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The paper introduces a numerical solution of the cost function in model predictive control of a voltage source inverter, considering a continuous control set. In each switching instance, it calculates a feasible voltage vector that minimizes a predefined cost function. The developed algorithm is tested on a case study represented by the flux and torque control of an induction motor drive. The investigated...
The recent increase in oil prices and environmental concerns have attracted various research efforts on hybrid electric vehicles (HEVs) which provide promising alternatives to conventional engine-powered vehicles with better fuel economy and fewer emissions. To speed up the design and prototyping processes of new HEVs, a method that automatically generates mathematics equations governing the vehicle...
This paper presents the manufacturing experience of an outer rotor permanent magnet synchronous machine with four different stators. The advantageous features of powder technology and molding techniques are tested when constructing and manufacturing the stators for a 28-pole 30-slot machine. The selected machine configuration is taking advantages of the concept of the modular windings and at the same...
Recent years have seen an increasing attention in electric vehicles. But due to high prices, there is only a moderate customer acceptance and market penetration. Companies need to build up new competencies to be able to develop and produce competitive electric vehicles. Moreover, a concentration on either cost or quality will not be sufficient to make electric mobility attractive to customers and...
Due to the ongoing success of electric motors for highly energy efficient direct drive applications, the adaptability of electric machines becomes more and more important. Beside the adjustment of the performance data according to the markets' demands, the ability to comply with different mechanical interfaces turns out to be an important demand. In order to meet customer specific requirements, today's...
This paper present a novel method for reducing or complete canceling some space harmonics of low order in the air-gap flux density of electric machines with fractional slots, tooth-concentrated winding using magnetic flux barriers in the stator teeth region. Furthermore, the new method increase simultaneously the efficiency of the working harmonic and with this the power density of the electric machine...
Modeling, handling and control of high innovative, multi-site, modular and flexible manufacturing systems is emerging as a high challenge for research. For the industry to control such complex manufacturing systems it becomes a dominating factor to distinguish oneself in international business rivalry. Thus, there is an operative demand for a powerful and stable kernel to successfully take part in...
This paper presents investigations into the eddy current losses of laminated electrical steel cores as implemented in electric motors, that were manufactured by applying various stacking processes. The application of interlocking and welding stacking processes create an electrical connection of the initially insulated laminations and therefore lead to additional eddy current losses. This paper considers...
The electrification of the powertrain brings new challenges to manufacturers: OEMs as well as suppliers within the entire automotive value chain have to deal with a variety of new electric powertrains and their components. Besides new requirements on production technologies, quality aspects as well as recruiting and training of employees with the necessary set of new skills, organizations have to...
Small two-stroke gasoline engines are the major power source for professional outdoor power equipment such as hedge trimmers, chain saws, blowers and cut-off saws. However, electric motors energized with Lithium-Ion-based batteries as a power source strongly catch up. For some time now, small non-professional equipment with a battery-based power source is available. But only since 2010 professional...
Electrical steel is mainly characterized by its magnetic properties, i.e. the specific total loss and the magnetic polarization. In addition, mechanical and physical properties as well as coating and workability can strongly influence the performance and the cost of the resulting electric machine. The various properties can be controlled e.g. via the chemical composition and the production process...
A mathematical model is developed with the purpose of estimating the scale of permanent magnet materials consumption in hybrid and electric automotive traction systems. These estimations are compared to consumption figures from industries such as wind power, HVAC, consumer electronics and industrial machinery. The estimations generated are useful in strategic decision-making for production planning.
Constantly rising fuel prices more and more encourage the development of innovative electric vehicle concepts. In order to follow this trend and to increase customer acceptance and the practicality of electro-mobility, vehicle concepts with inductive power transfer systems are developed. These have to be integrated into the production lines of the car manufacturers with in each case several adaptations...
Nowadays, heat conductive polymers show potential for new applications in different areas especially to dissipate heat in electronic devices. The processing by injection molding is particularly suitable for an efficient large-volume production of multifunctional components such as required for automotive and electronic industry. A thermosetting polymer matrix exhibits the potential to reach a high...
The growing consequences of global warming and rising prices for fossil fuels are calling for a broad substitution of combustion engines by electrical machines and an energy- and resource-efficient design of manufacturing systems. The present work proposes a conceptual approach for the holistic product lifecycle assessment (LCA) of an electric drive for the automotive industry. The proceeding is part...
The presented model describes the correlation between costs and component parameters, such as component type and specification for electric motors, inverters and energy storages. This paper takes a focus on already developed electric drivetrains in the product design process. The method used in the model, is based on physical relationships considering the state of the art and the application context...
A design model development for electrical machines with laminated windings is presented. The focus is to provide manufacturable solutions for commercial vehicle traction applications. The machine is designed with axially distributed single-layer wave-winding segments with a core that builds a modular three-phase machine. The phase segment, whose central part is a wave-winding made as a laminated winding,...
A novel design of IGBT half-bridge power-modules for automotive applications was developed. In comparison to standard modules, advantages regarding electrical, thermal and mechanical interfaces could be achieved. In the present paper, investigations regarding the general design, the increase of lifetime and robustness and advantages from the application point of view of this ‘Inverter Building Block’...
To make motors compact and lightweight yet producing high efficiency, the research on high density winding has been carried out. As a result, two new divided cores are proposed — one is a divided sliding core and the other is a divided core assembled by partial press fitting. Most conventional divided cores use welding to make the cores as a single body after winding. This conventional technique,...
In future the price of oil consumption will further increase. The emission of exhaust gases like CO2 will be restricted by politic regulations. This and also the desire of customers for green mobility drives OEM's to bring electric or hybrid vehicles on the market where the development of electro mobility currently is enforced by the worldwide competition. Within the engine compartment of modern cars...
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