High Performance Integrated Controller-PM Motor Utilizing Innovative Manufacturing Ideas

70442 A propulsion system for electric, hybrid electric, and fuel cell vehicles that provides a 4:1 constant power ratio is desired to eliminate the typical four-or-more speed transmission. The system must deliver 30kW of power while maintaining the high efficiency and power density of brushless DC permanent magnet motors. Also, the propulsion system should be integrated to include both a motor/generator and controller. This project will develop an intergrated controller/PM motor design by combining advanced technologies in rotor cooling, controller intergration, and manufacturing, with new innovations in sine-wave motor control and field weakening. The system will provide 30kW of power over a 4:1 constant power-speed ratio with improved performance, reliability, and cost. Phase I will define and create detailed models of an integrated 30kW propulsion system using advanced manufacturing methods. These models will be created using three-dimensional, computer-aided drafting software in conjunction with hardware test data to validate the models. A test fixture will be designed and built to develop a true rotor position sensor as an inexpensive alternative to resolvers. Commercial Applications and Other Benefits as described by the awardee: Automotive manufacturers are utilizing brushless PM motors in their electric, hybrid electric, and fuel cell vehicle development programs. As these vehicles move closer to volume production, the need exists for less expensive and more power dense motors, generators, and controllers. Other applications for this integrated system exist in material handling, agricultural, construction, and military vehicle markets.