WM983-15 Electrical machine design and manufacturing
Introductory description
This module provides in-depth knowledge of electric machine technologies, design and manufacturing for hybrid and electric vehicles. The modelling and design of electric machines are covered in depth through lectures, workshops and practical. Mechanical and thermal design fundamentals are introduced. This module also covers integration, control, condition monitoring and life cycle of electric machines in the context of electric vehicles. Future technologies and the upcoming EV applications are also included.
Module aims
The students will gain a high-standard of technical knowledge about electric machines, allowing them to act as component experts, understand stakeholder/interface requirements and limitations and liaise with researchers to translate state-of-art into business opportunities.
Outline syllabus
This is an indicative module outline only to give an indication of the sort of topics that may be covered. Actual sessions held may differ.
Topologies, operation and characteristics of induction machine, reluctance machine, synchronous permanent-magnet and wound-field machines
Mechanical design of electric machines including noise and vibration
Thermal modelling and thermal design of electric machines
Electric machine manufacturing
EV traction motor tear-down study
Electric machine modelling and design using commercial software
Electric machine testing and characterization
Electric machine control strategy
DC motor, actuator and power steering motors
E-machine condition monitoring, fault analysis and life cycles
Future Technology direction and state-of-art of electric machines research
Learning outcomes
By the end of the module, students should be able to:
- Differentiate electric machine technologies considering operation, characteristics, mechanical and cooling concepts.
- Evaluate and simulate electromagnetic, mechanical and thermal designs of electric machines.
- Interpret the practicality of electric machine designs considering manufacturing process and cost.
- Systematically design electric machines for hybrid/electric vehicles , with considerations of powertrain architecture, integration, diagnostic and condition monitoring.
- Critique design trade-offs and technological advances of electric machines for electric and hybrid vehicles.
Indicative reading list
- A. Hughes, B. Drury: "Electric motors and drives: fundamentals, types and applications", 4th edition, Newnes, Oxford, 2013., ISBN: 9780080983325 and 9780080993683 (e-book)
2- T. Wang, in Mechanical Design of Electric Motors, Boca Raton, CRC Press, 2014.
3- N. Mohan: "Electric machines and drives : a first course ", Wiley, 2012., ISBN: 9781118074817
4- N. Mohan: "Advanced electric drives: analysis, control, and modelling using MATLAB/Simulink", New Jersey, John Wiley & Sons, 2014, ISBN: 9781118911174 (e-book)
Subject specific skills
Ability to apply theoretical knowledge to solve problems in existing and emerging machine technologies.
Ability to simulate and design electric machines using commercial software such as MotorCAD.
Ability to evaluate limitations of design tools and choose appropriate methods and tools for designing electric machines.
Ability to propose mechanical design concepts (rotor/stator/bearing design/ NVH), cooling concepts relating to the development of electrical machines.
Ability to identify diagnostic methods, monitoring and test equipment required for integration of electrical machines for EV and hybrid vehicles.
Ability to interpret the practicality, and manufacturability of electrical machine designs considering manufacturing process and cost.
Transferable skills
Practical competence to deliver innovative products and services.
Ability to Interpret and analyse test results.
Ability to work with manufacturing specialists to ensure design can translate to manufacturing processes and system.
A critical awareness of current problems and/or new insights most of which is at, or informed by, the forefront of the specialisation.
Ability both to apply appropriate engineering analysis methods for solving complex problems in engineering and to assess their limitations.
Ability to use fundamental knowledge to investigate new and emerging technologies.
Knowledge and comprehensive understanding of design processes and methodologies and the ability to apply and adapt them in unfamiliar situations.
Study time
| Type | Required |
|---|---|
| Lectures | 11 sessions of 1 hour 30 minutes (11%) |
| Seminars | 2 sessions of 1 hour 30 minutes (2%) |
| Tutorials | 1 session of 2 hours (1%) |
| Practical classes | 1 session of 8 hours (5%) |
| Supervised practical classes | 2 sessions of 4 hours 30 minutes (6%) |
| Online learning (scheduled sessions) | 4 sessions of 1 hour (3%) |
| Online learning (independent) | 4 sessions of 6 hours (16%) |
| Other activity | 1 hour 30 minutes (1%) |
| Assessment | 82 hours (55%) |
| Total | 150 hours |
Private study description
No private study requirements defined for this module.
Other activity description
Visit to the e-machine Make-Like-Production facility 1 hour 30 minutes
Costs
No further costs have been identified for this module.
You do not need to pass all assessment components to pass the module.
Assessment group A
| Weighting | Study time | Eligible for self-certification | |
|---|---|---|---|
| Post Module Assessment report | 70% | 70 hours | Yes (extension) |
|
Post Module Assignment (PMA) based on the intended learning outcomes of the module. The first part of the PMA is a summary of the E-machine testing practical and discussion of test observations. The second part of the PMA is design proposal of an EV traction motor and critiques of integration, diagnostics, condition monitoring and manufacturing considerations. |
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| Mechanical design worksheet | 10% | 2 hours | Yes (extension) |
|
After the online pre-learning, the students will submit worksheets to answer multiple choice questions and provide solutions to mechanical design problems including rotor dynamics, torsional response study, modal analysis and bearing calculation. |
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| Video presentaion on E-machine design | 20% | 10 hours | No |
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The students will submit a video to present thermal modelling results and evaluate cooling concept of their machine design from the E-machine design workshop. |
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Feedback on assessment
The mechanical design worksheets will be marked and returned to students 4 weeks before the PMA deadline so that the feedback will help students with their PMA.
The video presentation will be marked with an assessment report which will be returned to students 3 weeks before the PMA deadline.
The PMA will be marked based on comprehension, effort and presentation.
An overall mark of the module is sent to students with the PMA assessment report.
There is currently no information about the courses for which this module is core or optional.