors have not been able to dominate the market, e.g, difficulties in part fabrication and motor assembly. In the wake of the development of new materials, it is possible to partly overcome these difficulties and simultaneously increase the power/torque density of the axial flux machine. This paper focuses on the identification of nonmagnetic components in an axial flux permanent magnet motor and the fabrication of these nonmagnetic parts using alternative materials and new fabrication technologies. For this purpose, the important motor parts like stator, rotor and housing are theoretically analyzed and the possibility of using nonmagnetic materials to manufacture them is verified. This will help in reducing the weight of the motor, offering enhancement of torque and power density. Less magnetic parts may also lead to better efficiency, as the losses due to induced currents are reduced.
{"title":"Alternative Fabrication Strategies for the Production of Axial Flux Permanent Magnet Synchronous Motors for Enhanced Performance Characteristics","authors":"A. Kampker, Patrick Treichel, K. Kreisköther, R. Pandey, M. Büning, Till Backes","doi":"10.1109/EDPC.2018.8658341","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658341","url":null,"abstract":"Axial flux permanent magnet (AFPM) motors, also known as disc type or pancake motors, offer many advantageous characteristics like high power density, compact design and diverse possibilities of motor design. Although distinctly better in few aspects compared to radial flux motors, there are definite reasons why axial flux motors have not been able to dominate the market, e.g, difficulties in part fabrication and motor assembly. In the wake of the development of new materials, it is possible to partly overcome these difficulties and simultaneously increase the power/torque density of the axial flux machine. This paper focuses on the identification of nonmagnetic components in an axial flux permanent magnet motor and the fabrication of these nonmagnetic parts using alternative materials and new fabrication technologies. For this purpose, the important motor parts like stator, rotor and housing are theoretically analyzed and the possibility of using nonmagnetic materials to manufacture them is verified. This will help in reducing the weight of the motor, offering enhancement of torque and power density. Less magnetic parts may also lead to better efficiency, as the losses due to induced currents are reduced.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114565120","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658276
Maximilian Volkan Baloglu, K. Willner
The specific design of components like rotor and stator as sheet-layered lamination stacks results in a structural behavior that is heavily dependent on the sheet interactions on the microscale. Due to the manufacturing process, these thin laminations may be just stacked and held together e.g. by welding or clamps, such that frictional contact of rough surfaces between single sheets is taking place and significantly affects the overall deformation behavior. Here, the elastic anisotropic, more precisely transversely isotropic, material parameters describing these lamination stacks are identified with the help of the homogenization taking efficiently care of the microstructure. For this purpose, different constitutive contact laws in normal direction capturing the sheet interactions by a penalty formulation and their effect on the macroscopic quantities are presented to emphasize the importance of this model parameter. Furthermore, it is shown that the derived stress-strain relation is identical to results of a numerical homogenization, where a representative volume element is simulated by the Finite-Element method incorporating Zero-Thickness elements for the contact simulation. The numerical results are finally compared to experiments showing a good accordance.
{"title":"Influence of the Constitutive Contact Law on the Anisotropic Material Parameters of Sheet-Layered Lamination Stacks","authors":"Maximilian Volkan Baloglu, K. Willner","doi":"10.1109/EDPC.2018.8658276","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658276","url":null,"abstract":"The specific design of components like rotor and stator as sheet-layered lamination stacks results in a structural behavior that is heavily dependent on the sheet interactions on the microscale. Due to the manufacturing process, these thin laminations may be just stacked and held together e.g. by welding or clamps, such that frictional contact of rough surfaces between single sheets is taking place and significantly affects the overall deformation behavior. Here, the elastic anisotropic, more precisely transversely isotropic, material parameters describing these lamination stacks are identified with the help of the homogenization taking efficiently care of the microstructure. For this purpose, different constitutive contact laws in normal direction capturing the sheet interactions by a penalty formulation and their effect on the macroscopic quantities are presented to emphasize the importance of this model parameter. Furthermore, it is shown that the derived stress-strain relation is identical to results of a numerical homogenization, where a representative volume element is simulated by the Finite-Element method incorporating Zero-Thickness elements for the contact simulation. The numerical results are finally compared to experiments showing a good accordance.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"61 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126719861","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-12-01DOI: 10.1109/EDPC.2018.8658272
Simon Strohmeyr, W. Schinköthe, Simon Gadegast
Aiming at high forces at low space in linear direct drives, favorable heat transfer conditions and high copper filling factors of the coils are of central importance [1]. For this reasons coils are mainly made of round copper wire and subsequently casted with impregnating resins or epoxy resins to increase stability and thermal conductivity. However, there are alternatives such as coils with rectangular wire, casted coils [2] or PCB (printed circuit boards) coils [3]. Due to the geometric design of linear direct drives PCB coils can be an alternative [4]. In this paper a coil in printed circuit board design is presented. The development and the process, from the selection of suitable PCB designs to optimization, assembly and comparison with conventionally round wire coils, is described. A linear direct drive is designed to compare the force-displacement characteristics and the increase of the temperature in static operation of the two types of coils. Slightly lower temperature of the overall system at the same mechanical motor parameters can be achieved with the PCB coil.
{"title":"Design of Printed Circuit Board Coils for Precision Engineering Linear Direct Drives","authors":"Simon Strohmeyr, W. Schinköthe, Simon Gadegast","doi":"10.1109/EDPC.2018.8658272","DOIUrl":"https://doi.org/10.1109/EDPC.2018.8658272","url":null,"abstract":"Aiming at high forces at low space in linear direct drives, favorable heat transfer conditions and high copper filling factors of the coils are of central importance [1]. For this reasons coils are mainly made of round copper wire and subsequently casted with impregnating resins or epoxy resins to increase stability and thermal conductivity. However, there are alternatives such as coils with rectangular wire, casted coils [2] or PCB (printed circuit boards) coils [3]. Due to the geometric design of linear direct drives PCB coils can be an alternative [4]. In this paper a coil in printed circuit board design is presented. The development and the process, from the selection of suitable PCB designs to optimization, assembly and comparison with conventionally round wire coils, is described. A linear direct drive is designed to compare the force-displacement characteristics and the increase of the temperature in static operation of the two types of coils. Slightly lower temperature of the overall system at the same mechanical motor parameters can be achieved with the PCB coil.","PeriodicalId":358881,"journal":{"name":"2018 8th International Electric Drives Production Conference (EDPC)","volume":"39 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122670234","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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