Including manufacturing effects in design tools of high-volume e-machines for automotive implications

Electric machine design is a complex task still with many unknowns. Simulations of losses in machines do not currently agree with experimental data from prototype machines, building factors are used to compensate. The discrepancy is a result of machine manufacturing processes causing residual stress in the material. Current literature aims to quantify the degradation of electrical steels magnetic properties, most studies are investigating a specific process and material with limited description of the material. Material microstructure and composition are rarely discussed in articles published by electric machine experts, while the studies presented on material samples rarely cover what happens in the electric machine once fully assembled. This project proposes to bridge the gap between these approaches, providing the understanding as to how magnetic properties degrade during manufacturing. Beginning from analysis of material samples both raw and processed, a theoretical understanding of the microstructure changes responsible for magnetic degradation will be found and applied to production components and fully assembled motors available through WMG's Advanced Propulsion Systems Group and the HVEMS project. The applications will include multiple machine components and manufacturing techniques to provide a tested solution to the building factor in machine design.
This project fits within the research area "Electrical motors and drives / electromagnetics" defined as a prioritized area by EPSRC ("grow") and contributes to the themes "Manufacture of the Future", "Engineering" and "Energy".