RADIAL FLUX MACHINES /
RADIAL FLUX ELECTRICAL MACHINES
At Alvier Mechatronics we have experience of developing radial flux electrical machines from initial application needs all the way to validated prototypes.
We have experience in a variety of machine types including permanent magnet, electrically excited, induction or ferrite magnet machines, using copper or aluminum windings, for traction or auxiliary applications.
We understand the importance of simulation in the market’s ever-increasing need for development speed. But a model is just a model, to build confidence we validate our models through extensive physical testing, from subsystems, through components and finally full system testing in both rigs and vehicles.
STRATEGY
RADIAL FLUX DEVELOPMENT
- Concept: Starting from your application needs or concept idea, we develop one or multiple electrical machine concepts. Using electromagnetic design tools such as MotorCAD, JMAG or COMSOL we first perform quick screenings to find the best machine candidates.
- Design and Optimization: Once the best machine candidates have been defined, we proceed with more detailed thermal and mechanical analysis. In parallel, the machines are designed and modelled in CAD, typically using Creo or Solid Works. On the electromagnetic side the detailed analysis can include demagnetization analysis, skinlosses and proximity loss analysis and we provide optimization for efficiency and performance.
- Prototyping: After the detailed design is frozen, we procure the components and build the electrical machines.
- Validation and Testing: We take the assembled prototypes and proceed with the testing and validation. Starting with basic observations like geometrical dimensions, phase resistance, phase inductance and insulation testing and moving onto to characterize the machine with BEMF and static torque tests. Finally, the machine is subjected to full testing to validate peak and continuous performance as well as efficiency.
USE CASE
Design for sustainability by using SMC cores for radial flux motors
An example of a radial flux project is the iDS RX Traction Motor with SMC based stator design.
Starting with the vehicle drive cycle specification, we define design space for combinations of electric machine, inverter and transmission. Using electrified Powertrain Optimization Process (ePOP) to generate and evaluate these combinations, we apply metrics including cost, sustainability, weight, and efficiency to establish which machine and system combination we will develop into a prototype.
In this project Alvier Mechatronics and Additive Drives teamed up to implement (3D printed) hairpin design into the innovative e-motor with SMC based stator core.
The usage of SMC material for stator cores enables significant reduction of CO2-footprint and excellent automation potential for series production.
SIMULATION
When designing e-motors for specific customers we regard simulation as a central development tool that provides a reliable basis for decision making at an early stage, makes it easier to compare numerous differenet alternatives and is essential for fine tuning the selected version.