Design, analysis and experiment of a high efficiency permanent magnet truck alternator

This paper presents the design and optimization of a high-efficiency permanent magnet synchronous alternator with the desired output power of 2 kW at 6 krpm applying to the truck power system. This kind of alternator requires low output voltage and high current. In order to effectively increase the overload power handing capability and efficiency of the designed alternator, the low torque angle is selected at the rated power and speed in the design. Key design methodologies and procedures are introduced and analyzed in detail. The corresponding finite element analysis (FEA) model is built. Structure optimization includes stator and rotor structure size, permanent magnet size, magnetic bridge and air gap length which are analyzed and simulated by ANSYS Maxwell 2D FEA. Thermal analysis is conducted, and the housing of alternator is designed. The alternator prototype is fabricated and tested based on our design. The simulation and test results verified the performance of the alternator.

[1]  Thomas Wu,et al.  Design and analysis of a V-type fractional-slots IPMSM with distributed winding for electric vehicles , 2016, 2016 XXII International Conference on Electrical Machines (ICEM).

[2]  M. Naidu,et al.  A high-efficiency, high power generation system for automobiles , 1995, IAS '95. Conference Record of the 1995 IEEE Industry Applications Conference Thirtieth IAS Annual Meeting.

[3]  Thomas Wu,et al.  Design, analysis and experiment of a permanent magnet brushless DC motor for electric impact wrench , 2016, 2016 XXII International Conference on Electrical Machines (ICEM).

[4]  Feng Liang,et al.  A vehicle electric power generation system with improved output power and efficiency , 1998, Conference Record of 1998 IEEE Industry Applications Conference. Thirty-Third IAS Annual Meeting (Cat. No.98CH36242).

[5]  Zhihui Chen,et al.  Analysis and Verification of the Doubly Salient Brushless DC Generator for Automobile Auxiliary Power Unit Application , 2014, IEEE Transactions on Industrial Electronics.

[6]  J. M. D. Coey,et al.  Permanent magnet applications , 2002 .

[7]  Jacek F. Gieras,et al.  Axial Flux Permanent Magnet Brushless Machines , 2005 .

[8]  M. Heuer,et al.  Energy management of vehicle electrical system with auxiliary power unit , 2009, 2009 IEEE Vehicle Power and Propulsion Conference.

[9]  Aashish Dalal,et al.  Design and development of a plug-in auxiliary power unit for heavy duty vehicle applications and stationary vocational equipment , 2011, 2011 IEEE Vehicle Power and Propulsion Conference.

[10]  Nady Boules,et al.  A high-efficiency, high power generation system for automobiles , 1995 .

[11]  D. Bouquain,et al.  Hybrid auxiliary power unit (APU) for automotive applications , 2002, Proceedings IEEE 56th Vehicular Technology Conference.