Designing a high power density electrical driver integrated with a high-speed and high-power electrical machine is the main topic of this research. The next step is controlling this machine to make it to work at the desired speed and torque. Designing a common cooling system for this integrated electrical drive and machine can help to reduce the size and cost of the system. All effective aspects like EMI, reliability, thermal issues, and sustainability are critical to take in account to build a prototype with maximum possible efficiency and power density and minimum cost and total harmonic distortion of the output waveform.
The conducted research focuses on exploring a novel design for synchronous reluctance motors (SynRM) aimed at improving their performance through the implementation of innovative rotor technology. Additionally, a comprehensive methodology will be developed to design and optimize these proposed SynRMs using advanced multi-objective optimization algorithms. The anticipated outcome of this research is an enhanced performance in SynRMs, particularly in terms of torque density and power factor. The optimization process will encompass both electromagnetic and mechanical analysis.
Research plan
Material part:
To make a material study from databases to investigate which material pairs are suitable according to mechanical, magnetic and thermal behaviour.
To develop a material model suited for FE analysis based on experimental investigation of manufacturing processes
Manufacturing part:
To analyse the impact of laser cutting on the magnetic properties of rotor laminations.
To investigate how diffusion bonding of composite stacks of materials will influence the magnetic properties of the finale sample.
Characterization part:
To characterize the pore filling kinetics in relation to material-dependent diffusion kinetics during diffusion bonding.
To describe the influence of pore structure on magnetic properties of the sample.
Real prototype development part:
To design a real rotor for high-speed synchronous reluctance machine utilizing material data set.
With the aim of furthering the research in high power density electric drives, this research will look into support systems that would aid in creating more compact and powerful machines. Specifically, there is a need for advanced cooling systems and mechanical structures which would enable compactness. In addition to this, integrated power electronics may assist in reducing the size of the complete drive system, though this would add to the complexity of the cooling system and machine design.
The main aspects to be covered in this project will be the thermal and structural support systems. Meanwhile, it will be important to consider the many physical disciplines and interdependencies of electric machine design. The goal is to devise a machine with high power density for mobile application based on the axial flux yokeless stator armature (YASA) topology. The work will focus on:
Planning and implementing a mechanical structure and cooling system in order to meet the structural and cooling demands of the electric machine.
Multiphysics-optimization to achieve low weight and/or size for a given power requirement.
Integrating the power electronics and PE-cooling system.
Design and manufacture of a prototype machine for testing.
Experimental validation of test results.
The goal of this study is to design a high speed electrically excited synchronous motor for application in electric vehicles. This motor helps to improve the reliability, flexibility, and sustainability of the synchronous motor. The study optimises the electromagnetic field and mechanical structure by analysing the multi-physical fields of the motor. High-speed rotation of the rotor and structural stability are ensured along with high efficiency and high-power density. The cooling system is also considered for practical applications. The effectiveness of the design will be verified experimentally.
ELECTROMAGNETIC INTERFERENCE ANALYSIS AND MITIGATION OF HIGHLY INTEGRATED POWER ELECTRONICS IN MOTOR DRIVES
The main objective of this PhD project is to develop a new systematic approach in characterizing EMI noise generation and propagation mechanisms in motor drives. Equivalent electrical circuit diagrams to understand behavioral characteristics will be
developed. This will result in suitable equivalent electrical circuits and digital twin to predict EMI behavior of the system which can consequently enable possibility of applying feasible mitigation methods and design trade-offs. This will ensure obtaining high power density power electronics in motor drives with electromagnetic compatibility (EMC) feature.
The expected outcomes from this project are:
• Design for EMC strategy for highly integrated power electronics
• Analytical-based EMI modeling graphical user interface (GUI) tool with significant improved calculation time
• Optimized EMI filter design to obtain maximum power density based on developed EMI digital twin
• Set of validated test results and designing an EMC optimized power electronic hardware prototype
The overall objective of this PhD project is to develop advanced manufacturing process chains to enable innovative design solutions for In-Wheel-Motor components. In addition, the developed process chains based on additive and subtractive techniques must ensure part dimensional and geometrical accuracy, allowing for industrial application of multi-material manufacturing approaches to support functional integration, flux and current paths optimization, design compaction, higher power density and efficient cooling.
