Development of High Power Density Motor – Part 1: Design and Analysis

Naoki Itasaka･Michiharu Kawano･Hisayuki Kabashima･Kentaro Nomura･Kazunori Hirabayashi (MCF Electric Drive)

This study reports design and analysis results for the development of high power density motor.
The design concept aimed at achieving world-standard power density is presented, along with performance predictions based on electromagnetic and thermal analyses.
Furthermore, the effectiveness of simulations is validated by incorporating experimental evaluation results.

Development of High Power Density Motor – Part 2: Experimental Verification

Hisayuki Kabashima･Naoki Itasaka･Michiharu Kawano･Kentaro Nomura･Kazunori Hirabayashi (MCF Electric Drive)

This paper reports the performance evaluation of high power density motor prototype based on design and analysis results. The testing methods and measurement environment are described, and evaluation results for performance characteristics, efficiency, and temperature distribution are presented.
Furthermore, issues observed during testing and the actual motor behavior are discussed, verifying consistency with the analytical results.

Development of High Power Density Motor – Part 3: Discussion and Optimization

Michiharu Kawano･Hisayuki Kabashima･Naoki Itasaka･Kentaro Nomura･Kazunori Hirabayashi (MCF Electric Drive)

This paper presents a discussion on the evaluation results of the prototype motor and further design optimization. Specifically, cooling performance is verified through a comparison of oil flow visualization results and analysis outcomes, followed by the identification of issues. Based on these insights, design improvements are proposed, and the outlook for realizing next-generation high power density motors is presented.

Development of Rotary-Fin Air-Cooling Technology for Small EV

Tetsuya Suto･Akeshi Takahashi (Astemo, Ltd.)･Makoto Ito (Hitachi)

We are developing an air-cooled outer-rotor direct-drive system for small cars and motorcycles with strict cost constraints. This drive system dissipates heat of motor losses from the rotary fins installed on the side of the rotor housing, achieving a continuous output of 5.5kW, which is top-class in air cooling. In this presentation, we report on the concept of this cooling structure and the test results.