Impact of Core Glue Coverage and Stacking Factor on Glue-laminated Motor Material Properties and Its NVH Behavior

The influence of core glue coverage and stacking factors on the mechanical properties of core material is investigated in this study. As these structural attributes of the motor directly affect the mechanical behavior of the e-drive system, such as the NVH and durability performance, their influence on NVH is also analyzed under electromagnetic loads. With the unit-cell method previously proposed for predicting laminated motor core material properties, the material used in the finite element analysis (FEA) model for the glue-laminated motor core is homogenized over the laminations and idealized macroscopically as a transversely isotropic material. A numerical FEA method to quantify the effect of the glue coverage rate and stacking factor in a statistical or averaged sense to establish their relationship with the linear transversely isotropic properties. The glue is assumed to be evenly distributed over the lamination plane, and changes in the in-plane and out-of-plane elastic modulus and shear modulus are investigated as a function of the overall coverage percentage of the glue and the stacking factor. Correlated core material properties for motors in production are used to verify the proposed analytical method and numerical results. Excellent agreement is achieved between the measured and the analytical results. Finally, to verify the effectiveness of the application of the material properties and the developed method, the NVH performance of a Motor Dyno system is analyzed and evaluated with different material properties, considering various glue coverage rates and core stacking factors. The effects of the glue distribution pattern and areas on the core material properties and thermal effects will be reported separately.