497-206: Innovating Motor Design: Creating Motor Test Platforms for Three IIT ECE Course Competitions

Meeting Days/Time
Tuesdays from 1:50 to 4:30 pm
Phil Lewis (INTM) (lewisp262@aol.com) and Ian Brown (ECE) (ibrown1@iit.edu)
Appropriate Disciplines
Aerospace Engineering, Applied Mathematics, Biomedical Engineering, Computer Engineering, Computer Information Systems, Electrical Engineering, Industrial Technology & Management, Materials Engineering, Mechanical Engineering, Physics
Technical Innovation

The aim of this IPRO project is to increase student interest, excitement, and practical experience in electromechanical and electric machine design courses at IIT. We propose to have the IPRO team develop two student-oriented hands-on prototype design testing platforms for use in ECE department courses: two undergraduate (ECE 319/ECE 412) and one graduate (ECE 539), as described below.

For the ECE 319/412 courses, the IPRO team will design a reluctance actuator test fixture and the common portion of the reluctance actuator with the winding that all students in the ECE 319/412 course will then use in the future. The students in the ECE 319/ECE 412 course will analyze and design an actuator that would only require laser or water jet cutting for construction. The students in this course will be evaluated based on the design that comes closest to achieving the Pareto front objectives and for their associated analysis.

Currently, for the final project in ECE 539, students in the class analyze the 2004 Toyota Prius IPM motor. The instructors would like to transform the final project into a mini-design competition whereby students in the ECE 539 course will design, fabricate and test the rotor for a synchronous reluctance machine. Students will be given a common stator design, which would be infeasible to design and construct during the semester anyway. Instead, the challenge for the students in ECE 539 is to design the rotor lamination with the objectives of maximizing torque for a provided current command and minimizing losses with constraints on torque ripple, winding temperature, and various geometric parameters using an integrated design approach developed in this research. The students will also predict torque as a function of current commands, thermal performance, and torque ripple for the full machine based on their rotor lamination design.

Given the above ECE 539 course, the IPRO team will be responsible for designing the stator, housing, shaft, and rotor shaft adapter/carrier that will be used in the mini-design competition in ECE 539 as described in the previous paragraph. Rotor laminations will be laser cut and a rotor shaft adapter/carrier will be used to easily rotate the student prototype designs in and out for testing. Currently, in the spring 2016 IPRO 206 project, the team is building the dynamometer and integrating the torque meter and power analyzer equipment for testing of future student actuator designs.

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