Development of Aluminum Winding Three Phase Induction Motor for Lightweight EV Applications

Global warming is the absorption of CO2, CFCs etc. in the atmosphere and with that, the average temperature of the earth rises. CO2 is emitted by other vehicles, and it adds 4.6 metric tons of CO2 to the atmosphere per year which is a huge contribution to global warming. The electric vehicle is the

Project Title

Development of Aluminum Winding Three Phase Induction Motor for Lightweight EV Applications

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

Global warming is the absorption of CO2, CFCs etc. in the atmosphere and with that, the average temperature of the earth rises. CO2 is emitted by other vehicles, and it adds 4.6 metric tons of CO2 to the atmosphere per year which is a huge contribution to global warming. The electric vehicle is the best application for meeting the basic requirements for global warming and their emissions of CO2 etc. are considerably lower than other vehicles. EV applications contribute to protecting the environment. The machines which are already installed and in use have copper winding on their stator like machines in mills, pumps, Autos etc. copper winding has many disadvantages the major one is, as induction motors have high magnetizing inrush current which results in low voltage. The motor used in EV has high starting torque. As the copper winding is housed in the stator of the induction motor and heats up due to an excessive current flowing in the winding at high torque region. Copper is less flexible, and this makes winding of motor a difficult task. Thus, alternate windings materials are required to be investigated for efficient and lightweight induction machines. Aluminum offers better overloading capacity than copper and a high current can be drawn in aluminum winding than copper which results in high torque in induction motor hence the need for high torque in induction motor is fulfilled with aluminum winding. Aluminum is cheaper than copper and lighter in weight. Aluminum is more flexible which makes winding easier and the most interesting advantage of aluminum in environmental aspect is that it is recyclable with steel easier than copper.

Project Objectives

Following are the main objectives of the proposed Project.

• To design an induction motor with aluminum winding on its stator for lightweight EV applications using JMAG software.
• To investigate the performance analysis of induction motor with aluminum winding and compare with induction motor available in the market having copper winding.
• To fabricate the induction motor with aluminum winding and experimentally validate it.

By accomplishing the above-mentioned objectives, EV applications will have a better induction motor. The high torque requirement for the induction motor will be easily fulfilled. The induction motor with aluminum design will have better loading capacity than the induction motor with copper winding. The weight of the induction machines will be reduced. The performance of the induction motor will be improved.

Project Implementation Method

The implementation of this project is in three phases:

1. The first phase of the implementation of this project is induction motor designing and it will be done in the Geometry editor. Aluminum winding will be assigned on the stator. A squirrel-cage rotor bar will be made.
2. The second phase is the investigation of performance analysis will be taken out i.e., torque performance, torque vs speed, torque density etc.
3. The third phase of project implementation will be the CAD model to solid work. An elimination sheet will be prepared and then fabrication followed by the winding of the induction motor will be done. At last experimental comparison of induction motors having aluminum and copper winding will be done.

Benefits of the Project

The benefits of this project are:

• Aluminum can be easily recycled with steel than copper.
• By using an induction motor with aluminum winding weight of the EV applications will be reduced. And the focus in EV applications is low weight which is easily achieved
• As compared to permanent magnets DC motor this induction motor will be smaller in size.
• During acceleration, torque will be easily controlled in an induction motor with aluminum winding due to a reduction in voltage at high speed.
• Brushes and rotor windings will be no longer needed in induction motor rotor design.
• Frequent maintenance will not be required.
• It will have very accurate speed regulation and by changing the frequency the speed will vary.
• This induction motor will work as a generator in electrical braking operation, and it will charge the battery when the electrical brakes are applied, and it will work as a motor normally

Technical Details of Final Deliverable

This induction motor will have a stator outer diameter of 83 mm, rotor outer diameter of 49 mm, and stack length of 100 mm. Distributed aluminum winding will be implemented on the stator. The overloading capacity of an induction motor with aluminum winding is better than an induction motor with copper wire so more current can be drawn which will offer high torque to the motor.

Final Deliverable of the Project

Hardware System

Core Industry

Transportation

Other Industries

Core Technology

Shared Economy

Other Technologies

Sustainable Development Goals

Affordable and Clean Energy

Required Resources

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