SBIR-STTR Award

NuGen Mobility has demonstrated that their Axial Flux Permanent Magnet motors have high Torque and Power densities, while exhibiting very high efficiencies. In addition, techniques utilized to vary the Rotor-Stator air gap have demonstrated that these high efficiencies can be realized at multiple points in the application’s Power-Torque-Speed continuum. Applying this same technique to the generator role of our Axial Flux design, we propose to exploit this ability and provide the generator with multiple “High-efficiency” points of operation. NuGen proposes to demonstrate analytically that as an Integrated Starter-Generator (ISG), high efficiencies can result at low-speed, high torque for engine Start and also at high-speeds for its Generator role. We propose to use this opportunity to both conduct a detailed study of the applicability of this innovation to 50-100kW ISGs and evaluate the potential of axial flux permanent magnet motors as measured against other motor topologies, and demonstrate the technical feasibility and performance gains from the air gap variation at different operating modes.

Keywords:
Integrated Starter-Generator, Permanent Magnet, Axial Flux, Variable Gap, High Efficiency, High Power Density, Motors, Generator

NuGen Mobility successfully demonstrated that its innovative technology for Integrated Starter Generator (ISG) applications offered significant benefits providing a cost effective solution while maintaining performance with higher efficiencies as compared to typical industry standards. As a continuation effort, NuGen proposes to take the achievements made in Phase I of its innovative method of extending the torque-speed envelope of a PM generator to the next level of commercialization bringing its technology to a TRL 5 or higher and to commence aligning the same with a suitable POR(s) in the DOD in combination with our present commercial beach heads. The proposed effort is a two step process for purposes of risk reduction, validation of scalability and time to commercialization. Step 1 consists of applying our innovations to an ISG in the range of 15kW allowing for additional refinements to be made on a power level closer to the efforts that were done during Phase I thus separating any potential issues of scalability versus applicability and commercialization. Step 2 will be a follow on where the primary intent during this stage will be to validate the scalability of the innovative technology by applying it to an ISG on the order of 60kW.

Keywords:
Integrated Starter-Generator, Permanent Magnet, Axial Flux, Variable Gap, High Efficiency, High Power Density, Motor, Generator