Continued advances are needed for automotive traction motors and controls to meet cost and performance goals, specifically $10/kW and 5 kW/kg for a 30kW combined controller and motor system. The key to meeting these very aggressive goals will require the coordination of multiple innovations in the design and manufacture of complete motor and controller systems. However, conventional methods for increasing motor power density lead to difficult cooling requirements and increased cost, and conventional cost-reduction methods lead to reduced motor performance. Therefore, this project will develop a systems approach for highly integrated motor and electronic modules to allow for the optimization of electromagnetic, thermal, structural, and control design parameters. This approach will provide the required motor performance while minimizing cost through high-volume production processes. In Phase I, existing computer models for vehicles, motors and electronics will be expanded to predict system performance as various sub-systems become integrated. Advanced thermal management techniques will be incorporated within the integrated motor and controller modules. Advanced motor coils, magnetic circuits, cooling techniques, control algorithms, and electronics will be analyzed for future integration.
Commercial Applications and Other Benefits as described by the awardee: The resulting permanent magnet motor should achieve a constant power ratio of 4:1 at a rated efficiency exceeding 98%. The integrated motor and controller modules should reduce the size, weight, and cost of hybrid electric vehicles, and be useful in many other industrial and military applications
