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Promising Steps In direction of Excessive-speed Motors for Gas Cell Elements


The transport sector is reworking in direction of climate-friendly powertrains with considerably diminished CO2 emissions. The electrification of powertrains stays a serious problem not just for vehicles, buses, trains, and ships but in addition for plane. These functions can’t be realized sooner or later with batteries due to the power necessities. The gasoline cell is a particularly promising power provider for these functions, which provides electrical power from saved hydrogen and ambient air.

Fraunhofer Institutes LBF, IFAM, IISB, and SCAI joined their forces to develop superior and extremely environment friendly parts for gasoline cells. The undertaking HABICHT goals to design and develop a high-speed motor for a gasoline cell compressor to allow innovation within the utility automobile and aviation area. The electrical machine ought to not less than obtain an influence density of 30 kW/kg by utilizing revolutionary supplies for direct cooling of the stator and maximizing the rotor’s high-speed functionality (< 150,000 rpm). The rotor design will use a brand new manufacturing course of to attach and pot the magnets to be appropriate for top circumferential speeds.

Present standing: First design based mostly on analytical and numerical calculations

Primarily based on the speedy definition of the specs, a viable idea for electromagnetic design has been developed with analytical and numerical assist. The work was carried out in interplay with structural-mechanical investigations on the velocity stability of the everlasting magnets in addition to with thermal investigations on the mandatory cooling capability, which is assured by the mix of cooling jacket, hole rotor shaft, and thermal connection of the winding head with a dielectric fluid. Inside HABICHT, Fraunhofer SCAI is chargeable for multi-physics modeling and the setup of a sensible design atmosphere for electrical engines.

Future work: Optimization and benchmarking

The long run work is concentrated on optimization of the present working design and execution in a way appropriate for manufacturing. For this function, diminished check carriers are for use for stator winding, electrical insulation, banding, sheet metallic slicing, bonding, and magnet shaping, amongst different issues, previous to the development of the complete system. The forming of cooling channels fashioned throughout potting is to be solved by way of course of and materials expertise based mostly on the literature research already carried out. The variation of the HABICHT machine to an present turbo compressor is to be realized with appropriate however on the similar time typical shaft and bearing expertise, whereby the frequency-dependent inherent dynamics of the mechanical transferring components are to be decided upfront.

The HABICHT undertaking is supported by exterior advisors from aviation, e-mobility, suppliers, and academia. Prof. Dr.-Ing. Jürgen Ulm from Heilbronn College of Utilized Sciences sees glorious potential within the undertaking outcomes for future necessities and functions from the trade:

“The undertaking entails the event of latest applied sciences within the area of high-speed electrical drives within the utility for gasoline cells and units new requirements, which in flip level the best way for future developments. The high-speed rotor, which poses a problem by way of its mechanical, thermal, and electromagnetic design, is of nice significance right here. This undertaking is a wonderful instance of pioneering high-tech product growth along side simultaneous supplies and measurement growth and simulation expertise.”

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