Three-Dimensional Finite-Element Analysis and Optimal Design of Hybrid-Excitation DC Brush Motor for Automotive Engine Start Applications

This paper presents the design of a hybrid-excitation-type DC brush motor, simulation and analysis commercially available diesel generator starter, use finite-element software, Maxwell 3D, to develop motor model. Moreover, an improvement is proposed for magnet fixing compared with traditional dovetail groove design. Magnet fixation via splicing method effectively mitigates magnetic saturation; therefore, power density performed demonstrate that improved can increase per unit volume. Additionally, this work involves another structural improvement, i.e., optimization design, along Taguchi algorithm optimize part stator structure; variance sensitivity are also considered. The analyses justify selection control factors At rated speed 3,400rpm, output increases by 25.1% relative prototype. Considering economic benefits applications automobile engines in product development, new configuration enables performance improvements without increasing weight car body.