fedeRo - Lightweight, efficient traction drives through springy rotor components


One of the key technologies of future, efficient and low-emission vehicle concepts, regardless of the type of drive, is lightweight design and holistic function integration. The rotor of permanent magnet synchronous machines makes a decisive contribution to the weight and efficiency of the drive. The "fedeRo" research project therefore aims to contribute to the development of lightweight and efficient vehicle drives by using springy rotor components.

  Traction drive and rotor Copyright: © IEM Traction drive with consideration of the influence of mechanical stress on the magnetic properties for rotor optimization.

The current design of rotors of high-speed drives does not meet the lightweight requirements and is time-consuming and cost-intensive in production due to the necessary processes. Furthermore, the mechanical stresses introduced lead to a reduction in the efficiency of the drive.

The overall objective of the fedeRo project is to develop electric motors for future vehicles with maximum efficiency, low weight and optimized use of installation space. The lever for this lies in the holistic development of the drive through simulation and integration of innovative components. To this end, the rotor design of a modern PMSM traction drive is being investigated and optimized by integrating springy components which, in addition to lightweight potential, also offer potential for increasing the efficiency and reducing the costs of future drive systems.

Based on existing concepts for the design of a lightweight rotor, an electromagnetic evaluation of the reference system is carried out by the IEM, considering the influences of mechanical stresses, as well as a redesign and optimization of the rotor laminations. At the same time, the electromagnetic force excitations of the electric machine with a spring-loaded rotor shaft are calculated. The aim is to gain knowledge of how the NVH behaviour of electrical machines is influenced by the use of the spring components. Design guidelines for future designs of electrical machines with a sprung rotor shaft are to be derived from this. In parallel, parasitic influences of the resilient components in the area of the magnetic pockets or at the rotor end faces will be researched and evaluated. Possibilities are being investigated as to whether and how these effects can be incorporated into future electromagnetic simulations in order to extend existing simulation methods.