Small Brush DC Motors using Soft Magnetic Composites for 42V Automotive Applications

This paper presents new design approaches for the realization of small DC motors with SMC, for 42V automotive applications. Several structural solutions are proposed which use new kinds of windings to improve the performance and to minimize the production cost. These structures are using a multi-layer concentrated winding with a small number of slots. They are well adapted to the production process of metal powder parts. The new design is validated by the experimental performance of a SMC 42V Brush-DC prototype and by a comparative analysis with a classical 12V laminated motor used for an automotive 180W application. A 50% gain on the copper volume is obtained for the same specifications and performance of this application.