Design of a Wound Field Synchronous Motor for a Propulsion Application

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The transportation sector is one of the most significant contributors to greenhouse gas (GHG) emissions. The transportation sector in Canada is responsible for 27% of GHG emissions. As a major contributor to GHG emissions, the transportation sector must transform from fossil fuel-powered vehicles to electrification. Automotive original equipment manufacturers (OEMs) have announced aggressive targets for electrification. Among the major auto OEMs, Stellantis has one of the most aggressive electrification goals. In 2030, hybrid and electric vehicle sales of Stellantis will account for 70% of the total sales of Stellantis in Europe and more than 40% in the United States.These aggressive electrification strategies target a significant increase in production volume and require electric propulsion motor solutions that can provide high power density, high efficiency, and a sustainable supply chain. Today, the majority of propulsion motors are permanent magnet synchronous motors. These motors provide high torque density and high efficiency, especially at low speeds. But they utilize high-energy-density permanent magnets on the rotor, which are made of rare earth metals. The issues with the cost, availability, and supply chain of rare earth metals might prevent the automotive industry from developing and manufacturing high-efficiency, high-performance, and affordable electric propulsion motors and, hence, achieving their aggressive electrification goals. The proposed project targets to address these issues by designing a rare-earth-free electric propulsion motor. Stellantis and McMaster University are joining forces in this project to design a wound-field synchronous motor for Stellantis' next-generation electrified powertrains. The outcome of this project will provide Stellantis with a rare-earth-free motor design that can be incorporated into their next-generation products.