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

doi:10.1109/ECCE.2015.7309773

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 proceeding › Conference Contribution (Conference Proceeding)

6 Citations (Scopus)

487 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 language	English
Title of host publication	2015 IEEE Energy Conversion Congress and Exposition (ECCE 2015)
Subtitle of host publication	Proceedings of a meeting held 20-24 September 2015, Montreal, Quebec, Canada
Publisher	Institute of Electrical and Electronics Engineers (IEEE)
Pages	813-820
Number of pages	8
ISBN (Electronic)	9781467371506
ISBN (Print)	9781467371520
DOIs	https://doi.org/10.1109/ECCE.2015.7309773
Publication status	Published - Jan 2016
Event	IEEE Energy Conversion Congress & Exposition (ECCE 2015) - Montreal, Quebec, Canada Duration: 20 Sept 2015 → 24 Sept 2015

Publication series

Name	Proceedings of the IEEE Energy Conversion Congress and Exposition (ECCE)
Publisher	Institute of Electrical and Electronics Engineers (IEEE)
ISSN (Print)	2329-3721

Conference

Conference	IEEE Energy Conversion Congress & Exposition (ECCE 2015)
Country/Territory	Canada
City	Montreal, Quebec
Period	20/09/15 → 24/09/15

Keywords

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

Access to Document

10.1109/ECCE.2015.7309773

Rafal Wrobel - Design of a Brushless PM Starter-Generator for Low-Cost Manufacture and a High-Aspect-Ratio Mechanical Space EnvelopeAccepted author manuscript, 1.5 MB

Handle.net

Persistent link

Low cost integrated electrical machines
Mellor, P. H. (Principal Investigator)
1/10/13 → 1/04/16
Project: Research

Cite this

Wrobel, R., Simpson, N., Mellor, P., Goss, J., & Staton, D. (2016). Design of a brushless PM starter-generator for low-cost manufacture and a high-aspect-ratio mechanical space envelope. In 2015 IEEE Energy Conversion Congress and Exposition (ECCE 2015): Proceedings of a meeting held 20-24 September 2015, Montreal, Quebec, Canada (pp. 813-820). (Proceedings of the IEEE Energy Conversion Congress and Exposition (ECCE)). Institute of Electrical and Electronics Engineers (IEEE). https://doi.org/10.1109/ECCE.2015.7309773

Wrobel, Rafal ; Simpson, Nick ; Mellor, Phil et al. / Design of a brushless PM starter-generator for low-cost manufacture and a high-aspect-ratio mechanical space envelope. 2015 IEEE Energy Conversion Congress and Exposition (ECCE 2015): Proceedings of a meeting held 20-24 September 2015, Montreal, Quebec, Canada. Institute of Electrical and Electronics Engineers (IEEE), 2016. pp. 813-820 (Proceedings of the IEEE Energy Conversion Congress and Exposition (ECCE)).

@inproceedings{9cb2f5c55d4b4b179dee1d99b118c88e,

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

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. Thepackaging 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 lumpedparameter 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.",

keywords = "PM starter-generator, design for manufacture, design for cost, low-cost aluminium winding, PM rotor, manufacturing variations",

author = "Rafal Wrobel and Nick Simpson and Phil Mellor and James Goss and David Staton",

year = "2016",

month = jan,

doi = "10.1109/ECCE.2015.7309773",

language = "English",

isbn = "9781467371520",

series = "Proceedings of the IEEE Energy Conversion Congress and Exposition (ECCE)",

publisher = "Institute of Electrical and Electronics Engineers (IEEE)",

pages = "813--820",

booktitle = "2015 IEEE Energy Conversion Congress and Exposition (ECCE 2015)",

address = "United States",

note = "IEEE Energy Conversion Congress & Exposition (ECCE 2015) ; Conference date: 20-09-2015 Through 24-09-2015",

}

Wrobel, R, Simpson, N , Mellor, P, Goss, J & Staton, D 2016, Design of a brushless PM starter-generator for low-cost manufacture and a high-aspect-ratio mechanical space envelope. in 2015 IEEE Energy Conversion Congress and Exposition (ECCE 2015): Proceedings of a meeting held 20-24 September 2015, Montreal, Quebec, Canada. Proceedings of the IEEE Energy Conversion Congress and Exposition (ECCE), Institute of Electrical and Electronics Engineers (IEEE), pp. 813-820, IEEE Energy Conversion Congress & Exposition (ECCE 2015), Montreal, Quebec, Canada, 20/09/15. https://doi.org/10.1109/ECCE.2015.7309773

Design of a brushless PM starter-generator for low-cost manufacture and a high-aspect-ratio mechanical space envelope. / Wrobel, Rafal; Simpson, Nick ; Mellor, Phil et al.
2015 IEEE Energy Conversion Congress and Exposition (ECCE 2015): Proceedings of a meeting held 20-24 September 2015, Montreal, Quebec, Canada. Institute of Electrical and Electronics Engineers (IEEE), 2016. p. 813-820 (Proceedings of the IEEE Energy Conversion Congress and Exposition (ECCE)).

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

TY - GEN

T1 - Design of a brushless PM starter-generator for low-cost manufacture and a high-aspect-ratio mechanical space envelope

AU - Wrobel, Rafal

AU - Simpson, Nick

AU - Mellor, Phil

AU - Goss, James

AU - Staton, David

PY - 2016/1

Y1 - 2016/1

N2 - 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. Thepackaging 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 lumpedparameter 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.

AB - 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. Thepackaging 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 lumpedparameter 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.

KW - PM starter-generator

KW - design for manufacture

KW - design for cost

KW - low-cost aluminium winding

KW - PM rotor

KW - manufacturing variations

U2 - 10.1109/ECCE.2015.7309773

DO - 10.1109/ECCE.2015.7309773

M3 - Conference Contribution (Conference Proceeding)

SN - 9781467371520

T3 - Proceedings of the IEEE Energy Conversion Congress and Exposition (ECCE)

SP - 813

EP - 820

BT - 2015 IEEE Energy Conversion Congress and Exposition (ECCE 2015)

PB - Institute of Electrical and Electronics Engineers (IEEE)

T2 - IEEE Energy Conversion Congress & Exposition (ECCE 2015)

Y2 - 20 September 2015 through 24 September 2015

ER -

Wrobel R, Simpson N , Mellor P, Goss J, Staton D. Design of a brushless PM starter-generator for low-cost manufacture and a high-aspect-ratio mechanical space envelope. In 2015 IEEE Energy Conversion Congress and Exposition (ECCE 2015): Proceedings of a meeting held 20-24 September 2015, Montreal, Quebec, Canada. Institute of Electrical and Electronics Engineers (IEEE). 2016. p. 813-820. (Proceedings of the IEEE Energy Conversion Congress and Exposition (ECCE)). Epub 2015 Sept 20. doi: 10.1109/ECCE.2015.7309773

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

Abstract

Publication series

Conference

Keywords

Access to Document

Handle.net

Fingerprint

Projects

Low cost integrated electrical machines

Cite this