Application of Copper-Clad Aluminum Wire to Design of Low-Cost and Lightweight PMSM for Water Pump

Abstract

The motor using aluminum wire as the coil windings has the advantages of light weight and low cost compared with the motor with copper windings in the mainstream market but the relatively low electrical conductivity of aluminum could leads to some defects in motor volume and performance Copper clad aluminum wire (CCAW) is a composite wire which has the characteristics of both copper and aluminum Therefore in terms of specific gravity price and electrical conductivity CCAW is a trade-off between the two materials with great business opportunities Many literatures on the application of CCAW to design of permanent magnet motor have shown that the purposes of weight and cost reduction can be effectively attained however volume and performance still need to be improved Due to the problems mentioned above in this thesis the vehicle water pump motor is chosen as the research object To start with the basic characteristics of CCAW will be discussed and compared with the copper wire the difference of materials will be implemented into the motor design process which can quickly and efficiently convert copper windings into CCAW ones Under the constraints of motor volume and material consumption the best balance between cost and performance will be found by parametric modelling of the split ratio coil windings and stator design Through the FEA software simulation the result shows that the final design with fixed volume not only reduces the weight and cost but improves the performance of rated point

Date of Award	2019
Original language	English
Supervisor	Min-Fu Hsieh (Supervisor)