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Studies on the influence of manufacturing processes on the eddy current losses of single-tooth stator lamination stacks for use in hybrid and electric drives

制造工艺对混合动力和电力驱动用单齿定子叠片组涡流损耗影响的研究

基本信息

批准号：
253525297
负责人：
Professor Dr.-Ing. Jörg Ernst Franke
金额：
--
依托单位：
Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS)
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2014
资助国家：
德国
起止时间：
2013-12-31 至 2015-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/253525297?language=en
关键词：
Studies influence manufacturing processes eddy

项目摘要

Due to societal and political demand for environmental-friendly and sustainable automotive technology, the industry is facing requests to develop new powertrain concepts. Many of the powertrain concepts are based on a drive system with electric motors. This can be a full electric vehicle with a large battery, a hybrid vehicle or a fuel cell vehicle. All concepts do have, as a common main powertrain component, an electric motor. The reduction of the power loss of the electric motor is one major focus of the development activities. The power loss has straight impact to the compliance with the CO2 emission regulations, the operating range of the electric vehicle, the cost and weight of the battery and the cooling power demand of the system. For this reason the entire types of power losses have to be investigated fundamentally, power loss reduction potentials have to be identified and improvements have to be established and implemented.One type of losses is the eddy current losses. The eddy current losses are mainly generated in the laminations of the iron cores of the electric motor. For eddy current loss minimisation the individual laminations of the stack are electrically insulated. However the application of manufacturing processes can lead to electrical connections of the laminated, initially insulated stack and will therefore lead to additional eddy current losses. The impact of the manufacturing processes concerning additional eddy current losses is currently not sufficiently known.A major component of the electric motor is the laminated stator core. The manufacturing process steps, cutting of the individual lamination, stacking of the laminations to a core and the assembly of the stator core in a housing differ concerning their eddy current loss impact. The main target of the presented research project is therefore the determination of the eddy current losses created through the impact of various manufacturing processes. For this purpose, the eddy current paths caused by the manufacturing processes have to be identified and the relevant geometrical and electrical dimensions have to be detected. In a next step FEM simulations have to be carried out and based on the found eddy current characteristics analytical calculation models can be developed. Finally, the simulation and calculation results have to be validated by measurements.Based on the identified eddy current characteristics requirements for loss minimisation of the applied processes and the part quality can be specified. In addition a guide line for the design of stator cores with the focus on loss reduction can be offered. Further the results of the investigations will be the basis for the determination of additional manufacturing processes for loss reduction e.g. the insertion of insulation layers at certain locations to disconnect eddy current paths. In a last step the identified loss reduction actions have to be evaluated concerning their effectiveness by measurements.

由于社会和政治对环保和可持续汽车技术的需求，该行业正面临开发新动力总成概念的要求。许多动力系统的概念是基于一个驱动系统与电动机。这可以是具有大电池的全电动车辆、混合动力车辆或燃料电池车辆。所有的概念都有一个共同的主要动力总成部件，电动机。减少电动机的功率损耗是开发活动的主要重点之一。功率损耗对符合CO2排放法规、电动车辆的运行范围、电池的成本和重量以及系统的冷却功率需求具有直接影响。因此，必须从根本上研究所有类型的功率损耗，确定降低功率损耗的潜力，并制定和实施改进措施。涡流损耗是其中之一。涡流损耗主要产生在电动机的铁芯的叠片中。为了使涡流损耗最小化，堆叠的各个叠片是电绝缘的。然而，制造工艺的应用可能导致层压的、初始绝缘的堆叠的电连接，并且因此将导致额外的涡电流损耗。制造过程对附加涡流损耗的影响目前还不清楚。电动机的主要部件是叠片定子铁芯。制造工艺步骤、单个叠片的切割、叠片到芯的堆叠以及定子芯在壳体中的组装在它们的涡流损耗影响方面不同。因此，本研究项目的主要目标是确定通过各种制造过程的影响而产生的涡流损耗。为此，必须识别由制造过程引起的涡流路径，并且必须检测相关的几何尺寸和电气尺寸。在下一步中，必须进行FEM模拟，并且基于所发现的涡流特性，可以开发分析计算模型。最后，仿真和计算结果必须通过测量进行验证。基于识别的涡流特性，可以指定应用过程和零件质量的损耗最小化要求。此外，还可以为定子铁芯的设计提供一个以降低损耗为重点的指导方针。此外，调查结果将成为确定用于降低损耗的附加制造工艺的基础，例如，在某些位置插入绝缘层以断开涡流路径。在最后一步中，必须通过测量评估所确定的减少损失行动的有效性。