ReFreeDrive - Deliverable 3.1: Preliminary Copper Rotor Induction Motor Design

The present report covers a preliminary design analysis for Copper-Rotor Induction Motors for traction systems in Electric Drive Technologies (EDT). This is one of the technical solutions investigated by ReFreeDrive project. Deliverable D3.1 (Preliminary Copper Rotor-Induction Motor Design) aims at designing proof of concept designs for Internal Rotor-Induction Motor and Outer Rotor-Induction Motor solutions that are scalable and ready to be used at various power and supply levels according to the EV type. This report is divided in four main sections Section 1 (Introduction), it is presented the logic of the design process and how various parameters are selected to act in concert to meet the specified requirements, including rotor and stator dimensions, number of slots / poles / bars, optimal winding pattern and materials to be used. Section 2 (CR-IM Electromagnetic Design) describes the first pass design with various motor configurations, when the number of poles is changed. The design analysis is based on a hybrid 2D Finite-Element Analysis (FEA) method and analytical magnetic equivalent circuit. Section 3 (CR-IM Mechanical Analysis) describes the dimensions and speed limits from the mechanical stress and modal analysis point of view. The analysis makes use of 2D/3D FEA models and analytical expressions. Section 4 (CR-IM Thermal Analysis) describes the first pass design with various motor configurations, when the cooling system comprises a stator water jacket, a rotor cooling jacket and/or an oil spray cooling system. The design analysis is based on a lumped analytical thermal network method, validated with 2D FEA method