Modifications to PM-Assisted Synchronous Reluctance Machine to Achieve Rare-Earth Free Heavy-Duty Traction

Automotive applications require electrical machines designed for high torque density, wide speed range, and low cost. NdFeB magnets can achieve a high torque density and wide speed range, and however, they have a high cost. Therefore, this article explores the capability of rare-earth-free (REF) design through a PM-assisted synchronous reluctance (PM-SynRel) motor. A PM-SynRel design with NdFeB has been used in this study where the NdFeB magnets have been replaced with ferrite magnets. Then, several modifications on the rotor have been made to ensure mechanical safety. Thermal analysis has been conducted last to evaluate the temperatures in the different machine parts to avoid exceeding the required limits. Finally, a prototype has been made and tested to validate the simulation results.