Electric Motor Research Articles

Improving Electrical Conductivity of Commercially Pure Aluminium: The Synergistic Effect of AlB8 Master Alloy and Heat Treatment

This study aims to enhance the electrical conductivity of commercially pure aluminium by minimizing impurities and grain boundaries in its microstructure, ultimately improving the efficiency of electric motors constructed from rotors with squirrel cages made from this material. For this purpose, an aluminium–boron (AlB8) master alloy was added to aluminium with a purity of 99.7%, followed by the application of a grain-coarsening heat treatment to the rotors. To obtain commercially pure aluminium with boron additions of 0.05% and 0.1% by weight, specific amounts of the AlB8 master alloy were added into aluminium with a purity of 99.7%. Using these materials, squirrel cage components of rotors were produced via the high-pressure die-casting method. Subsequently, a grain-coarsening heat treatment of the rotors was performed at temperatures of 450 °C, 500 °C, and 550 °C, with holding times of 2, 6, and 10 h. The Box–Behnken design, which is based on statistical experimental design and response surface methodology, was employed to investigate the effects of adding boron and varying the heat treatment temperature and holding time on the electrical conductivity of commercially pure aluminium. The results showed that the synergistic effect of adding boron at 0.05 wt.% and applying the grain-coarsening heat treatment at a temperature of 550 °C for a holding time of 10 h significantly enhanced the electrical conductivity of commercially pure aluminium, increasing it from 60.62% IACS to 63.1% IACS. Correspondingly, the efficiency of the electric motor increased from 90.35% to 91.53%. These findings suggest that this hybrid method not only enhances the electrical conductivity of commercially pure aluminium but also has strong potential to improve its other properties, such as thermal conductivity. This will lead to products composed of components manufactured from the materials exhibiting better performance characteristics, such as increased efficiency and extended service life. Consequently, this innovative method will contribute economically and environmentally by facilitating the manufacture of high-performance products.

Design and Analysis of a Liftfan for eVTOL Aircraft

Abstract Ducted liftfans provide greater hovering efficiency to eVTOL aircraft than open propellers of equal disk area. Liftfans are designed with minimised length to limit propulsor weight added and drag incurred during forward flight. Three challenges posed by the liftfan propulsor configuration are addressed in this paper. First, instead of a single-row propeller, liftfans require the design of a fully integrated stage. To maximise the hovering figure of merit, a non-dimensional measure of power consumption, the preliminary and 3D design variables of the rotor and splittered-diffuser stator rows are optimised simultaneously using 3D CFD. The resulting prototype liftfan design is validated through experimental testing. Second, despite efficiency improvements during hover, liftfans sustain additional inlet distortion and drag during forward flight due to their surrounding nacelles. A low-order model is developed to investigate the maximum range for different fan designs with varying diffuser area ratios and forward flight tilt angles. Design selections are validated using full annulus 3D CFD and experimental wind tunnel tests. Third, as the electric motors of liftfans are mounted within the hub, fan-driven active cooling is necessary to prevent overheating. The stagnation pressure losses incurred by cooling airflow must be minimised without impeding heat transfer. Low-order models are developed to predict motor heat transfer and loss and to guide the design of a mixed-flow cooling fan. Experimental testing and 3D CFD simulations confirm that the addition of forward sweep and adoption of a high blade count can reduce cooling fan losses.

Multi-dimensional failure risk load prediction of electric motor based on physical model and data-driven approach

Dynamic prediction of failure risk loads is a critical prerequisite for system damage monitoring and service life evaluation. As the failure mechanism of electric vehicle drive motors under multi-source load excitations is complex, and the risk load poses challenges in rapid acquisition, a physics-based and data-driven method for multi-dimensional failure risk load prediction of motors is proposed. Based on actual operational data collected from users, we analyze the failure risk loads of various components of a motor. A physical simulation model of the motor is established to extract multi-dimensional failure risk load time history, and the effectiveness of the simulation model is verified using data from bench tests. Moreover, using the physical model simulation data as a foundation, a two-stage data-driven model is constructed. In the first stage, the genetic algorithm optimized back propagation neural network (GA-BPNN) model is implemented for multi-dimensional loss prediction of the motor, and serves as the primary input for the second stage model, which integrates prediction accuracy and training efficiency. In the second stage, by comprehensively considering the spatial and temporal correlation features with the input layer reconstructed using correlation matrix weights, an improved convolutional neural network with bidirectional long short-term memory (CNN-BiLSTM) model is employed to predict multi-scale loads. Compared with traditional models, the proposed method exhibits significantly improved prediction accuracy, with R2 greater than 0.95. Furthermore, the damage error between the predicted load and the expected load is within 10%, which provides technical support for reliability evaluation and life prediction of electric motor.

Case Study on Optimum Utilization of Hybrid Energy for Race Car Performance

—Hybrid energy systems have transformed the auto- motive and motorsport industries, offering an effective balance between performance and sustainability. This paper explores the optimum utilization of hybrid energy in race cars, focusing on advanced energy management strategies and their impact on performance metrics like lap times, fuel efficiency, and emissions. Utilizing insights from Quasi-Pontryagin’s Minimum Principle (Q-PMP) [1], energy allocation frameworks [2], and real-time op- timization techniques under battery constraints [3], this study ex- amines the synergy between internal combustion engines (ICEs) and electric motors in high-performance scenarios. Additionally, the role of hybrid energy storage systems, such as batteries and ultra-capacitors, in enhancing power delivery is analyzed [4]. Results from case studies and simulations demonstrate significant improvements in race performance, including faster lap times and reduced energy consumption, highlighting the practical viability of hybrid systems in motorsports [5][6]. These findings emphasize the importance of adaptive energy strategies in advancing the competitive edge and sustainability of hybrid race cars. Index Terms—Hybrid Energy, Energy Optimization, Fuel Ef- ficiency in Racing, Energy Distribution in Hybrid Vehicles

Changes in the Overdrive Signal of the Electric Motor of Trimble's EZ-Pilot Parallel Driving System

Changes in the Overdrive Signal of the Electric Motor of Trimble's EZ-Pilot Parallel Driving System

Performance Comparison of Permanent Magnet Synchronous Motor with Different Magnet Configuration Used in Electric Vehicle

Due to the depletion of fossil fuels, increasing environmental pollution, and global warming, the use of electric vehicles is becoming more widespread. Electric vehicles offer numerous advantages, including high efficiency, quiet and vibration-free operation, and being environmentally friendly. Electric motors provide high power density and a wide torque-speed range. Therefore, many engineering studies, analyses, and comparisons are conducted for electric motors used in electric vehicles. In this study, modeling and analyses of interior permanent magnet synchronous motors with different magnet configurations were carried out, taking as a reference an interior permanent magnet synchronous motor used in a mass-produced and well-selling electric vehicle. At the end of the study, structures with different magnet configurations were compared in terms of performance characteristics such as torque, torque ripple, and efficiency.

"Modernization of the power unit of tractors of traction class 1.4 by using a reversible electric machine"

The technical development of tractor designs is characterized by an increase in consumer power, the use of electric drive units. Therefore, the load on the electrical system of a modern tractor is constantly increasing and exposes existing systems to excessive load. Today, with the relatively low efficiency of traditional generators, it is impossible to meet the growing needs of tractors and their systems. An integrated starter generator can serve as a solution to the problem of increasing power simultaneously with increasing efficiency (up to 85...90%). With sufficient power in the engine mode (up to 8 kW), the starter generator allows you to improve the starting and energy characteristics of the tractor's internal combustion engines. The proposed design of electric machines is placed between the cylinder block of the internal combustion engine and the tractor clutch. The adopted layout allows you to transfer significant power in both directions, improves the starting qualities of tractor diesel engines, and also implements the functions of damping torsional vibrations of the crankshaft, which significantly reduces engine noise and vibration. Based on the results of the study, the choice of a starter-generator device (SGU) based on a reversible electric machine is justified in relation to diesel engines of tractors of traction class 1.4 and a scheme for its placement in the clutch crankcase without changing its basic design is developed. The advantage of the proposed design is the use of electric machines to start the engine, which in this case turns on the electric motor mode and switches to generator mode during operation, providing power to the on-board network with electric energy. In addition, combining the starter and generator in a single unit simplifies the design, reduces manufacturing and assembly costs, which is an advantage in terms of production costs, replacing the starter and generator and on some tractors the starting piston engine.

A Common DC Bus Circulating Current Suppression Method for Motor Emulators of New Energy Vehicles

In contrast to the conventional topology, wherein the Device Under Test (DUT) controller and the electric motor emulator (EME) are powered by the DC (Direct Current) voltage source independently, the common DC bus topology necessitates a single power supply. This reduces the cost and complexity of the motor emulator system, making it more favorable for large-scale industrial applications. However, this topology introduces significant circulating current issues in the system. A common DC bus circulating current suppression method is proposed in this paper for the motor emulator. First, the mechanism of zero-sequence circulating current generation in the common DC bus topology is analyzed and the expression for the system’s zero-sequence voltage difference is derived. Then, a control method based on a Hybrid PWM (Pulse Width Modulation) strategy that unifies SPWM (SIN Pulse Width Modulation) and SVPWM (Space Vector Pulse Width Modulation) is proposed, which has been shown to be effective in suppressing the zero-sequence circulating current in a motor emulator system with a common DC bus topology. The proposed control method has been experimentally validated using a motor emulator system.

Statistical analysis of technical specifications of self-propelled reversible plate compactors with different types of engines

Introduction. Reversible plate compactors are soil compaction machines with a flat operating device, having two or more unbalanced shafts and ability to reverse the direction and movement speed. Reversible plate compactors may be driven by gasoline, diesel or electric engines. The efficient operation of reversible plate compactors is only possible with the rational selection of technical specifications, such as oscillation frequency and driving force of the vibration exciter, base plate width, engine power, etc. To establish correlations between the technical specifications of reversible plate compactors, to assess the influence of the engine type on the main parameters and to identify the areas for improving this type of equipment, the statistical analyses was conducted.Materials and methods. 484 models of reversible plate compactors were scrutinized. The information on the models were obtained from official websites of plate compactors manufacturers and their dealers. Data processing was performed in Microsoft Excel.Results. The variation ranges of the main parameters were determined and regression equations for correlations between the oscillation frequency of the vibration exciter, the driving force, the width of the base plate, the relative exciting force and the mass of reversible plate compactors were derived. Correlation coefficients were obtained for each regression dependence. The influence of the engine type on the variation range of reversible plate compactors’ main parameters was analyzed.Conclusion. The type of engine has almost no effect on the parameters of reversible plate compactors in the corresponding mass ranges. Relatively low correlation coefficients let us suggest that manufacturers do not have reliable methods for justification of the technical specifications of reversible plate compactors. The obtained correlations may be recommended for verification of some technical specifications of reversible plate compactors. In recent decades, the values of oscillation frequency and relative exciting force have increased significantly, which affects the nature of interaction between a reversible plate compactor and soil.

Optimizing electric traction motor design: Analyzing the benefits of a circular economy

Optimizing electric traction motor design: Analyzing the benefits of a circular economy

Electric vehicle motor control principle and optimization analysis

Electric vehicle motor control principle and optimization analysis

Investigation of traction and dynamic properties of wheeled vehicles with electric and hybrid power plants on the test stands with running drums

Introduction. Modern wheeled vehicles with electric and hybrid power plants are becoming more and more widespread. It is obvious that with the increasing number of wheeled vehicles with electric and hybrid power plants, there is a need to conduct a full-fledged and qualitative study of the working processes of wheeled vehicles both at the stages of production and fine-tuning at manufacturing enterprises, and in operating conditions at the service stations and other organizations. The research of the technical condition of a wheeled vehicle with electric and hybrid power plants with a classic layout of the power unit and transmission (front or rear axle drive) is quite possible to be conducted on existing stands. But when testing wheeled vehicles with electric and hybrid power plants with all-wheel drive or with an electric motor generator for each drive wheel, a problem arises due to the lack of methods and means to measure traction force on each wheel individually.Materials and methods. This section provides an analysis of the possibilities of conducting a study of the technical condition of wheeled vehicles with electric and hybrid power plants on modern power and inertia stands that apply the principle of reversibility of motion.Results. Methods have been developed to study the traction and dynamic properties of wheeled vehicles with electric and hybrid power plants, to implement it was proposed to use developed research stand complex, which includes a hybrid stand with control and measuring systems that allow to determine forces and power on the driving wheels of vehicles, as well as time and kinematic parameters of its functioning process. During the experimental studies, the results of Kia Soul EV and Toyota Prius NHW20 operation processes were obtained, their power and kinematic parameters were analyzed.Conclusion. As a result of the study, it has been proved that in order to ensure highly informative and stable test modes of wheeled vehicle’s operation in the process of studying their traction and dynamic properties, it is necessary to use hybrid stands.

The Effect of Throttle Signal Output Voltage Variation and Load on Current Consumption

Many electric motorcycle users complain about the difficulty in controlling acceleration with precision, especially if they have never ridden a motorized vehicle before. This control difficulty is a result of the characteristics of BLDC motors, which have high torque instantly. While this characteristic is generally considered an advantage, in this discussion it is a disadvantage that can reduce rider comfort when operating an electric motorcycle. When the rider twists the throttle for the first time, the electric motor immediately spins at maximum power. The issues mentioned serve as the background for the this research entitled "The Effect of Throttle Signal Output Voltage Variations and Load on Current Consumption and BLDC Motor Speed in Electric Motorcycles."The method used in this research is an experimental method by varying the load at 60 kg, 70 kg, and 80 kg and three levels of throttle output voltage changes.The results of this study show that changes in load and throttle output voltage affect current consumption and BLDC motor speed. The highest current consumption is achieved when the vehicle is loaded with 80 kg and using mode 1 at 3.5309 A. The lowest current consumption is achieved when the vehicle is loaded with 60 kg and using mode 3 at 1.4403 A. The highest rotational speed is obtained in mode 1 with a 60 kg load at 219.341 rpm. The lowest rotational speed is obtained in mode 3 with an 80 kg load at 141.37 rpm.

Autogenetic Carbon Oxyanions Enable Interfacial OH− Deconfinement for Reinforced Biomass Electrooxidation over Wide Potential Window

AbstractThe preferential adsorption toward OH− on the anode most likely blocks the accessibility of organic molecules and triggers competitive oxygen evolution reaction (OER), typically precipitating a narrow potential window. Here, an OH− deconfinement strategy enabled by CO32− self‐transformed from C2O42− on metallic nickel oxalate (NiC2O4) for efficient synthesis of bioplastic monomer 2,5‐furanedicarboxylic acid (FDCA) with faradaic efficiency of >95% via electrocatalytic 5‐hydroxymethylfurfural (HMF) oxidation reaction (e‐HMFOR) at a wider potential window of 1.38–1.56 VRHE, outperforming state‐of‐the‐art Ni‐based electrocatalysts is presented. In situ, tests corroborate that the construction of NiOOH with surface‐adsorbed CO32− (NiOOH‐CO32−) from NiC2O4 can be facilitated by self‐liberating CO32−. The CO32− ions serving as an electric field engine can effectively weaken OH− coverage through electrostatic repulsion and enhance HMF adsorption at the NiOOH‐CO32− surface, thereby heightening e‐HMFOR while inhibiting OER. Computational results further indicate that the CO32− on NiOOH hoists the energy barrier of oxygen intermediate conversion (O* → OOH*) to suppress OER but promotes the e‐HMFOR kinetics. The precise modulation of OH− adsorption behavior on the electrocatalyst offers a powerful kit for boosting the oxidative upgrading process while circumventing the competing reaction OER.

Building Green Trust: The Influence of Green Perceived Value and Green Product on Purchase Intentions

Transitioning to a low-carbon energy system is essential to achieving Indonesia's net-zero emission target by 2060. Electric motor vehicles are a strategic solution to reducing greenhouse gas emissions, yet their adoption faces challenges in stimulating public interest. This study investigates the impact of green perceived value and green product on green purchase intention, with green trust as a mediating variable, focusing on electric motor vehicle consumers in Palembang City. Using a quantitative approach, primary data was collected through structured questionnaires from 107 respondents selected via purposive sampling. Data analysis employed Structural Equation Modelling (SEM) with Smart-PLS version 3.2.9. Results show that green perceived value and green product positively influence green trust, which in turn enhances green purchase intention. Green trust also mediates the relationship between the independent variables and purchase intention. Practical implications include improving consumer education, ensuring product quality, and implementing sustainability-focused marketing strategies.

Improving Energy Efficiency and Autonomy Through the Development of a Hybrid Battery–Supercapacitor System in Electromobility

This study focuses on the development of a hybrid battery-supercapacitor system aimed at enhancing energy efficiency and autonomy in electromobility. The energy supply system of an electric vehicle must ensure high performance and autonomy, even after numerous battery life cycles. Previous approaches to hybrid systems that combine batteries and supercapacitors focus on reducing power losses by relying on controllers that evaluate the state of charge (SOC) of the energy sources to determine which one should provide power at any given time. These systems typically use a controller that monitors only the SOC of the battery and supercapacitor. In contrast, our study introduces an innovative controller that not only evaluates the SOC of both energy sources but also incorporates the current of the electric motor, taking into account its operational state. This approach allows for a more accurate representation of energy consumption and motor performance, providing significant advantages in terms of energy efficiency, extended battery life, and improved performance under high motor loads, which are characteristic of modern electric vehicle requirements. The current paper encompasses both experimental and simulated results, indicating that the hybrid approach provides significant advantages, such as improved energy autonomy, extended battery life as the primary energy source, and enhanced performance at high motor speeds that stress the battery.

Fuzzy System for fault detection in electric motors for aluminum casting

This study presents the development of a fuzzy logic-based system for predictive fault detection in electric motors used in aluminum casting processes. The addressed problem concerns the need to optimize predictive maintenance in a competitive industrial environment, minimizing unexpected downtimes and costs associated with corrective maintenance. The main objective was to create a fuzzy algorithm for real-time monitoring of critical variables such as temperature, pressure, and electric current. The methodology involved simulations of operational scenarios validated through experimental tests in a controlled environment. Results indicate that the proposed fuzzy system accurately identifies anomalies and issues preventive alerts, contributing to extending motor lifespan and improving operational efficiency. It is concluded that the developed solution can be integrated into industrial supervisory systems, enhancing reliability and productivity.

ANALYSING THE ENERGY SATURATION OF CYLINDRICAL GRINDING MACHINES

Constantly rising energy prices and the current challenges of securing a sustainable power supply are driving research into how to reduce the energy consumption of metalworking equipment. To efficiently manage and reduce energy consumption by grinding machines, a system of measures to minimize energy consumption for cutting, for moving elements of the technological system, and for auxiliary equipment has been proposed. The nature of the change in power consumption depending on the period of engine operation is shown on the graph. When determining the total power of the technological system of a grinding machine, it is proposed to take into account the power of electric motors for driving the rotation of the grinding wheel, workpiece, hydraulic drive pump, cooling fan, spindle bearing lubrication pump, guide lubrication pump, coolant supply pump, magnetic separator drive, coolant cleaning filter-transporter drive.

Solving the problem of technological object identification

Abstract. Problem. The identification task is formulated as follows: based on the results of observations of the input and output variables of a system, a model, i.e. a formalized representation of this system, should be built that is optimal in some sense. This shows the connection between the identification task and the above general scheme of establishing regularities based on the results of observations. The identification task is based on modern control theory. To solve it, modern computers are used. The latter, with their high speed and virtually unlimited memory capacity, create the prerequisites for receiving, transmitting and processing large arrays of observations that are necessary for building adequate models of real objects. Goal. Studying the possibilities of solving the problem of identifying technological objects using MATLAB+Simulink. Job tasks: to consider the tasks of identifying technological objects of management; to choose an identification method; identify the electric motor model. Methodology. The research problems should be solved by methods of analysis and synthesis of automatic control systems by the method of least squares. Results. In the work, experimental data on the dependence of the engine idling speed on the excitation current were obtained and solved the identification problem using the MATLAB+SIMULINK package. Originality. Based on the analysis of existing solutions, it was found that the works did not consider the calculation of absolute and relative errors of the results of identifying the object and the model developed using the least squares method. Thus, there is a need to develop a system for identifying a model of a technological object made by the least squares method. To solve the identification problem, an electric motor is chosen as the object of study. Practical value. The paper examines the methods used to identify complex objects. The comparative analysis showed that the most acceptable method is the least squares method, due to simple mathematical calculations in comparison with the other methods. To illustrate the application of this method, two tasks were solved: identification of the model of an electric motor; identification of the model of an alarm system. The studies have shown that model identification can be performed using the MATLAB+Simulink package. The research results obtained on the model differ from the experimental data by no more than 4 %

Features of thermistor protection of three-phase asynchronous motors with short-circuit rotor with voltage up to 0.66 kV

The article analyzes the features of thermistor protection against overheating of three-phase asynchronous motors with a squirrel-cage rotor with a voltage of up to 0.66 kV. A comparative analysis of different types and types of thermistors is carried out, in particular their design features, operating principles and characteristics, which provides effective protection of motor windings from critical overheating. The advantages and disadvantages of different types of thermistor protection of asynchronous motors are determined, which allows you to reasonably choose the optimal protection option depending on the operating conditions and requirements for the reliability of electric motors in accordance with modern standards.