First steps toward high-speed motors for fuel cell components
Prototype of a high-speed motor for a gas cell compressor. Credit score: Fraunhofer undertaking HABICHT

The transport sector is reworking in direction of climate-friendly powertrains with considerably decreased CO2 emissions. The electrification of powertrains stays a serious problem not just for vehicles, buses, trains, and ships but in addition for plane. These functions can’t be realized sooner or later with batteries due to the power necessities. The gas cell is an especially promising power provider for these functions, which provides electrical power from saved hydrogen and ambient air.

Fraunhofer Institutes LBF, IFAM, IISB, and SCAI joined their forces to develop superior and extremely environment friendly parts for gas cells. The undertaking HABICHT goals to design and develop a high-speed motor for a gas cell compressor to allow innovation within the utility car and aviation area. The electrical machine ought to at the very least obtain an influence density of 30 kW/kg by utilizing progressive supplies for direct cooling of the stator and maximizing the rotor’s high-speed functionality (< 150,000 rpm). The rotor design will use a brand new manufacturing course of to connect and pot the magnets to be appropriate for top circumferential speeds.

Present standing: First design primarily based on analytical and numerical calculations

Primarily based on the fast definition of the specs, a viable idea for electromagnetic design has been developed with analytical and numerical help. The work was carried out in interplay with structural-mechanical investigations on the velocity stability of the everlasting magnets in addition to with thermal investigations on the mandatory cooling capability, which is assured by the mix of cooling jacket, hole rotor shaft, and thermal connection of the winding head with a dielectric fluid. Inside HABICHT, Fraunhofer SCAI is answerable for multi-physics modeling and the setup of a wise design atmosphere for electrical engines.

Future work: Optimization and benchmarking

The long run work is concentrated on optimization of the present working design and execution in a way appropriate for manufacturing. For this goal, decreased take a look at carriers are for use for stator winding, electrical insulation, banding, sheet metallic chopping, bonding, and magnet shaping, amongst different issues, previous to the development of the whole system. The forming of cooling channels shaped throughout potting is to be solved by way of course of and materials expertise primarily based on the literature research already carried out. The difference of the HABICHT machine to an current turbo compressor is to be realized with appropriate however on the identical time typical shaft and bearing expertise, whereby the frequency-dependent inherent dynamics of the mechanical transferring components are to be decided upfront.

The HABICHT undertaking is supported by exterior advisors from aviation, e-mobility, suppliers, and academia. Prof. Dr.-Ing. Jürgen Ulm from Heilbronn College of Utilized Sciences sees wonderful potential within the undertaking outcomes for future necessities and functions from the trade:

“The undertaking entails the event of recent applied sciences within the discipline of high-speed electrical drives within the software for gas cells and units new requirements, which in flip level the way in which for future developments. The high-speed rotor, which poses a problem by way of its mechanical, thermal and electromagnetic design, is of nice significance right here. This undertaking is a superb instance of pioneering high-tech product improvement along with simultaneous supplies and measurement improvement and simulation expertise.”


Immediately cooled electrical motor produced from polymer supplies


Supplied by
Fraunhofer Institute for Algorithms and Scientific Computing (SCAI)

Quotation:
First steps towards high-speed motors for gas cell parts (2022, July 22)
retrieved 24 July 2022
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