Traction motor design trade-offs with additively manufactured anisotropic bonded magnets

Vandana Rallabandi; Shajjad Chowdhury; Himel Barua; M. Parans Paranthaman; Mostak Mohammad; Steve Bullock; Emily Cousineau

doi:10.1109/ITEC55900.2023.10187005

Traction motor design trade-offs with additively manufactured anisotropic bonded magnets

Vandana Rallabandi, Shajjad Chowdhury, Himel Barua, M. Parans Paranthaman, Mostak Mohammad, Steve Bullock, Emily Cousineau

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

2 Scopus citations

Abstract

Extrusion based big area additive manufacturing (BAAM) has been previously demonstrated for the fabrication of dense anisotropic bonded magnets. This paper reports on design trade-offs when such magnets are employed in a motor designed for electric vehicle applications. An external rotor fractional slot permanent magnet synchronous machine designed with sintered dysprosium free magnets rated for 100kW peak and 50kW continuous power is used as the baseline. The impact of using the bonded BAAM magnets on the motor and inverter volumes, motor loss and cooling systems as well as demagnetization margins is evaluated. It is found that although the motor power density reduces due to the lower energy product of the BAAM magnets, there are other system level benefits including reductions in the cooling system requirement, lower inverter rating and volume, decrease in short circuit current and improved demagnetization marains.

Original language	English
Title of host publication	2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023
Publisher	Institute of Electrical and Electronics Engineers Inc.
ISBN (Electronic)	9798350397420
DOIs	https://doi.org/10.1109/ITEC55900.2023.10187005
State	Published - 2023
Event	2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023 - Detroit, United States Duration: Jun 21 2023 → Jun 23 2023

Publication series

Name	2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023

Conference

Conference	2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023
Country/Territory	United States
City	Detroit
Period	06/21/23 → 06/23/23

Funding

ACKNOWLEDGMENT This work was supported by the Critical Materials Institute (CMI), an Energy Innovation Hub funded by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office.. This manuscript has been authored by UT-Battelle LLC under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan)

Keywords

Permanent magnet motors
additive manufacturing

Access to Document

10.1109/ITEC55900.2023.10187005

Cite this

Rallabandi, V., Chowdhury, S., Barua, H., Paranthaman, M. P., Mohammad, M., Bullock, S., & Cousineau, E. (2023). Traction motor design trade-offs with additively manufactured anisotropic bonded magnets. In 2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023 (2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023). Institute of Electrical and Electronics Engineers Inc.. https://doi.org/10.1109/ITEC55900.2023.10187005

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abstract = "Extrusion based big area additive manufacturing (BAAM) has been previously demonstrated for the fabrication of dense anisotropic bonded magnets. This paper reports on design trade-offs when such magnets are employed in a motor designed for electric vehicle applications. An external rotor fractional slot permanent magnet synchronous machine designed with sintered dysprosium free magnets rated for 100kW peak and 50kW continuous power is used as the baseline. The impact of using the bonded BAAM magnets on the motor and inverter volumes, motor loss and cooling systems as well as demagnetization margins is evaluated. It is found that although the motor power density reduces due to the lower energy product of the BAAM magnets, there are other system level benefits including reductions in the cooling system requirement, lower inverter rating and volume, decrease in short circuit current and improved demagnetization marains.",

keywords = "Permanent magnet motors, additive manufacturing",

author = "Vandana Rallabandi and Shajjad Chowdhury and Himel Barua and Paranthaman, {M. Parans} and Mostak Mohammad and Steve Bullock and Emily Cousineau",

note = "Publisher Copyright: {\textcopyright} 2023 IEEE.; 2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023 ; Conference date: 21-06-2023 Through 23-06-2023",

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doi = "10.1109/ITEC55900.2023.10187005",

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Rallabandi, V, Chowdhury, S, Barua, H , Paranthaman, MP , Mohammad, M , Bullock, S & Cousineau, E 2023, Traction motor design trade-offs with additively manufactured anisotropic bonded magnets. in 2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023. 2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023, Institute of Electrical and Electronics Engineers Inc., 2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023, Detroit, United States, 06/21/23. https://doi.org/10.1109/ITEC55900.2023.10187005

Traction motor design trade-offs with additively manufactured anisotropic bonded magnets. / Rallabandi, Vandana; Chowdhury, Shajjad; Barua, Himel et al.
2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023. Institute of Electrical and Electronics Engineers Inc., 2023. (2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AU - Chowdhury, Shajjad

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AU - Mohammad, Mostak

AU - Bullock, Steve

AU - Cousineau, Emily

PY - 2023

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N2 - Extrusion based big area additive manufacturing (BAAM) has been previously demonstrated for the fabrication of dense anisotropic bonded magnets. This paper reports on design trade-offs when such magnets are employed in a motor designed for electric vehicle applications. An external rotor fractional slot permanent magnet synchronous machine designed with sintered dysprosium free magnets rated for 100kW peak and 50kW continuous power is used as the baseline. The impact of using the bonded BAAM magnets on the motor and inverter volumes, motor loss and cooling systems as well as demagnetization margins is evaluated. It is found that although the motor power density reduces due to the lower energy product of the BAAM magnets, there are other system level benefits including reductions in the cooling system requirement, lower inverter rating and volume, decrease in short circuit current and improved demagnetization marains.

AB - Extrusion based big area additive manufacturing (BAAM) has been previously demonstrated for the fabrication of dense anisotropic bonded magnets. This paper reports on design trade-offs when such magnets are employed in a motor designed for electric vehicle applications. An external rotor fractional slot permanent magnet synchronous machine designed with sintered dysprosium free magnets rated for 100kW peak and 50kW continuous power is used as the baseline. The impact of using the bonded BAAM magnets on the motor and inverter volumes, motor loss and cooling systems as well as demagnetization margins is evaluated. It is found that although the motor power density reduces due to the lower energy product of the BAAM magnets, there are other system level benefits including reductions in the cooling system requirement, lower inverter rating and volume, decrease in short circuit current and improved demagnetization marains.

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Rallabandi V, Chowdhury S, Barua H , Paranthaman MP , Mohammad M , Bullock S et al. Traction motor design trade-offs with additively manufactured anisotropic bonded magnets. In 2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023. Institute of Electrical and Electronics Engineers Inc. 2023. (2023 IEEE Transportation Electrification Conference and Expo, ITEC 2023). doi: 10.1109/ITEC55900.2023.10187005

Traction motor design trade-offs with additively manufactured anisotropic bonded magnets

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