SBIR-STTR Award

Hybrid electric propulsion of Army vehicles is beneficial in terms of fuel economy and silent mobility. High torque and high power density PM motors are needed for these applications.Electrodynamics proposes innovative concepts to achieve and exceed specified goals in power and torque density, efficiency, and scalability. This proposal explores various configurations including inside rotor, outside rotor, and axial gap. After selecting one of these approaches, proprietary innovative concepts are proposed to substantially increase the power density, torque density, and efficiency. These concepts also include the design of controller to match the motor and provide the ability to extend the operating speed range to cover operation from standstill to 10000 RPM. Sensorless design incorporated within software based control using a DSP is proposed. A team of experts in electromagentics, control, software, structural, thermal, and dynamic design of the motor and controller will address all the design issues during Phase I and Phase I Option to be ready to produce demonstrable hardware during Phase II. Military and commercial applications for the product are proposed

Electrodynmaics Associates, Inc. has under development a 50 kW 10000 RPM electric propulsion motor and controller. The Phase I activity is in progress, and the electromagnetic analysis, structural analysis as well as thermal analysis of the motor is completed indicating satisfactory operation at the rated load continuously, and 5 minute operation at 100 kW load. In addition 350% of the nominal torque is available at speeds to 2000 RPM. The power density is 14 kW/liter and the torque density is 51 Nm/liter. The motor design utilizes innovative concepts that allow reduced winding end turn length, and high magnetic flux density in the air gap. The controller uses innovative concepts needing low current draw during transient operations. During Phase II, two motors and controllers will be fabricated, the controller will be fine tuned, and the complete set will be demonstrated for operation under steady state and transient loads. Performance analysis including, efficiency mesurements, and transient response will be done. The units will be supplied to US Army for further tests in Warren, and at the SIL facility.

Keywords:
Propulsion Motor, Vector Control, Sensorlesss Control, Internal Permanent Magnet Motor, Hybrid Electric Vehicle Propulsion