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In the past decade, the transportation industry has witnessed a rapid transition from conventional fossil fuels to electric power. This shift has spurred diverse electrification initiatives spanning various vehicle categories, including E-cycles, 2-wheelers, 3-wheelers, cars, and commercial vehicles. Central to these road transport vehicles are essential components such as battery systems, electric motors, and field-oriented controllers. These controllers’ interface with the vehicle control unit, optimizing motor performance across diverse operational conditions. The reliability of the core motor and controller system is of paramount importance, ensuring seamless operation throughout its life. Notably, certain applications, like 2-wheeler, demand customized designs with compact configurations to save space and eliminate excessive wiring. This necessitates heightened reliability due to limited serviceability within these confined designs.

Belt-driven starter generator claw pole electric motors are used in hybrid automobiles to start the engine, charge the battery and to power the electrical system when its engine is running. Shaft and claw pole are important components in the claw pole electric motor. The claw pole is fitted onto the shaft through press-fit force. Press-fit is a widely used fastening process to join two different components by pushing a component inside or over another component with high press force which will create a strong bond between the components. Determining press-fit force required to assemble parts is very complex since it depends on a lot of factors such as mechanical material properties of components, interference fit condition whether it is in Min, mean and max condition, amount of contact pressure induced by contact surface, co-efficient of friction created in between components. The press-fit will help to prevent loosening components from its bond at high torque and speed.

This paper presents a proposed space vector pulse width modulation (SVPWM) controller for permanent magnet synchronous motor (PMSM). The Space vector pulse width modulation controller is used for power loss, torque ripple minimization of this type of motors. The proposed controller is a newly applied of Belt starter generator (BSG). The dynamic response of the BSG with the proposed controller is studied during the starter and generator modes with desired torque and speed with the optimal Id, Iq current input. The effectiveness of the proposed space vector pulse width modulation is then analyzed with Field oriented control (FOC) characteristics in the BSG operating system. The analysis results are presented to demonstrate the characteristics and effectiveness of the proposed control techniques.

In this paper, the study of plastic bonded magnetic material is studied for the surface adhesion of the material on to the surface of a metal cup. The bonded magnetic material is formed as a mixture of plastic material blended with ferrite or NdFeB Magnetic powder. The amount of magnetic material used is confined to the magnetic property of the magnetic powder that can exhibit the required magnetic performance as higher rotational speed and higher temperature. The magnet is injection moulded onto the outer circumference of the metal cup. The magnet is bonded onto the metal surface which is of cup shape and this assembly is magnetized to form a multipole magnet. This multipole magnet is designed to withstand high centrifugal force during the magnet rotation at higher rpm say 40000 rpm.

SAE 8620 and 20CrMo materials were subjected to carburizing process to obtain the identical hardened layer of HRC 61-64. The carburized surface and core properties of the materials were examined and characterized through optical microstructure to measure the presence of cementite carbides and Retained Austenite (RA). From the results, it was found that the SAE 8620 and 20CrMo materials have 10 % and 14% of RA respectively. Whereas, the core and case structure were free from network carbides. The fatigue test was conducted to correlate the RA and fatigue strength of the materials. It was revealed that material with lower RA has higher fatigue strength than material with higher RA. Higher amount of retained austenite leads to reduction in amount of martensitic and compressive residual stress attributed to lower the contact fatigue strength.

In Micro hybrid, start-stop system automatically stop and start the engine to reduce the idling time of engine spend in traffic jams and signals, thereby reducing fuel consumption and emissions. Starter motors used in Micro hybrid (Start/Stop) application has 5~10 times more life cycles than compare to conventional starter because of need to starter in every idling time of engine. There are multiple components in starter motor have sliding contact (mechanical/electrical), rolling contact will inflict the life cycles of starter motor. Brush is one of the major sliding contact elements to inflict the life cycle of starter, brushes are commonly used to conduct current between the stationary and moving part of starter. Brushes are exposed both mechanical and electrical loading conditions. Brush wear is affected by the association of Mechanical wear and electrical wear.

Global Automotive Industry is mandated with the task of emission reduction and mileage improvements. One of the key areas being looked at from mileage standpoint is light weighting. While Aluminum body is replacing Steel is many vehicular applications, in Starter Motor Aluminum is the key component. Therefore, any attempt at light weighting must consider Aluminum. A Starter motor fits directly on to the engine. Aluminum being the housing material provides structural stability. It also performs the role of heat dissipation being a good thermal conductor and source of electrical ground path. Aluminum constitutes 20 - 25% of Starter motor weight. Any significant weight reduction cannot be achieved unless we look at the components made of Aluminum, namely die cast Housing and End plate. The alternatives considered in this study include engineered plastics, magnesium alloy and composites.

Magnesium alloy current being used for automotive sector and are being significantly used for manufacturing engine block as offering higher power to weight ratio to the vehicle. In this context, the magnesium alloy has been used in the replacement of aluminium alloy for the starter housing which in turn increase the power to weight ratio of the motor. Considering the operation condition of starter motor in the engine of the vehicles, the starter motor is being exposed to the harsh environment, where its system is being tested for Noise, Vibration and Harshness. In this paper, the magnesium alloy housing is used to study the vibration and noise developed in the starter motor and the same is compared with the noise and vibration of the motor when it being used with Aluminium alloy Housing. First, the vibration study is carried out for the housing part alone to capture the resonant frequency of the both housing alloy say, Aluminium and Magnesium.