The design of permanent magnet-excited crankshaft starter-alternators

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The design of permanent magnet-excited crankshaft starter-alternators

Sonnenburg, R. / Heyden, M. van

The interest in alternative drive concepts in the car industry essentially derives from the demand to reduce hazardous substances. At the same time the constantly increasing demand for secondary equipment on the on-board network leads to thoughts of replacing the previous types of generator by more powerful technology. A solution to this is offered by a crankshaft starter-generator located between the engine and the clutch, which takes over the function of the conventional generator and starter. The development of electrical equipment - in particular for the drive technology as well as for the starter-generators in vehicles - is subject to particularly high demands with respect to power density, efficiency and cost-effective manufacture. To achieve competitive solutions here there must be a close link between simulation methods and trials during the design process. This contribution is devoted to the development of pein anently-excited synchronous machines for vehicle drives and crankshaft starter-generators, as manufactured by Mannesmann Sachs. These machines are based on sintered Nd-Fe-B magnets and are characterized by exceptional values for power density and efficiency. In the first part the basic design of the machines are briefly discussed. Following this some examples of the use of FE methods are discussed which essentially concern the achievement of the required power densities and restriction of the losses.