Design Optimization of a Very High Power Density Motor with a Reluctance Rotor and a Modular Stator Having PMs and Toroidal Windings

Peng Han; Murat G. Kesgin; Dan M. Ionel; Rohan Gosalia; Nakul Shah; Charles J. Flynn; Chandra S. Goli; Somasundaram Essakiappan; Madhav Manjrekar

doi:10.1109/ECCE47101.2021.9595129

Design Optimization of a Very High Power Density Motor with a Reluctance Rotor and a Modular Stator Having PMs and Toroidal Windings

Peng Han
, Murat G. Kesgin
, Dan M. Ionel
, Rohan Gosalia
, Nakul Shah
, Charles J. Flynn
, Chandra S. Goli
, Somasundaram Essakiappan
, Madhav Manjrekar

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

18 Scopus citations

Abstract

This paper proposes a new high power density permanent magnet (PM) motor design for traction applications to achieve the 50kW/L target set by the US Department of Energy by increasing the torque capability and operating speed compared to conventional PM machine topologies. A large-scale multi-objective design optimization based on 2D finite element analysis (FEA) and differential evolution algorithm was conducted to achieve the best trade-off among high efficiency, high power density and high power factor. The torque-speed envelopes are also checked for the Pareto front designs to make sure they have a constant power speed ratio of at least 3:1. An open frame lab prototype (OFLP) motor has been fabricated and tested to validate the principle of operation and design optimization approach, and to identify the potential challenges in manufacturing and testing. Ongoing work on further pushing the electromagnetic performance to the limit and improving the manufacturing and cooling techniques are also discussed.

Original language	English
Title of host publication	2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings
Pages	4424-4430
Number of pages	7
ISBN (Electronic)	9781728151359
DOIs	https://doi.org/10.1109/ECCE47101.2021.9595129
State	Published - 2021
Event	13th IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Virtual, Online, Canada Duration: Oct 10 2021 → Oct 14 2021

Publication series

Name	2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings

Conference

Conference	13th IEEE Energy Conversion Congress and Exposition, ECCE 2021
Country/Territory	Canada
City	Virtual, Online
Period	10/10/21 → 10/14/21

Bibliographical note

Publisher Copyright:
© 2021 IEEE.

Funding

VIII. ACKNOWLEDGMENT This work was supported by the Vehicle Technologies Office, U.S. Department of Energy, under award no. DE-EE0008871. The material presented in this paper do not necessarily reflect the views of the U.S. Department of Energy. The authors would also like to gratefully acknowledge the direct support provided by QM Power, Inc.

Funders	Funder number
U.S. Department of Energy EPSCoR	DE-EE0008871

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 7 Affordable and Clean Energy

Keywords

Design optimization
electric machine
high power density
modularization
multi-objective
permanent magnet
reluctance machine

ASJC Scopus subject areas

Renewable Energy, Sustainability and the Environment
Energy Engineering and Power Technology
Electrical and Electronic Engineering

Access to Document

10.1109/ECCE47101.2021.9595129

Cite this

Han, P., Kesgin, M. G., Ionel, D. M., Gosalia, R., Shah, N., Flynn, C. J., Goli, C. S., Essakiappan, S., & Manjrekar, M. (2021). Design Optimization of a Very High Power Density Motor with a Reluctance Rotor and a Modular Stator Having PMs and Toroidal Windings. In 2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings (pp. 4424-4430). (2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings). https://doi.org/10.1109/ECCE47101.2021.9595129

@inproceedings{4417926a2f7f4932b9ee66e71caa66f6,

title = "Design Optimization of a Very High Power Density Motor with a Reluctance Rotor and a Modular Stator Having PMs and Toroidal Windings",

abstract = "This paper proposes a new high power density permanent magnet (PM) motor design for traction applications to achieve the 50kW/L target set by the US Department of Energy by increasing the torque capability and operating speed compared to conventional PM machine topologies. A large-scale multi-objective design optimization based on 2D finite element analysis (FEA) and differential evolution algorithm was conducted to achieve the best trade-off among high efficiency, high power density and high power factor. The torque-speed envelopes are also checked for the Pareto front designs to make sure they have a constant power speed ratio of at least 3:1. An open frame lab prototype (OFLP) motor has been fabricated and tested to validate the principle of operation and design optimization approach, and to identify the potential challenges in manufacturing and testing. Ongoing work on further pushing the electromagnetic performance to the limit and improving the manufacturing and cooling techniques are also discussed.",

keywords = "Design optimization, electric machine, high power density, modularization, multi-objective, permanent magnet, reluctance machine",

author = "Peng Han and Kesgin, \{Murat G.\} and Ionel, \{Dan M.\} and Rohan Gosalia and Nakul Shah and Flynn, \{Charles J.\} and Goli, \{Chandra S.\} and Somasundaram Essakiappan and Madhav Manjrekar",

note = "Publisher Copyright: {\textcopyright} 2021 IEEE.; 13th IEEE Energy Conversion Congress and Exposition, ECCE 2021 ; Conference date: 10-10-2021 Through 14-10-2021",

year = "2021",

doi = "10.1109/ECCE47101.2021.9595129",

language = "English",

series = "2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings",

pages = "4424--4430",

booktitle = "2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings",

}

Han, P, Kesgin, MG, Ionel, DM, Gosalia, R, Shah, N, Flynn, CJ, Goli, CS, Essakiappan, S & Manjrekar, M 2021, Design Optimization of a Very High Power Density Motor with a Reluctance Rotor and a Modular Stator Having PMs and Toroidal Windings. in 2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings. 2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings, pp. 4424-4430, 13th IEEE Energy Conversion Congress and Exposition, ECCE 2021, Virtual, Online, Canada, 10/10/21. https://doi.org/10.1109/ECCE47101.2021.9595129

Design Optimization of a Very High Power Density Motor with a Reluctance Rotor and a Modular Stator Having PMs and Toroidal Windings. / Han, Peng; Kesgin, Murat G.; Ionel, Dan M. et al.
2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings. 2021. p. 4424-4430 (2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Design Optimization of a Very High Power Density Motor with a Reluctance Rotor and a Modular Stator Having PMs and Toroidal Windings

AU - Han, Peng

AU - Kesgin, Murat G.

AU - Ionel, Dan M.

AU - Gosalia, Rohan

AU - Shah, Nakul

AU - Flynn, Charles J.

AU - Goli, Chandra S.

AU - Essakiappan, Somasundaram

AU - Manjrekar, Madhav

PY - 2021

Y1 - 2021

N2 - This paper proposes a new high power density permanent magnet (PM) motor design for traction applications to achieve the 50kW/L target set by the US Department of Energy by increasing the torque capability and operating speed compared to conventional PM machine topologies. A large-scale multi-objective design optimization based on 2D finite element analysis (FEA) and differential evolution algorithm was conducted to achieve the best trade-off among high efficiency, high power density and high power factor. The torque-speed envelopes are also checked for the Pareto front designs to make sure they have a constant power speed ratio of at least 3:1. An open frame lab prototype (OFLP) motor has been fabricated and tested to validate the principle of operation and design optimization approach, and to identify the potential challenges in manufacturing and testing. Ongoing work on further pushing the electromagnetic performance to the limit and improving the manufacturing and cooling techniques are also discussed.

AB - This paper proposes a new high power density permanent magnet (PM) motor design for traction applications to achieve the 50kW/L target set by the US Department of Energy by increasing the torque capability and operating speed compared to conventional PM machine topologies. A large-scale multi-objective design optimization based on 2D finite element analysis (FEA) and differential evolution algorithm was conducted to achieve the best trade-off among high efficiency, high power density and high power factor. The torque-speed envelopes are also checked for the Pareto front designs to make sure they have a constant power speed ratio of at least 3:1. An open frame lab prototype (OFLP) motor has been fabricated and tested to validate the principle of operation and design optimization approach, and to identify the potential challenges in manufacturing and testing. Ongoing work on further pushing the electromagnetic performance to the limit and improving the manufacturing and cooling techniques are also discussed.

KW - Design optimization

KW - electric machine

KW - high power density

KW - modularization

KW - multi-objective

KW - permanent magnet

KW - reluctance machine

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DO - 10.1109/ECCE47101.2021.9595129

M3 - Conference contribution

AN - SCOPUS:85123378240

T3 - 2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings

SP - 4424

EP - 4430

BT - 2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings

T2 - 13th IEEE Energy Conversion Congress and Exposition, ECCE 2021

Y2 - 10 October 2021 through 14 October 2021

ER -

Han P, Kesgin MG, Ionel DM, Gosalia R, Shah N, Flynn CJ et al. Design Optimization of a Very High Power Density Motor with a Reluctance Rotor and a Modular Stator Having PMs and Toroidal Windings. In 2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings. 2021. p. 4424-4430. (2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings). doi: 10.1109/ECCE47101.2021.9595129

Design Optimization of a Very High Power Density Motor with a Reluctance Rotor and a Modular Stator Having PMs and Toroidal Windings

Abstract

Publication series

Conference

Bibliographical note

Funding

UN SDGs

Keywords

ASJC Scopus subject areas

Access to Document

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Cite this