Motor design for maximum material exploitation and magnetization procedure with in-line quality check for mass production

To reduce the amount of Rare-earth Elements in high efficient permanent magnet electric motors, the magnetic stray flux has to be reduced. Additonally, a temperature reduction inside the motor reduces the necessary amount of the so called Heavy Rare-earth Elements, which account for the bulk part of the magnet material costs. In this thesis a permanent magnet motor in wet rotor configuration for an automotive application is designed. It was shown that by simple thermal improvements of the electric insulation system the maximum temperature of the stator can be reduced. Extensive measurements on different combinations of insulation material of the stator and the development of a new thermal model for orthocyclic wound stators were performed. Due to the use of fiber cans eddy current losses could be eliminated and the stray flux minimized. In a second stage a magnetizing fixture was build up, which is able to magnetize the buried magnets inside the rotor. The rotor and the magnetizing fixture was developed, so that the magnets can be optimal magnetized. To check the quality of the magnets the magnetizing coil was developed in a way, such that the hysteresis curve of every single magnet during magnetization can be measured. Different magnets were tested and ways to calculate parasitics are given.