High-Power-Density, Non-Permanent-Magnet, Electric motor Development for Hybrid, Plug-in Hybrid, and Fuel Cell Vehicles

Current permanent magnet (PM) machinery designs for hybrid and electric vehicles are limited by rotor tip speed and PM material costs. In addition, the ¿always on¿ PM field results in design voltage compromises and high magnetically-induced losses during partial power operation. In this project, induction machine alternatives for vehicle power train applications will be designed to compete with the PM machinery solutions. In Phase I, concept designs will be developed, and prototype induction machine rotors will be fabricated using cast copper rotor techniques. The rotors will be tested to verify the design models and inform improved designs. In Phase II a complete induction drive system with 30kW steady-state capability and 55kW transient capability will be fabricated and tested with a mating drive and controller. Commercial Applications and other Benefits as described by the awardee: The use of induction machines would benefit hybrid and electric vehicles by requiring fewer compromises for high speed operation and reducing losses associated with partial power use. Furthermore, by avoiding the need to use PM materials, the sensitivity to limited foreign supply and cost volatility would be reduced