Riassunto analitico
Our century can be considered the transition epoque of the automotive field.
The green footprint of society and the consequent decarbonisation aim, are leading the
car manufacturer to electrification.
The results of these changes are already visible in the car's exterior design, more and more
rounded to reduce drag resistance.
Analysing deeply the transformation we can understand that the real difference is in the
heart of a vehicle: the powertrain.
In future, cars will not be moved anymore by an engine but by a motor. The tank won’t
be filled anymore with carbon fuel but with electric energy. The accelerator pedal will
not open a valve or inject gasoline but provide current.
The results will be more efficient vehicles, less pollutants, and more performance even
for standard road cars.
To reach this future faster an automotive engineer must work hard to develop better and
better components that help the transition.
The e-motors are the key element of the transition, being able to exploit the braking to
recharge the batteries and having higher efficiency than an internal combustion engine.
A more efficient motor means a higher range and a smaller one means lower weight and
less material needed.
This thesis aims to reach both targets on a motor design which can be able to power a
high-performance car, for both road and track applications, making it suitable for the
market requirements.
A combination of MATLAB and MAGNET simulations is used to develop the motor and
optimise it up to the best trade-off possible.
The simulations will show the performance, the operative zones and the limits of the
motor developed.
The analysis will be integrated with the material choice and the structural simulation, to
complete the development of the motor and start the prototyping phase.
Then the motor will be compared with the competitor and show the benefits of the
developed technologies.
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The development started with a patented technology called Halbach solution, which is
already present in the company know-how.
The thesis will end up with two solutions:
1. High voltage application – IPM - 750V
2. Low voltage application – SPM - 280V
The first solution is optimised for the rear axle of a racing car, with the requirements set
through a historical Italian automotive brand.
The power delivered is more than 600kW and the torque is over 1000Nm, which is 30%
higher than the competitors.
The second solution is more adaptable and usable in the front axle of a sportscar or the
drivetrain of a motorcycle. Even for this application, the requirements were based on real
customer needs.
This motor has one of the highest power density in the market and can deliver more than
150kW, 40% more than the competitors.
The results have shown that, with the available inverters’ technology and manufacturing
techniques, not every design choice can properly work. Anyway, the large motor type
range allows us to successfully accomplish our tasks.
The last chapter will analyse the most advanced technologies that in the future will change
the design approach but now were discarded due to manufacturing limitations.
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