Materialentwicklung für Elektromotoren

Introduction and Motivation

Electromobility is essential for sustainable mobility strategies. At present, passenger vehicles mainly consist of an accumulator, a power electronic actuator and a drive engine. Usually these functional units are engineered separately, linked by connection cables. Therefore, heat dissipation and electromagnetic compatibility has to be considered independently. Quickly changing potentials occur due to the clocked mode of operation. Since motor and power electronics behave as parasitic capacitances, the potentials cause unwanted asymmetrical interference currents. In this project, the power electronics of the motor will be integrated into the stator (cf. Figure 1). The power density should, therefore, increase substantially. Furthermore, due to suitable electrical activation and the elimination of the connection cables, the asymmetrical interference currents should be reduced. The higher power density leads to a rising heat dissipation, which makes it necessary to reengineer the cooling system of the motor. Hereby new requirements regarding mechanical, thermal and electromagnetic properties arise, which make a functionalisation of the used polymers necessary. Through the appropriate choice of base polymer, fillers, filler content and particle geometry, electrically insulating, thermally conductive polymers should be produced which make a decisive contribution to the cooling of the engine.

Figure 1: Electronic motor coil

Objectives

• Production of thermally conductive, electrically insulating polymers
• Production of three-dimensional complex parts for the cooling system
• Characterization of the produced material composites in order to evaluate the process parameters

Methods

• Mechanical Characterisation
• Thermal Characterisation
• Electronic Characterisation

Founding

State Baden-Wuerttemberg, Innovationscampus „Mobilität der Zukunft“

Project Partners

University Stuttgart Institute for Power Electronics and Electrical Drives

University Stuttgart Institute of Electrical Energy Conversion