A segmented claw-pole motor for traction applications considering recycling aspects

With the expansion of the fleet of electric and hybrid electric vehicles worldwide, it is of interest to consider recycling aspects of the parts that are introduced in these new vehicles. This paper focuses on the design of an electrical machine, a claw-pole motor, considering recycling of its components. The suggested design has segmented core parts of soft magnetic composites which yield a design very suitable for recycling as the core material is brittle and it thus simplifies the access of the copper winding. The windings are pre-formed ring-coils with a high fill-factor and with no end-windings. Through the use of direct water cooling, employing space between the claws, the current density can be high, and the machine can be compact. The results of finite element simulations of the electromagnetic properties (previously validated against measurements) show that a high performance recyclable motor with ratings above 10 kW can be made. In comparison with a commercial motor, the claw-pole motor has similar performance, a higher core and magnet weight and a lower copper weight. It also has an expected advantage regarding manufacturing cost and cost of recycling and it has lower copper loss.