Design of an Axial Flux Machine with an Integrated Hydraulic Pump for Off-Highway Vehicle Electrification

F. N.U. Nishanth, Garrett Bohach, Md Minal Nahin, James Van De Ven, Eric L. Severson

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Axial flux machines offer an inherent torque density advantage over conventional radial flux machines and are increasingly being considered for transportation electrification applications. Electrification of off-highway vehicles is notoriously challenging due to extreme power density requirements. This paper investigates the use of axial flux machines for off-highway vehicle electrification. To maximize the power density, a hydraulic pump is integrated with the axial flux machine, resulting in a single modular, electric/hydraulic machine. This paper first compares three popular axial flux machine variants using an FEA-based design optimization approach. The single rotor, single stator variant is identified to be the most promising for integration with the hydraulic pump. Next, a multi-physics framework of the complete integrated hydraulic pump and axial flux machine is developed to search the design space. The results indicate promising potential for this concept to realize efficiency over 85% and power density over 5kW/kg for the complete machine (electric machine, hydraulic pump, and thermal management system), while utilizing conventional materials (thin gauge silicon steel, N45 magnets, and magnet wire).

Original languageEnglish (US)
Title of host publicationECCE 2020 - IEEE Energy Conversion Congress and Exposition
PublisherInstitute of Electrical and Electronics Engineers Inc.
Pages1772-1779
Number of pages8
ISBN (Electronic)9781728158266
DOIs
StatePublished - Oct 11 2020
Event12th Annual IEEE Energy Conversion Congress and Exposition, ECCE 2020 - Virtual, Detroit, United States
Duration: Oct 11 2020Oct 15 2020

Publication series

NameECCE 2020 - IEEE Energy Conversion Congress and Exposition

Conference

Conference12th Annual IEEE Energy Conversion Congress and Exposition, ECCE 2020
CountryUnited States
CityVirtual, Detroit
Period10/11/2010/15/20

Bibliographical note

Funding Information:
This material is based upon work supported by the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy (EERE) under the Award Number DE-EE0008384. Electromagnetic simulation tools used in this investigation were generously provided by Mentor Graphics, a Siemens business.

Keywords

  • Axial flux motor
  • Electric-hydraulic conversion
  • Machine design
  • Multi-objective optimization
  • Multi-physics optimization
  • Off-highway vehicle electrification

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