The world is continually changing towards more energy efficient alternatives and less pollution. For the traction market, electric powertrains have become the go-to method, superior to both steam and diesel-electric hybrid systems. For subways and trams the natural development now is towards smaller motors with high power output, the goal is to use as much space as possible for the passengers and keep the performance of a larger motor setup. One problem with increasing the power density of the motors is that the accumulated heat from losses also increases per volume. All motors have different efficiency and different limits on temperatures in different parts. For this project a closed, self-ventilated traction motor with axis height 250mm (CSV250) was evaluated. The motor has an input power just above 140kW and the identified limiting factor is the temperature of the bearings, specifically the front bearing located at the fan side of the motor.   An already existing and partly validated ANSYS MotorCAD model was used for full system overview and as a guide to build a COMSOL Multiphysics model of the motor rotor. The COMSOL model could be effectively changed to represent different configurations of the solution. The COMSOL solver is based on the finite element method, FEM, whereas the MotorCAD model is built as a thermal network with lumped parameter method, LPM.    The proposed solution to the high temperature is implementation of heat-pipes in strategic positions. This project only contains evaluation of heat-pipes positioned in the center of the shaft deployed in three different configurations: a short heat-pipe transferring heat from the bearing to the fan, a long heat-pipe transferring heat from the active rotor parts to the fan and a long heat-pipe similar to previous case but with the heat-pipe insulted at the bearing section. The simulations yield performance specifications for the solution design that will give the expected result, complemented with theory this can then give the full appliable solution to the specified problem.   For the short heat-pipe case a decrease in temperature form 116.5 to 96.5°C was achieved in the front bearing by increasing the heat-transfer from the bearing towards the fan with 84.4W. This is well under the preferred temperature of maximum 110°C. In the long heat-pipe case a total of 360W was dispersed through the fan and this lowered the highest temperature point in the rotor from 172.2 to 160.8°C but with the negative effect of increasing the temperature of the front bearing. In the third case the insulation of the long heat-pipe in the bearing section managed to lower this increased temperature from 130.4 to 122.4°C while 360W were still transferred through to the fan. This is under the absolute maximum at 130°C but over 110°C. The results point towards the possibility to increase power density and keeping temperatures manageable using heat-pipes but further work and experiments is needed to prov the concept.

The application of Model Reference Adaptive Control (MRAC) for train dynamic braking is investigated in order to control dynamic braking forces while remaining within the allowable adhesion and coupler forces.  This control method can accurately determine the train braking distance.  One of the critical factors in Positive Train Control (PTC) is accurately estimating train braking distance under different operating conditions.  Accurate estimation of the braking distance will allow trains to be spaced closer together, with reasonable confidence that they will stop without causing a collision.  This study develops a dynamic model of a train consist based on a multibody formulation of railcars, trucks (bogies), and suspensions.   The study includes the derivation of the mathematical model and the results of a numerical study in Matlab.  A three-railcar model is used for performing a parametric study to evaluate how various elements will affect the train stopping distance from an initial speed.  Parameters that can be varied in the model include initial train speed, railcar weight, wheel-rail interface condition, and dynamic braking force.  Other parameters included in the model are aerodynamic drag forces and air brake forces. An MRAC system is developed to control the amount of current through traction motors under various wheel/rail adhesion conditions while braking.  Minimizing the braking distance of a train requires the dynamic braking forces to be maximized within the available wheel/rail adhesion.  Excessively large dynamic braking can cause wheel lockup that can damage the wheels and rail.  Excessive braking forces can also cause large buff loads at the couplers.  For DC traction motors, an MRAC system is used to control the current supplied to the traction motors.  This motor current is directly proportional to the dynamic braking force.  In addition, the MRAC system is also used to control the train speed by controlling the synchronous speed of the AC traction motors.  The goal of both control systems for DC and AC traction motors is to apply maximum available dynamic braking while avoiding wheel lockup and high coupler forces.  The results of the study indicate that the MRAC system significantly improves braking distance while maintaining better wheel/rail adhesion and coupler dynamics during braking.  Furthermore, according to this study, the braking distance can be accurately estimated when MRAC is used.  The robustness of the MRAC system with respect to different parameters is investigated, and the results show an acceptable robust response behavior. / Ph. D.

Insulating sheets, impregnants and encapsulation materials commonly used for winding insulation offer low thermal conductivities. This leads to an increased heating of the winding of electrical machines and to the existence of hotspots. The electromagnetical utilization of the machine has to be reduced with respect to the allowed maximum winding temperature. In this paper, the development and experimental investigation of novel polysiloxane composites with ceramic fillers are presented. The materials are tested by means of impregnated and encapsulated samples of a round-wire winding as well as the main insulation of electrical steel sheets and laminated cores. Numerical models are implemented for determining the equivalent thermal conductivity of the winding compound comprising the enameled wire and the impregnant. Based on the example of a permanent-magnet synchronous machine with outer-rotor in modular construction, the potential for increasing the electromagnetical utilization is shown.

The electrification of automobiles has emerged as the sustainable powertrain solutionto meet United Nations sustainable development goals of sustainable cities andcommunities, affordable and clean energy, and climate action. The success of theelectrification depends on the efficiency of traction motors. Hence, the automobileindustry is dedicated to improving the performance of electrical traction machinesfor high performance and sustainability. The thesis aims to build various electricalmachine’s concept designs and quantify their behaviour on sustainability andperformance. The thesis objective is to design Permanent Magnet Synchronous Motor (PMSM),Synchronous Reluctance Motor (SynRM), and Permanent Magnet SynchronousReluctance Motor (PM­SynRM). The thesis work comprises of accurate performanceestimation and optimisation of these electrical machines through a finite element based method. The in­house scripts are developed to estimate the performance, electrical losses, and efficiency of these electrical machines through flexible open-source tools. The performance of PMSM with rare-­earth magnet Neodymium Ferrite Boron(NdFeB) and without rare­-earth magnet (ferrite) is done to evaluate the role of bothmagnets in producing torque density. The SynRM is evaluated and optimized usinggenetic algorithms in the thesis. The electrical machines are designed without the useof rare-­earth magnets to eliminate the degradation of the environment and reduce thecost and weight of the motor. / The electrification of automobiles has emerged as the sustainable powertrain solutionto meet United Nations sustainable development goals of sustainable cities andcommunities, affordable and clean energy, and climate action. The success of theelectrification depends on the efficiency of traction motors. Hence, the automobileindustry is dedicated to improving the performance of electrical traction machinesfor high performance and sustainability. The thesis aims to build various electricalmachine’s concept designs and quantify their behaviour on sustainability andperformance. The thesis objective is to design Permanent Magnet Synchronous Motor (PMSM),Synchronous Reluctance Motor (SynRM), and Permanent Magnet SynchronousReluctance Motor (PM­SynRM). The thesis work comprises of accurate performanceestimation and optimisation of these electrical machines through a finite element based method. The in­house scripts are developed to estimate the performance, electrical losses, and efficiency of these electrical machines through flexible open-source tools. The performance of PMSM with rare-­earth magnet Neodymium Ferrite Boron(NdFeB) and without rare­-earth magnet (ferrite) is done to evaluate the role of bothmagnets in producing torque density. The SynRM is evaluated and optimized usinggenetic algorithms in the thesis. The electrical machines are designed without the useof rare-­earth magnets to eliminate the degradation of the environment and reduce thecost and weight of the motor.   Sammanfattning på svenska / Abstract in Swedish Elektrifieringen av bilar har framstått som en hållbar drivlinelösning för att mötaFörenade Nationernas hållbara utvecklingsmål för hållbara städer och samhällen, medprisvärda och rena energi och klimatåtgärder. Framgången med elektrifieringen berorpå effektivitet på motorer för framdrivningen. Därför är bilindustrin dedikerad tillatt förbättra prestanda för elmotorer för hållbarhet och hög prestanda. Avhandlingensyftar till att bygga olika konceptdesign för elmotorer för framdrivning och kvantifieraderas beteende på hållbarhet och prestanda. Uppsatsmålet är att utforma Permanent Magnet Synchronous Motor (PMSM),Synchronous Reluktance Motor (SynRM) och permanent magnetassisterad SynRM(PM­SynRM). Examensarbetet består av noggrann prestationsuppskattning ochoptimering av dessa elektriska maskiner genom finit element metod (FEM). Deskripten för att hantera FEM för elektormagnetisk design är in­house utveckladeför att uppskatta flexibelt prestanda, elektriska förluster och effektiviteten hos dessaelektriska maskiner genom att använda öppen källkod. Prestanda för PMSM med en sällsynta jordartsmagnet (NdFeB) och PMSM utansällsynta jordartsmagnet (ferrit) räknades fram för att utvärdera båda magneternasroll för att producera vridmomentdensitet. SynRM och PM­SynRM maskinernautvärderas och optimeras med hjälp av genetiska algoritmer i avhandlingen.De studerade elektriska maskinerna är designad utan användning av sällsyntajordartsmagneter för att eliminera miljöförstöring och minska motorns kostnad ochvikt.

This report summarizes the thesis study carried out at Scania CV AB. The study presents design optimization of an interior permanent magnetic (IPM) synchronous machine. A parameterised Matlab tool was developed in order to serve the optimization routine. In this routine, multiple IPM geometries are dynamically generated and analyzed using the finite element method (FEM) software Flux 2D. Using the Secant method, algorithms to estimate the optimum current and control angle throughout the speed range both below and above base speed, were developed and integrated with the Matlab tool to perform design optimization towards the drive cycle. The genetic algorithm available in the Matlab’s global optimization toolbox has been utilised for the multi-objective optimization setup. / Denna rapport sammanfattar examensarbetet som genomförts på Scania CV AB. Studien presenterar en designoptimering av en permanentmagnetiserad (IPM) synkronmaskin. Ett parametriserat Matlab-verktyg för optimeringar utvecklades for att dynamiskt generera geometrier för att utföra simuleringar med hjälp av FEM-programvara (Flux2D®). Med hjälp av Sekant-metoden utvecklades och integrerades algoritmer för att estimera den optimala strömmen och styrvinkeln i hela varvtalssområdet, både under basvarvtal och i fältförsvagningsområdet. Med hjälp av Matlab-verktyget kunde sedan designoptimering för en given k¨orcykel utföras. Den genetiska algoritmen som finns tillgänglig i Matlabs globala optimeringsverktygslåda har använts för det multi-objektiva optimeringsprogrammet.

<p dir="ltr">In our daily lives, we rely on a multitude of discrete products to meet our needs. Traditional product design approaches have primarily focused on economic and technical aspects, often overlooking the pressing environmental and social challenges facing society. Recognizing the limitations of our ecological systems to cope with the waste generated by our current industrial processes, there is a growing need to anticipate the potential consequences of product design across technical, economic, environmental, and social dimensions to pave the way for a sustainable future. One promising strategy within this context is the integration of sustainability principles into optimization-based design models that consider a product's entire life cycle. While there have been previous efforts to optimize product life cycles, a comprehensive exploration of optimization-based design methods with a focus on multiple objectives for discrete products is essential. This dissertation explores the integration of sustainability principles with optimization-based design by taking the electric traction motor used in electric vehicles as a case study. This complex and environmentally significant technology is ideal for investigating the tradeoffs and benefits of incorporating sustainability objectives into the design process.</p><p dir="ltr">The key tasks undertaken in this study are as follows:</p><ul><li>Development of a parametric design and optimization framework for a surface-mounted permanent magnet synchronous motor. In this task, a special emphasis is placed on reducing reliance on materials with a high supply risk, such as rare earth elements.</li><li>Creation of a parametric life cycle assessment model that combines life cycle assessment and optimization-based design to minimize a single-score environmental impact. This model offers insights into the environmental performance of product design and underscores the importance of minimizing environmental impact throughout a product's life cycle.</li><li>Integration of a life cycle costing model, incorporating techno-economic assessment and total cost of ownership perspectives, into the parametric life cycle assessment and optimization-based design models. This model is used to minimize levelized production and driving costs, shedding light on the trade-offs within this family of cost metrics and the optimization of manufacturing systems for motor production.</li><li>Proposal of a circular economy model/algorithm to assess the advantages of integrating the circular economy paradigm during the early design phase. All the mentioned objective functions are considered to study the impacts of applying the circular economy paradigm.</li></ul><p dir="ltr">The contributions of this research can be summarized as follows:</p><ul><li>Utilized a diverse array of analytical methodologies to parameterize the design process of a motor, incorporating the integration of Life Cycle Assessment (LCA) and Techno-Economic Analysis (TEA) models, as well as the incorporation of disassembly planning for informed decision-making in the early stages of design.</li><li>Proposed a generalized objective function denoted as the Supply Risk-equivalent (SR-eq.), aimed at mitigating the risks associated with the dependency on critical materials in product manufacturing.</li><li>Introduced a novel approach for visualizing non-dominated solutions within a multi-objective framework, with experimentation conducted on up to six distinct objectives.</li><li>Substantiated the significance of decarbonizing the electric grid while maintaining competitive cost structures, the importance of advancing non-destructive evaluation (NDE) procedures for assessing the condition of end-of-life (EoL) subassemblies, and optimizing the collection rate of EoL motors.</li></ul><p dir="ltr">Demonstrated that the optimization of technical metrics as surrogate indicators for economic and environmental performance does not necessarily yield designs that are concurrently optimal in economic and environmental terms.</p>