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Electrical Machine Design and Manufacturing (for new MSc Sustainable Automotive Electrification)

Introduction

This module provides in-depth knowledge of electric machine technologies, design and manufacturing for hybrid and electric vehicles. The modelling and design of electric machines are covered in depth through lectures, workshops and practical. Mechanical and thermal design fundamentals are introduced. This module also covers integration, control, condition monitoring and life cycle of electric machines in the context of electric vehicles. Future technologies and the upcoming EV applications are also included.

The students will gain a high-standard of technical knowledge about electric machines, allowing them to act as component experts, understand stakeholder/interface requirements and limitations and liaise with researchers to translate state-of-art into business opportunities.

Objectives

Upon successful completion participants will be able to:

  • Differentiate electric machine technologies considering operation, characteristics, mechanical and cooling concepts.
  • Evaluate and simulate electromagnetic, mechanical and thermal designs of electric machines.
  • Interpret the practicality of electric machine designs considering manufacturing process and cost.
  • Systematically design electric machines for hybrid/electric vehicles , with considerations of powertrain architecture, integration, diagnostic and condition monitoring.
  • Critique design trade-offs and technological advances of electric machines for electric and hybrid vehicles.

Syllabus

  • Topologies, operation and characteristics of induction machine, reluctance machine, synchronous permanent-magnet and wound-field machines
  • Mechanical design of electric machines including noise and vibration
  • Thermal modelling and thermal design of electric machines
  • Electric machine manufacturing
  • EV traction motor tear-down study
  • Electric machine modelling and design using commercial software
  • Electric machine testing and characterization
  • Electric machine control strategy
  • DC motor, actuator and power steering motors
  • E-machine condition monitoring, fault analysis and life cycles
  • Future Technology direction and state-of-art of electric machines research

Assessment

  • Post Module Assessment report (70% weighting)
  • Mechanical design worksheet (10% weighting)
  • Video presentaion on E-machine design (20% weighting)

Duration

1 week, including 16.5 hours of lectures, 3 hours of seminars, 2 hours of tutorials, 8 hours of practical classess and 9 hours of supervised practical classes.