Design, Optimization, and Control of a 100 kW Electric Traction Motor Meeting or Exceeding DOE 2025 Targets

The overall objective of the electric motor portion of the Electric Drives Technology consortium is to research, develop, and test electric motors for use in electric vehicle applications capable of a peak power greater than 100 kW, power density greater than or equal to 50 kW/l, and a cost less than 3.3 $/kW. To meet the electric traction motor power density and cost targets a number of approaches were pursued simultaneously throughout the course of this project which address all of the major volumetric power density variables. The specific research thrusts at the Illinois Institute of Technology (IIT) are the following: multiphysics design for increased power density through maximum utilization of active materials, synthesis of electric machine windings and PM flux barriers with controlled space harmonics, high slot fill windings for increased current loadings or efficiency, aggressive cooling strategies, and design studies and prototype construction of candidate electric machines.. Authors: Brown, Ian Patrick [Illinois Institute of Technology, Chicago, IL (United States)] (ORCID:0000000337603916). DOE Contract: EE0008713. Subjects: 32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; 33 ADVANCED PROPULSION SYSTEMS; cast windings; die compressed windings; electric machines; electric motors; electric vehicles; hybrid electric vehicles; power density; slot fill; thermal system identification; topology optimization; windings