Design of a Permanent-Magnet Synchronous Machine with Non-Overlapping Concentrated Windings for the Shell Eco Marathon Urban Prototype

Abstract: This thesis deals with the design of a permanent-magnet synchronous inner rotor motor for an in-wheel application for the Shell Eco Marathon Urban concept vehicle. First of all, concepts related to permanent magnet motors are studied. Likewise, different features of permanent magnet motors are qualitatively evaluated in order to choose the most suitable. A radial flux motor is selected based on its solid, economic and acceptable characteristics. Next, a detailed study of concentrated windings is carried out. Through this investigation, undesirable configurations of pole and slot numbers due to unbalanced magnetic pull or a low fundamental winding factor will be avoided and how to determine the different winding layouts for different pole and slots configuration will be explained. As well, based on this study, and the magnetic and electric behavior of the machine, an analytical model is created. This model calculates the optimum size and characteristics of a machine in order to obtain lightweight design. After that, the design of a program based on a finite element method that simulates different situations for the machine is accomplished, dealing with the difficulties that entails the concentrated windings. Finally, through the use of this program, the machine calculated by the analytical model is analyzed, specially regarding that it does not surpass some important margin in order not to be demagnetized or not to surpass the maximum phase voltage supplied by the batteries.