James Pellegrino Alexander

Advanced High-Power-Density Interior Permanent Magnet Motor for Traction Applications

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the ground transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. This paper will provide details of the design, analysis and testing of an advanced interior permanent magnet (IPM) machine that was developed to meet the FreedomCar 2020 specifications. The 12 slot/10 pole machine has segmented stator structure equipped with fractional-slot concentrated-windings (FSCW). The rotor has a novel spoke structure. Several prototypes with different thermal management schemes have been built and tested. The paper will cover the test results for all these prototypes and highlight the tradeoffs between the various schemes.

Effect of Magnet Types on Performance of High-Speed Spoke Interior-Permanent-Magnet Machines Designed for Traction Applications

Interior permanent magnet (PM) machines are considered the state of the art for traction motors, particularly in light-duty hybrid and electrical vehicles. These motors usually use neodymium-iron-boron (NdFeB) PMs. These magnets include both light rare-earth materials such as neodymium (Nd) as well as heavy rare-earth materials such as dysprosium (Dy). The main purpose of Dy is to enhance the magnet coercivity to avoid demagnetization under both high temperatures as well as flux weakening. One of the key risks in terms of using these rare-earth magnets is the significant fluctuation/increase in their prices over the past few years. Applications that use large quantities of these magnets, such as traction motors and wind generators, are the most affected by these fluctuations. There has been an ongoing global effort to try to reduce or eliminate the use of rare-earth materials (particularly Dy which is the most expensive) without sacrificing too much performance. This paper will focus on advanced spoke designs targeting traction applications. The goal of this paper is to come up with new spoke designs using various grades of Dy-free magnets as well as ferrites targeting the same set of specifications. This paper will provide a detailed comparison between the various designs highlighting the key tradeoffs in terms of power density, efficiency, flux-weakening capability, and magnet susceptibility to demagnetization. Also, a prototype using ferrites has been built and tested, and the experimental results will be presented.

Development of a High Speed HTS Generator for Airborne Applications

General Electric, under contract with the Air Force Research Labs (AFRL), has successfully developed and tested a high speed, multimegawatt superconducting generator. The generator was built to demonstrate high temperature superconducting (HTS) generator technology for application in a high power density Multimegawatt Electric Power System (MEPS) for the Air Force. The demonstration tested the generator under load conditions up to 1.3 MW at over 10,000 rpm. The new MEPS generator achieved 97% efficiency including cryocooler losses. All test results indicate that the generator has a significant margin over the test points and that its performance is consistent with program specifications. This demonstration is the first successful full-load test of a superconducting generator for the Air Force. In this paper we describe the development of the generator and present some key test results used to validate the design. Extrapolation to a higher power density generator is also discussed.

Reduced Rare-Earth Flux-Switching Machines for Traction Applications

There has been growing interest in electrical machines that reduce or eliminate rare-earth material content. Traction applications are among the key applications where reducing cost and, hence, reduction of rare-earth materials are key requirements. This paper will assess the potential of different variants of flux-switching machines (FSMs) that either reduce or eliminate rare-earth materials in the context of traction applications. Two designs use different grades of dysprosium-free permanent magnets (PMs), and the third design is a wound-field variant that does not include PMs at all. A detailed analysis of all three designs in comparison to the required set of specifications will be presented. The key opportunities and challenges will be highlighted. The impact of the high pole-count/frequency of the FSMs will also be evaluated. Experimental results for one of the designs with dysprosium-free PMs will also be presented.

Advanced high power-density interior permanent magnet motor for traction applications

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the ground transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. This paper will provide details of the design, analysis, and testing of an advanced interior permanent magnet (PM) machine that was developed to meet the FreedomCAR 2020 specifications. The 12-slot/10-pole machine has segmented stator structure equipped with fractional-slot nonoverlapping concentrated windings. The rotor has a novel spoke structure/assembly. Several prototypes with different thermal management schemes have been built and tested. This paper will cover the test results for all these prototypes and highlight the tradeoffs between the various schemes. Due to the high machine frequency (~1.2 kHz at the top speed), detailed analysis of various loss components and ways to reduce them will be presented. In addition, due to the high coolant inlet temperature and the fact that the machine is designed to continuously operate at 180 °C, detailed PM demagnetization analysis will be presented. The key novelty in this paper is the advanced rotor structure and the thermal management schemes.

Rotor End Losses in Multiphase Fractional-Slot Concentrated-Winding Permanent Magnet Synchronous Machines

Fractional-slot concentrated windings (FSCW) have been gaining a lot of interest in permanent magnet (PM) synchronous machines. This is due to the advantages they provide including shorter nonoverlapping end turns, higher efficiency, higher power density, higher slot fill factor, lower manufacturing cost, better flux-weakening capability resulting in wider constant power versus speed range, and fault tolerance. This paper focuses on eddy-current losses in the rotor clamping rings. Additionally, the loss in the nonmagnetic shaft with the option of i) metallic, ii) nonmetallic, and iii) metallic with shielding laminations clamping rings is analyzed. The study is based on finite element analysis (FEA). Desirable slot/pole combinations for different number of phases with both single- and double-layer windings are investigated. Experimental results for a three-phase 12 slot/10 pole design are presented to confirm that the losses in the rotor clamping rings can be very significant in case of FSCW machines and should not be overlooked during the design phase.

Reduced rare-earth flux switching machines for traction applications

There has been growing interest in electrical machines that reduce or eliminate rare-earth material content. Traction applications are among the key applications where reducing cost and hence reduction of rare-earth materials is a key requirement. This paper will assess the potential of different variants of flux-switching machines that either reduce or eliminate rare-earth materials in the context of traction applications. Two designs use different grades of Dysprosium-free permanent magnets and the third design is a wound-field variant that does not include permanent magnets at all. Detailed analysis of all three designs in comparison to the required set of specifications will be presented. The key opportunities and challenges will be highlighted. The impact of the high pole-count/frequency of the flux-switching machines will also be evaluated. Preliminary experimental results for one of the designs with Dysprosium-free permanent magnets will also be presented.

Rotor end losses in multi-phase fractional-slot concentrated-winding permanent magnet synchronous machines

Fractional-slot concentrated-windings (FSCW) have been gaining a lot of interest in Permanent Magnet (PM) synchronous machines. This is due to the advantages they provide including shorter non-overlapping end turns, higher efficiency, higher power density, higher slot fill factor, lower manufacturing cost, better flux-weakening capability resulting in wider constant power vs. speed range, and fault-tolerance. This paper focuses on eddy current losses in the rotor clamping rings. Losses in the non-magnetic shaft with the option of i) metallic, ii) nonmetallic, and iii) metallic with shielding laminations clamping rings are analyzed. The study is based on Finite Element Analysis (FEA). Desirable slot/pole combinations for different number of phases with both single- and double-layer windings are investigated. Experimental results for a 3-phase 12slot/10pole design will be presented to confirm that the losses in the rotor clamping rings can be very significant in case of FSCW and should not be overlooked during the design phase.

Scalable, low-cost, high performance IPM Motor for Hybrid Vehicles

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the ground transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. This paper will provide an overview of the DoE/GE project to develop scalable, low-cost, high-performance next generation IPM traction motors for hybrid applications. The goal is to leap frog the state of the art and meet the FredomCar 2020 specifications. The paper will include the analytical and test results of the first proof-of-principle machine, analytical and preliminary test results for the second proof-of-principle machine as well as next steps.

Design of synchronous reluctance motor utilizing dual-phase material for traction applications

While interior permanent magnet (IPM) machines have been considered the state-of-the art for traction motors, synchronous reluctance (SynRel) motors with advanced materials can provide a competitive alternative. IPM machines typically utilize Neodymium Iron Boron (NdFeB) permanent magnets, which pose an issue in terms of price, sustainability, demagnetization at higher operating temperatures, and uncontrolled generation. On the other hand, SynRel machines do not contain any magnets and are free from these issues. However, the absence of magnets as well the presence of bridges and centerpost limit the flux-weakening capability of a SynRel machine and limit the achievable constant power speed ratio (CPSR) for a given power converter rating. In this paper, a new material referred to as the dual-phase magnetic material will be evaluated for SynRel designs. This material allows for non-magnetic regions to be selectively introduced in the bridge and post regions, thereby eliminating one of the key limitations of the SynRel designs in terms of torque density and flux-weakening. This paper will focus on advanced SynRel designs utilizing dual-phase material targeting traction applications. The paper will provide a detailed comparison between a dual-phase SynRel design, a conventional SynRel design and a spoke PM design with rare-earth-free magnets. It will highlight the key tradeoffs in terms of power density, efficiency, and flux-weakening capability.