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Dr. Mircea Popescu,
Motor Design Ltd. (UK), IEEE Member

Dr Mircea Popescu is the Head of Engineering for Motor Design, Ltd., a software and consultancy company headquartered in the UK and with offices in the US, and has more than thirty years of engineering experience. He received MEng and PhD degrees in electrical engineering from University ‚ÄúPolitehnica‚ÄĚ Bucharest, Romania and DSc (Tech) degree from Aalto University, Helsinki, Finland. Earlier in his career, he was with the Research and Design Institute for Electrical Engineering, (ICPE) Bucharest, Romania, Helsinki University of Technology (now Aalto University) in Finland and with the SPEED Lab at University of Glasgow, UK. Dr. Popescu published more than one hundred papers and his publications have received three IEEE best paper awards. His consultancy contributions for industry are incorporated in many state-of-the-art products. Current major projects include electrical machines and drives for hybrid/electrical vehicles, and formula-e racing cars involving OEM as GKN or 1st Tier manufacturer as Ricardo, Equipmake. An IEEE Fellow, Dr. Popescu is the Past Chair of the IEEE Industry Application Society (IAS) Electrical Machines Committee and a Prominent Lecturer for Region 8, IEEE IAS.


Solutions and Challenges - Electric Machines Design for Automotive Applications

Abstract:

There is currently significant activity in the development of electric machines for automotive applications where a wide variety of possible solutions can be seen. An evaluation of a range of the most common design options in terms of performance, cost and manufacturability is given in this presentation:
  • Machine configurations: A comparison between the permanent magnet motor solutions - with magnetless solutions ‚Äď induction motors and synchronous reluctance motors is briefly given.
  • Winding technologies: The two main winding categories, concentrated and distributed, are compared and within these various technologies evaluated: (a) for concentrated windings, open slot tooth wound, segmented and edge wound; (b) for distributed, bar wound and multi-stranded.
  • Material variations: Copper and aluminium have interesting trade-offs in terms of cost, conductivity, density and AC loss which is considered in the choice of winding material. Different magnet materials are investigated with ferrite magnets proving an interesting option for low cost designs. Various electrical steel grades are also compared.
  • Cooling approaches: The common cooling mechanisms found in automotive designs are discussed and their effectiveness with various machine and winding types evaluated. These cooling approaches include stator water jackets, shaft cooling, oil spray cooling and air cooling.