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Theses

Electrical machine designs based on 3D flux paths with reuse & recycle magnet concepts for automotive applications

Abstract : The research work presented in this thesis aims at developing a permanent magnet based claw-pole machine for automotive application with permanent magnet reuse and recycle concept. The aforesaid research is under the aegis of Project DEMETER which is in the framework of European Union’s Horizon 2020 Marie Sklodowska-Curie actions. The project focuses on the recovery of rare earth permanent magnets utilized in automotive applications due to the prevailing problems of price fluctuations and supply-demand issues of these permanent magnets.The claw-pole machine is employed in almost all of the automobiles in the world for alternator application. With the increase in power demands, the claw-pole machine is also being developed as a motor-generator utilized in the hybrid electric vehicles. At present the permanent magnet based claw-pole machine is being used in mild hybrid electric vehicles for energy savings. The literature is replete with various configurations of claw-pole machines that can be developed to achieve better performances. However, easy assembly and disassembly of various parts of the machine is also important for the reuse and recycle of magnets. In this research work two concepts have been developed; first, the direct reuse concept i.e. easy assembly/disassembly of the rotor and magnets, so as to easily take out the magnets for direct reuse or recycle and; second, the direct recycle concept i.e. utilization of recycled magnets in the machine to achieve the desired performance.In the course of this research the base design of the claw-pole machine was developed, analyzed and optimized so as to attain best torque versus magnet-weight ratio. This helped in the reduction of magnet cost for almost the same torque. The optimization was carried out using 3-D numerical analysis. The optimized model was developed in a way that the assembly process of the magnets and claw-poles remained the same. However, during disassembly the magnets can easily be withdrawn without disassembling the complete rotor; therefore utilizing these magnets for direct reuse in other applications or sent for recycling. In the direct recycle concept, the magnets used in the machine are recycled magnets with deteriorated performance. The type of recycling process is a strong determinant of the deterioration in performance of these recycled magnets. The aim of the direct recycle concept was to analyze the machine with virgin and recycled magnets, and evaluate the energy consumption of the machine under different drive cycles. It was observed that with utilization of recycled magnets in the claw-pole machine, the energy consumption was almost same as that of the machine with virgin magnets. Thus it can be concluded that for the permanent magnet based claw-pole machine, the utilization of recycled magnets is more sustainable for the environment as it can lead to consequential limits on the mining of rare earth materials. The price fluctuations and supply-demand problems can also be reduced with the increase in utilization of recycled magnets, albeit policy and norms are effectuated.The prototype of the machine with virgin magnets have been developed and tested for performance. It has been observed that the experimental results match fairly well with the design analysis results, hence validating the design process and methodology.
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Submitted on : Tuesday, September 24, 2019 - 12:26:16 PM
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  • HAL Id : tel-02130959, version 2

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Pranshu Upadhayay. Electrical machine designs based on 3D flux paths with reuse & recycle magnet concepts for automotive applications. Electric power. Université Grenoble Alpes, 2018. English. ⟨NNT : 2018GREAT103⟩. ⟨tel-02130959v2⟩

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