Design of a brushless PM starter-generator for low-cost manufacture and a high-aspect-ratio mechanical space envelope

Rafal Wrobel, Nick Simpson, Phil Mellor, James Goss, David Staton

Research output: Chapter in Book/Report/Conference proceedingConference Contribution (Conference Proceeding)

5 Citations (Scopus)
278 Downloads (Pure)

Abstract

This paper presents results from a design study into a brushless PM starter-generator. The automotive application demands a low-cost solution within a highly constrained mechanical space-envelope. Material costs are reduced through the use of ferrite permanent magnets and aluminium conductors. Design challenges include the selection of an appropriate machine topology to realise a high specific output given the lower performance materials and managing the additional losses associated with the higher resistivity of an aluminium winding. The problem is further exacerbated by the demanding space-envelope, operating requirements and the necessity of a design suited to volume manufacture. The
packaging arrangement suits an internal-rotor radial-flux topology and the limited mechanical space-envelope means that the aspect ratio of the stator outer diameter to the machine active length is high. The design approach outlined in the paper combines numerical electromagnetic analyses with a lumped
parameter thermal model and is calibrated with tests on machine subassemblies. The methodology allows for a more informed design process, where the manufacture and assembly nuances affecting the performance of the starter-generator are identified and accounted for prior to the prototyping of a complete machine assembly.
Original languageEnglish
Title of host publication2015 IEEE Energy Conversion Congress and Exposition (ECCE 2015)
Subtitle of host publicationProceedings of a meeting held 20-24 September 2015, Montreal, Quebec, Canada
PublisherInstitute of Electrical and Electronics Engineers (IEEE)
Pages813-820
Number of pages8
ISBN (Electronic)9781467371506
ISBN (Print)9781467371520
DOIs
Publication statusPublished - Jan 2016
EventIEEE Energy Conversion Congress & Exposition (ECCE 2015) - Montreal, Quebec, Canada
Duration: 20 Sep 201524 Sep 2015

Publication series

NameProceedings of the IEEE Energy Conversion Congress and Exposition (ECCE)
PublisherInstitute of Electrical and Electronics Engineers (IEEE)
ISSN (Print)2329-3721

Conference

ConferenceIEEE Energy Conversion Congress & Exposition (ECCE 2015)
CountryCanada
CityMontreal, Quebec
Period20/09/1524/09/15

Keywords

  • PM starter-generator
  • design for manufacture
  • design for cost
  • low-cost aluminium winding
  • PM rotor
  • manufacturing variations

Fingerprint Dive into the research topics of 'Design of a brushless PM starter-generator for low-cost manufacture and a high-aspect-ratio mechanical space envelope'. Together they form a unique fingerprint.

Cite this