I-Corps: High - Reliability and Low - Cost Design of Electric Motor for Automotive Industry Application

最近对清洁能源的需求和化石燃料供应的减少导致了基于替代能源的发电的研究和应用取得了显着的进展。电机和发电机是绿色技术的重要组成部分，产生或消耗的电能大部分来自替代能源，特别是在包括汽车和航空航天在内的公共交通领域。随着稀土材料三相电机在公交系统(电源管理、储能等)中的广泛应用。在安全被优先考虑的地方，成本和可靠性也成为关键的市场问题。因此，i-Corps团队的重点是设计高可靠性、低成本、容错和不含稀土材料的电机，以满足汽车行业目标市场细分的需求。目标产品将是无稀土材料的多相同步磁阻电机(FMSM)。与传统的低功率电机设计为单相或三相电机不同，所提出的多相电机采用五相结构设计，在市场上所有理论和实际可用的低功耗电机中，这是一种提供最低成本和最高可靠性的最佳解决方案。所提出的结构还提供了紧凑的尺寸和延长的寿命，并减少了电磁干扰(EMI)。为了进一步降低制造成本，铁氧体材料将取代稀土材料。铁氧体材料在自然界中储量丰富，价格约为稀土材料的10倍。此外，输出功率将基于创新和替代的扭矩产生机制产生，这将进一步降低材料利用成本，同时显著简化设计。

The recent need for clean energy and the decreasing availability of fossil fuels have resulted in a noticeable progress in research and application of power generation based on alternative energy sources. Electric Motors and Generators are important components in the green technology, generating or consuming majority of the electric energy from alternative energy sources, especially in public transportation area including automotive industry and aerospace industry. As the rare-earth-material-based three-phase electric machine has been popularly applied to the public transportation systems (for power management, energy storage, etc.) where safety is a priority, cost and reliability have also become critical market issues. This I-Corps team's focus is, therefore, on the design of high-reliability, low-cost electric machines that are fault-tolerant and free of rare-earth materials to meet the needs of target market segmentation in automotive industry.The target product will be a Rare-earth material Free Multiphase Synchronous reluctance Motor (FMSM). Unlike the conventional low-power machine, which is designed as a single- or three-phase machine, the proposed multiphase motor is designed using a 5-phase architecture, an optimal solution to provide the lowest cost and highest reliability among all theoretically and practically available low-power machines in the market. The proposed architecture also provides compact size and extended lifetime with reduced electro-magnetic interferences (EMI). To further reduce manufacturing costs, Rare-earth materials will be substituted by Ferrite materials. Ferrite materials are abundant in nature and about 10 times cheaper than Rare-earth materials. In addition, the output power will be generated based on an innovative and alternative torque generation mechanism which will lead to further reduced costs in material utilization while significantly simplifying the design.