Impact Study of Isolated and Correlated Manufacturing Tolerances of a Permanent Magnet Synchronous Machine for Traction Drives

Mülder, Christoph; Franck, Marius; Schröder, Michael; Balluff, Markus; Wanke, Andreas; Hameyer, Kay

doi:10.1109/iemdc.2019.8785274

Cited by 7 publications

(3 citation statements)

References 5 publications

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“…One of the most important aspects to consider when designing an IPMSM, which is often neglected in the scientific literature, is the analysis of forces acting on magnets. This information is important at the stage of construction of the machine itself, where aspects related to manufacturing and assembling tolerances [31][32][33][34], as well as their impact on the operation, are frequently overlooked. The manufacturing tolerance is of particular importance in the case of surface-mounted magnets, less in the case of recessed mounting, but the knowledge of local influences allows unambiguous determination of the position of individual segments forming a pole immediately after assembly.…”

Section: (B) Magnetic Forces On Magnetsmentioning

confidence: 99%

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Influence of a Winding Short-Circuit Fault on Demagnetization Risk and Local Magnetic Forces in V-Shaped Interior PMSM with Distributed and Concentrated Winding

et al. 2021

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This paper presents a comparison of 30/8 and 12/8 AC permanent magnet motors with distributed (DW) and concentrated winding (CW) designed for electric vehicle traction. Both prototypes are based on an interior permanent magnet (IPM) motor topology and contain V-shape magnets. The radial flux AC IPM motors were designed for an 80 kW propulsion system to achieve 125 N·m. Finite element models (FEM) used to design the geometry of IPM motors and the required useful parameters of electric motors are widely investigated. The accuracy of finite element models is verified and validated on the basis of test data. Numerical simulations of healthy and faulty operation states, and studies of winding faults based on the FEM offer a deeper understanding of the associated phenomena. Therefore, in this paper, a short-circuit fault in a stator winding was simulated to investigate the transient currents under an external load collapse, for all winding phases. These simulations were used to define other important machine parameters to improve mechanical reliability of the motors and to assess the potential risk of permanent magnet (PM) demagnetization. Furthermore, the analysis of local magnetic forces affecting the PMs in the rotor and their possible displacement in a short-circuit situation were performed, also taking into account the centrifugal force. Lastly, it is demonstrated that the choice of winding configuration has a significant impact on the uncontrolled displacement of magnets in the rotor.

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Section: (B) Magnetic Forces On Magnetsmentioning

confidence: 99%

“…These harmonics are highly sensitive to the degree of fault. Another extremely important reason for the poorer performance of an electrical motor is the tolerance of PM mounting in the rotor core [31][32][33][34].…”

Section: Introductionmentioning

confidence: 99%

Influence of a Winding Short-Circuit Fault on Demagnetization Risk and Local Magnetic Forces in V-Shaped Interior PMSM with Distributed and Concentrated Winding

et al. 2021

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“…Manufacturing tolerance refers to the permissible variation from the specified dimension or parameter during the production process [5]. In the sequential e-motor manufacturing process, even minor variations can cause significant e-motor performance disparity.…”

Section: Introductionmentioning

confidence: 99%

Influence of Electric Motor Manufacturing Tolerances on End-of-Line Testing: A Review

Popsi,

Anik,

Verma

et al. 2024

Energies

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Electric vehicles (EVs) are propelled by electric traction drive systems (ETDSs), which consist of various components including an electric motor, power electronic converter, and gear box. During manufacturing, end-of-line testing is the ultimate step for ensuring the quality and performance of electric motors in electric vehicle (EV) traction drive systems (ETDSs). The outcome of end-of-line testing of electric motors is significantly influenced by the tolerances of their structural parameters, such as stator inner and outer diameters, magnet dimensions, air gaps, and other geometric parameters. The existing literature provides insights into parametric sensitivity, offering guidance for enhancing the reliability of end-of-line testing. In this manuscript, the importance of end-of-line testing and the role of manufacturing tolerances of e-motor structural parameters in the manufacturing process of ETDSs are discussed. The impact of tolerances of e-motor structural parameters on the test results, such as torque, efficiency, back EMF, and e-NV (noise and vibration), is investigated. Finally, key challenges and research gaps in this area are identified, and recommendations for future research to mitigate the drawbacks of end-of-line testing are provided.

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Elektrische Maschinen

Hameyer,

Butterweck,

Driendl

et al. 2023

Elektromobilität

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Impact Study of Isolated and Correlated Manufacturing Tolerances of a Permanent Magnet Synchronous Machine for Traction Drives

Cited by 7 publications

References 5 publications

Influence of a Winding Short-Circuit Fault on Demagnetization Risk and Local Magnetic Forces in V-Shaped Interior PMSM with Distributed and Concentrated Winding

Influence of a Winding Short-Circuit Fault on Demagnetization Risk and Local Magnetic Forces in V-Shaped Interior PMSM with Distributed and Concentrated Winding

Influence of Electric Motor Manufacturing Tolerances on End-of-Line Testing: A Review

Elektrische Maschinen

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