Inductive Electrically Excited Synchronous Machine for Electrical Vehicles—Design, Optimization and Measurement

The demand for electric machines has been rising steadily for several years—mainly due to the move away from the combustion engine. Synchronous motors with rare earth permanent magnets are widely used due to their high power densities. These magnets are cost-intensive, cost-sensitive and often environmentally harmful. In addition to dispensing with permanent magnets, electrically excited synchronous machines offer the advantage of an adjustable excitation and, thus, a higher efficiency in the partial load range in field weakening operation. Field weakening operation is relevant for the application of vehicle traction drive. The challenge of this machine type is the need for an electrical power transfer system, usually achieved with slip rings. Slip rings wear out, generate dust and are limited in power density and maximum speed due to vibrations. This article addresses an electrically excited synchronous machine with a wireless power transfer onto the rotor. From the outset, the machine is designed with a wireless power transfer system for use in a medium-sized electric vehicle. As an example, the requirements are derived from the BMW’s i3. The wireless power transfer system is integrated into the hollow shaft of the rotor. Unused space is thus utilized. The overall system is optimized for high efficiency, especially for partial load at medium speed, with an operation point-depending optimization method. The results are compared with the reference permanent magnet excited machine. A prototype of the machine is built and measured on the test bench. The measured efficiency of the inductive electrically excited synchronous machine is up to 4% higher than that of the reference machine of the BMW i3.