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Title: Alternative High-Performance Motors with Non-Rare Earth Materials, Final Publishable Report

Abstract

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. The goal of the project is to develop traction motors that reduce or eliminate the use of rare-earth materials and meet the DoE specifications for such a traction motor. This is accomplished by evaluating and developing multiple motor topologies in conjunction with advanced materials. Eight non-permanent magnet motor topologies and two reduced or non-rare earth motor topologies are analyzed and compared using a common set of requirements. Five of the motors are built and tested to validate the analysis. This paper provides a detailed quantitative comparison of the different machine topologies that reduce or eliminate rare-earth materials. Conclusions are drawn from the analysis and test data to show the tradeoffs related to selecting each of the motor topologies with the hope of providing practicing engineers and researchers in the field enough guidelines for choosing the “optimum” machine topology that suits their applications and set of performance requirements. Fourmore » materials technologies were investigated for their ability to enable a reduced rare earth electric motor. Two of the technologies were soft magnetic materials, one was a non-rare-earth containing permanent magnet technology, and the last was an insulation material. These processing and performance of these materials were first demonstrated in small coupons. The coupon tests justified proceeding to larger scale processing for two of the materials technologies: 1) a dual-phase soft magnetic material for use in rotor laminates and 2) a high temperature insulation material for use as a slot liner in the stator. The dual phase soft magnetic material was produced at a scale sufficient to build and test a sub-scale motor prototype. The high temperature insulation material was first evaluated in a series of “statorettes” before being demonstrated in the stator of one of the full-scale motor prototypes. Testing of the dual phase material revealed issues with process variability in larger production volumes that are being addressed in a subsequent project. The performance of the high-temperature slot liner insulation was demonstrated during the operation of a full-scale prototype. Furthermore, the insulation material was shown to survive aging tests of 2000 hours and 280 °C and 800 hours at 300 °C. This program provides analysis and data to accelerate the introduction of hybrid electric vehicles into the U.S. road vehicle fleet and bring the added benefits of reduced fuel consumption and environmental impacts« less

Authors:
 [1];  [1]
  1. General Electric Global Research, Niskayuna, NY (United States)
Publication Date:
Research Org.:
General Electric Global Research, Niskayuna, NY (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V)
OSTI Identifier:
1349071
Report Number(s):
DOE-GEGR-5573-1
DOE Contract Number:
EE0005573
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; 33 ADVANCED PROPULSION SYSTEMS; 36 MATERIALS SCIENCE; Electric machines; motors; generators; rare earths; permanent magnets; soft magnetic materials; insulation

Citation Formats

Galioto, Steven, and Johnson, Francis. Alternative High-Performance Motors with Non-Rare Earth Materials, Final Publishable Report. United States: N. p., 2017. Web.
Galioto, Steven, & Johnson, Francis. Alternative High-Performance Motors with Non-Rare Earth Materials, Final Publishable Report. United States.
Galioto, Steven, and Johnson, Francis. Thu . "Alternative High-Performance Motors with Non-Rare Earth Materials, Final Publishable Report". United States. doi:.
@article{osti_1349071,
title = {Alternative High-Performance Motors with Non-Rare Earth Materials, Final Publishable Report},
author = {Galioto, Steven and Johnson, Francis},
abstractNote = {Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. The goal of the project is to develop traction motors that reduce or eliminate the use of rare-earth materials and meet the DoE specifications for such a traction motor. This is accomplished by evaluating and developing multiple motor topologies in conjunction with advanced materials. Eight non-permanent magnet motor topologies and two reduced or non-rare earth motor topologies are analyzed and compared using a common set of requirements. Five of the motors are built and tested to validate the analysis. This paper provides a detailed quantitative comparison of the different machine topologies that reduce or eliminate rare-earth materials. Conclusions are drawn from the analysis and test data to show the tradeoffs related to selecting each of the motor topologies with the hope of providing practicing engineers and researchers in the field enough guidelines for choosing the “optimum” machine topology that suits their applications and set of performance requirements. Four materials technologies were investigated for their ability to enable a reduced rare earth electric motor. Two of the technologies were soft magnetic materials, one was a non-rare-earth containing permanent magnet technology, and the last was an insulation material. These processing and performance of these materials were first demonstrated in small coupons. The coupon tests justified proceeding to larger scale processing for two of the materials technologies: 1) a dual-phase soft magnetic material for use in rotor laminates and 2) a high temperature insulation material for use as a slot liner in the stator. The dual phase soft magnetic material was produced at a scale sufficient to build and test a sub-scale motor prototype. The high temperature insulation material was first evaluated in a series of “statorettes” before being demonstrated in the stator of one of the full-scale motor prototypes. Testing of the dual phase material revealed issues with process variability in larger production volumes that are being addressed in a subsequent project. The performance of the high-temperature slot liner insulation was demonstrated during the operation of a full-scale prototype. Furthermore, the insulation material was shown to survive aging tests of 2000 hours and 280 °C and 800 hours at 300 °C. This program provides analysis and data to accelerate the introduction of hybrid electric vehicles into the U.S. road vehicle fleet and bring the added benefits of reduced fuel consumption and environmental impacts},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Thu Mar 30 00:00:00 EDT 2017},
month = {Thu Mar 30 00:00:00 EDT 2017}
}

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