High Performance Integrated Controller-PM Motor with Low Cost Rotor Position Sensor

70442S02-II Future fuel-cell-vehicle propulsion motors will have to provide power over a wide speed range, deliver at least 30 kW of continuous power, maintain the high efficiency and power density of brushless, DC permanent magnet (PM) motors, and integrate both a motor/generator and a controller into a single package. To support these goals, this project will build an integrated controller/PM motor that will provide at least 30kW of continuous power over a 4:1 constant power-speed ratio. This will be accomplished by integrating recently developed advanced technologies in rotor cooling, controller integration, and manufacturing methods with innovations in field oriented motor control and field weakening. In Phase I, two versions of an integrated 30 kW motor and controller were designed using three-dimensional computer aided drafting tools. The Phase II project will implement the Phase I technology into hardware that can be used in advanced fuel cell vehicles. The integrated motor and controller design will be fully engineered, detailed, built, and tested; and a full evaluation of the new controller technologies will be performed. Commercial Applications and Other Benefits as described by awardee: All automotive manufacturers require electric motors in their fuel cell vehicles. As these vehicles move closer to volume production, this technology should address their need for less expensive and more power-dense motors, generators, and controllers.