Improved Rotor Cooling for PM Machines--Unique Mobility, Inc., 425 Corporate Circle, Golden, CO 80401-5635; 303-278-2002
Mr. Jon F. Lutz, Principal Investigator
Mr. Donald A. French, Business Official
DOE Grant No. DE-FG03-99ER82914
Amount: $749,072

Electric drive motors for hybrid electric vehicles require improvements in cost reduction and power density. In particular, the brushless permanent magnet (PM) motor, which has thus far demonstrated superior performance, requires improvements in both cost-effectiveness and packaging. This project will improve the rotor cooling of a brushless PM motor by utilizing an innovative self-cooling concept. This cooling method not only will reduce the cost of the permanent magnets, but also will reduce the size of the motor for a given power rating. Phase I produced several innovative cooling ideas that were fitted to a current motor. The motor was run through thermal tests to optimize the cooling effectiveness, cost effectiveness, and modularity. Phase II will design a modular set of three motors that will have will have higher power density and be more cost effective to produce than those using the current technology. Cost reductions will be achieved by lowering the magnet content in the motors (cooler rotors), sharing common parts between designs, and using advanced manufacturing techniques.

Commercial Application and Other Benefits as described by the awardee: The hardware developed as part of this program should have application to parallel hybrid, series hybrid, battery electric, and fuel cell electric passenger cars. Other applications include parallel hybrid sport utility vehicles and trucks, series hybrid wheel motors for large vehicles, and starter/motor/generators for high voltage and 42 volt vehicles.