The majority of battery electric vehicle manufacturers rely on highly efficient permanent magnet synchronous machines (PMSM or PSM) in radial flux design for their eDrives. As with all iron-core electric motors, frequency-dependent losses occur in the stator circuit, which increase disproportionately as the speed increases. This reduces the operating range and reduces the efficiency of the machine. The Vaionic team has fundamentally rethought the principle of the permanent magnet synchronous machine (PSM) and developed a stator that completely eliminates the use of stator iron. With the “ironless PSM” (iPSM), the frequency-dependent losses are reduced to a minimum, resulting in significant efficiency and design advantages. The fully modular design of the motor also allows the motor output to be quickly adapted by adding identical rotor and stator modules, while the simple diameter scaling enables a wide range of applications from automotive to wind power. Two examples of battery-electric traction applications are used to demonstrate the advantages of the iPSM in terms of power adjustment, efficiency and driving performance compared to the eDrive concepts of popular reference vehicles and to show the potential cost savings. Thanks to its performance and efficiency, the Vaionic iPSM enables new design strategies in a wide range of applications. In addition, it offers two further key advantages over conventional PSMs: firstly, it opens up considerable savings potential thanks to a significant reduction of the active material mass and significantly less complex manufacturing processes. Secondly, the valuable active components can be fully recycled, thus opening up new approaches for future circular economy concepts for electric drives.

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iPSM: The Potential Of The Ironless Stator For Electric Drives

  • Lennart Leopold,
  • Tino Paruschkewitz,
  • Helene L. Blum

摘要

The majority of battery electric vehicle manufacturers rely on highly efficient permanent magnet synchronous machines (PMSM or PSM) in radial flux design for their eDrives. As with all iron-core electric motors, frequency-dependent losses occur in the stator circuit, which increase disproportionately as the speed increases. This reduces the operating range and reduces the efficiency of the machine. The Vaionic team has fundamentally rethought the principle of the permanent magnet synchronous machine (PSM) and developed a stator that completely eliminates the use of stator iron. With the “ironless PSM” (iPSM), the frequency-dependent losses are reduced to a minimum, resulting in significant efficiency and design advantages. The fully modular design of the motor also allows the motor output to be quickly adapted by adding identical rotor and stator modules, while the simple diameter scaling enables a wide range of applications from automotive to wind power. Two examples of battery-electric traction applications are used to demonstrate the advantages of the iPSM in terms of power adjustment, efficiency and driving performance compared to the eDrive concepts of popular reference vehicles and to show the potential cost savings. Thanks to its performance and efficiency, the Vaionic iPSM enables new design strategies in a wide range of applications. In addition, it offers two further key advantages over conventional PSMs: firstly, it opens up considerable savings potential thanks to a significant reduction of the active material mass and significantly less complex manufacturing processes. Secondly, the valuable active components can be fully recycled, thus opening up new approaches for future circular economy concepts for electric drives.