Including manufacturing effects in design tools of high-volume e-machines for automotive implications

电机设计是一项复杂的工作，仍有许多未知数。机器中损失的模拟目前与原型机器的实验数据不一致，建筑系数被用来补偿。这种差异是由于机械制造过程导致材料中的残余应力造成的。目前的文献旨在量化电工钢的磁性能退化，大多数研究都是研究特定的工艺和材料，对材料的描述有限。在电机专家发表的文章中，很少讨论材料的微观结构和成分，而对材料样本进行的研究也很少涵盖电机完全组装后发生的情况。该项目建议弥合这些方法之间的差距，提供对制造过程中磁性如何退化的理解。从分析原材料和加工的材料样品开始，将从理论上了解导致磁性降解的微观结构变化，并将其应用于通过WMG的先进推进系统集团和HVEMS项目获得的生产部件和完全组装的电机。这些应用将包括多个机器部件和制造技术，为机器设计中的建筑因素提供经过测试的解决方案。该项目符合EPSRC(“Growth”)定义的优先领域“电机和驱动器/电磁学”的研究领域，并为主题“制造未来”、“工程”和“能源”做出贡献。

Electric machine design is a complex task still with many unknowns. Simulations of losses in machines do not currently agree with experimental data from prototype machines, building factors are used to compensate. The discrepancy is a result of machine manufacturing processes causing residual stress in the material. Current literature aims to quantify the degradation of electrical steels magnetic properties, most studies are investigating a specific process and material with limited description of the material. Material microstructure and composition are rarely discussed in articles published by electric machine experts, while the studies presented on material samples rarely cover what happens in the electric machine once fully assembled. This project proposes to bridge the gap between these approaches, providing the understanding as to how magnetic properties degrade during manufacturing. Beginning from analysis of material samples both raw and processed, a theoretical understanding of the microstructure changes responsible for magnetic degradation will be found and applied to production components and fully assembled motors available through WMG's Advanced Propulsion Systems Group and the HVEMS project. The applications will include multiple machine components and manufacturing techniques to provide a tested solution to the building factor in machine design.This project fits within the research area "Electrical motors and drives / electromagnetics" defined as a prioritized area by EPSRC ("grow") and contributes to the themes "Manufacture of the Future", "Engineering" and "Energy".