64 July/August 2024 | E-Mobility Engineering Peter Donaldson details the many processes involved in creating new motor systems Principles of geometry As with any sophisticated industrial process, the development of motor systems for e-mobility is a complex and multi-stage endeavour, subject to rapid change under pressure, both to innovate and ramp up to high production volumes. The first stage is conceptualisation and definition, whereby key requirements are identified and the specifications of the motor are defined, based on the intended application, vehicle type, powertrain configuration and the regulatory standards that apply in the markets in which it will operate. Next comes design to flesh out the details of the motor geometry, including the stator, rotor, windings, housing and design software, and the subsequent electromagnetic and thermal simulations to optimise motor performance, efficiency and cooling requirements. Designs are then validated using finite element analysis (FEA) and computational fluid dynamics (CFD) simulations. Prototype development comes next, beginning with the fabrication of components such as stator and rotor assemblies, increasingly using rapid techniques such as 3D printing. Prototype motors are then assembled and put through initial bench testing to verify performance characteristics and validate simulation results. More comprehensive testing and validation follows, focused on the prototype’s performance, efficiency and durability, including dynamometer tests that evaluate torque, speed, power and efficiency under a range of operating conditions. Thermal performance testing assesses the new motor’s ability to operate reliably within the design temperature limits, while durability testing helps to evaluate its longevity and resistance to mechanical stress, vibrations and environmental factors. Data from these tests is used to inform iterative design modifications and optimisations to address any shortcomings identified during testing. Repeat testing and validation cycles are then carried out to ensure any design changes meet the desired performance objectives. In parallel, the processes required for production are developed and tailored to the intended scale. Critical to this is optimisation of the methods for component fabrication and assembly, and quality control. Making complete motors, particularly at scale, requires many different types of equipment, which, individually and Simulation has become an indispensable tool in the development of e-machines, enabling the visualisation of magnetic flux, for example, as engineers chase performance and efficiency (Image courtesy of Additive Drives)
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