As interdisciplinary, technical focal points, novel functional solutions are investigated by means of an aerostatic mounting of active parts as well as the realization of components with hybrid fiber composite materials. As a result, the innovation potential of novel engine concepts in terms of design, lightweight construction, performance parameters and efficiency will be described in the form of a technical design framework and a methodology for design, validation and optimization of the entire drive system will be developed.
The aim of the joint research project is to develop the fundamentals for the principle of a new type of electric motor that is characterized by a particularly high torque or power density. Against the background of the current state of the art, two further basic components are to be introduced into the development and their potential for improving electric drives is to be worked out. These are the use of fiber composites for the production of mechanically highly stressed construction parts and an aerostatically stabilized rotating active part. Both components in the composite form the basis for the proposed further research.
Within the scope of the project, the fundamentals of the simulation and modelling of the air flow in the narrow air gap as well as the occurring heat flows under load are to be worked out. The weight of the motor is to be minimized by using a rotor made of fiber-reinforced plastic. The challenge here is to develop a layer structure of textile semi-finished products that ensures a quasi-isotropic stiffness of the rotor and at the same time a weight advantage compared to metallic materials.
The rotor of the motor can preferably be designed as a functionally integrated roller (radial magnetic flux guide) or disc (axial magnetic flux guide). To increase the efficiency of the motor, the air gap between the stator and the rotor must be minimized and the heat generated during induction must be dissipated as quickly and continuously as possible.
In the course of the last few years, there has been a trend and an opportunity to transfer the knowledge gained on smaller electrical machines to larger sizes. This is advantageous because samples and demonstrators can be produced for smaller motors at comparatively low cost and in a manageable amount of time, and a large number of measurements can be carried out in a shorter time. Coupled with the fact that low-power motors are usually manufactured in much higher quantities, the pressure to innovate in terms of material, energy and cost efficiency is significantly higher for smaller sizes than for motors in the much higher power range. The aim is to examine the transferability of these findings to larger sizes and, where it seems sensible and advantageous, to transfer them. Mobile applications in particular form a suitable basis for this. The power range envisaged for the proposed sub-project is between 70kW and 200kW.
The application target is in the area of electric auxiliary drives for commercial vehicles that are expected in the future. The existing solutions are among others hydraulics based. In particular, the field of rotating applications (hydraulic motor) is of interest. These drives are in the above-mentioned power range and offer an ideal basis for testing the considerations made above using the example of the turbine drive of a suction excavator.