Riassunto analitico
This work presents the project developed during a six-month internship in the Advanced Powertrain Department at Toyota Motor Europe.
The goal of this project is to find new solutions to improve the efficiency, the cooling and to reduce the cost of the Interior Permanent Magnet (IPM) motors employed in the Toyota Hybrid System (THS).
Initial research has been performed to understand the state of the art of the new technologies in the field of electric motors, giving particular attention to electromagnetism, cooling, and production efficiency topics. To deepen these themes, a large number of patents, papers and international documents have been analyzed, becoming a source of inspiration for innovative ideas to optimize the THS motors.
Following a multiphysics engineering approach, the e-motor optimization feasibility studies have been carried out with the support of fluid dynamics, thermal and magnetic simulations.
More than twenty variations of Motor Generator 2 (MG2) have been analysed, obtaining for most of them an improvement in electromagnetic or mechanical performances. The cooling system of Motor Generator 1 (MG1) has been improved by implementing a cooling device, which finally leads to the reduction of vehicle fuel consumption.
Each step is further described in the following, offering an overview of the work done at one of the most important companies of the automotive sector and sustainable mobility.
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