Traction Motor Design Trade-Offs with Additively Manufactured Anisotropic Bonded Magnets
Extrusion based big area additive manufacturing (BAAM) has been previously demonstrated for the fabrication of dense anisotropic bonded magnets. This paper reports on design trade-offs when such magnets are employed in a motor designed for electric vehicle applications. An external rotor fractional slot permanent magnet synchronous machine designed with sintered dysprosium free magnets rated for 100kW peak and 50kW continuous power is used as the baseline. The impact of using the bonded BAAM magnets on the motor and inverter volumes, motor loss and cooling systems as well as demagnetization margins is evaluated. It is found that although the motor power density reduces due to the lower energy product of the BAAM magnets, there are other system level benefits including reductions in the cooling system requirement, lower inverter rating and volume, decrease in short circuit current and improved demagnetization marains.
- Research Organization:
- National Renewable Energy Laboratory (NREL), Golden, CO (United States)
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing and Materials Technologies Office (AMMTO)
- DOE Contract Number:
- AC36-08GO28308
- OSTI ID:
- 1998677
- Report Number(s):
- NREL/CP-5400-87365; MainId:88140; UUID:90e1f3c3-fb18-4edf-92db-20f5d7e13e5b; MainAdminID:70412
- Resource Relation:
- Conference: Presented at the 2023 IEEE Transportation Electrification Conference & Expo (ITEC), 21-23 June 2023, Detroit, Michigan
- Country of Publication:
- United States
- Language:
- English
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