87
Integration
Technology to Reduce the Cost of Vehicle Propulsion--Kinetic
Art & Technology Corp., 9540 Highway 150, P.O. Box 250, Greenville, IN
47124-0250; 812-923-7474
Mr.
Roy L. Kessinger, Jr., Principal Investigator, roy@katech.com
Mr.
Robert J. Westerkamp, Business Official, robert@katech.com
DOE
Grant No. DE-FG02-02ER83475
Amount:
$100,000
Continued
advances are needed for automotive traction motors and controls to meet cost and
performance goals, specifically $10/kW and 5 kW/kg for a 30kW combined
controller and motor system. The key to meeting these very aggressive goals will
require the coordination of multiple innovations in the design and manufacture
of complete motor and controller systems. However,
conventional methods for increasing motor power density lead to difficult
cooling requirements and increased cost, and conventional cost-reduction methods
lead to reduced motor performance. Therefore,
this project will develop a systems approach for highly integrated motor and
electronic modules to allow for the optimization of electromagnetic, thermal,
structural, and control design parameters. This approach will provide the
required motor performance while minimizing cost through high-volume production
processes. In Phase I, existing
computer models for vehicles, motors and electronics will be expanded to predict
system performance as various sub-systems become integrated. Advanced
thermal management techniques will be incorporated within the integrated motor
and controller modules. Advanced
motor coils, magnetic circuits, cooling techniques, control algorithms, and
electronics will be analyzed for future integration.
Commercial Applications and Other Benefits as described by the awardee: The resulting permanent magnet motor should achieve a constant power ratio of 4:1 at a rated efficiency exceeding 98%. The integrated motor and controller modules should reduce the size, weight, and cost of hybrid electric vehicles, and be useful in many other industrial and military applications.