Design and evaluation of moulded powder-core machine for in-wheel drive application

The challenge of integration and moulding techniques is putting the electromagnetic design for manufacturability to the test when focusing on electrical machines for in-wheel application. 28-pole 30-slot permanent magnet synchronous machine (PMSM) is proposed and analysed for different arrangements for a stator magnetic core. A soft magnetic mouldable composite (SM²C) is used as a crucial part of the stator core and is supported with compressed primitives of soft magnetic composite (SMC). The 2D and 3D FE analyses are compared and used to estimate the machine characteristics of the different arrangements for the stator core. A Number of stator prototypes are made in order to validate the designs.