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This paper aims to propose a new topology of direct current (DC) machine using claw-pole stator to replace standard DC starter in micro-hybrid vehicles. The main interest of such a topology is the reduction of copper volume.

The design of the claw-pole machine is based on a multi-objective optimization of several topologies, based on a three-dimensional (3D) reluctance network modeling. The 3D finite element (FE) model is used to check the results of the optimization, and a prototype is manufactured and tested with satisfactory results.

The claw-pole topology with wave-shape windings allows to replace the current DC series classical starter because of to its copper volume saving.

This model is only limited to the optimization of the claw-pole stator for a fixed geometry of the rotor.

The research outcome shows that claw-pole machine can replace the series-excited DC machines of starters and at the same time achieve the same performance at reduced copper volume.

The paper deals with a new DC machine topology to reduce the copper volume through the suppression of the classical stator end-windings. The use of Claw-Pole inductors ensures this copper reduction.

Optimization processes and movement modeling usually require a high number of simulations. The purpose of this paper is to reduce global central processing unit (CPU) time by decreasing each evaluation time.

Remeshing the geometry at each iteration is avoided in the proposed method. The idea consists in using a fixed mesh on which functions are projected to represent geometry and supply.

Results are very promising. CPU time is reduced for three dimensional problems by almost a factor two, keeping a low relative deviation from usual methods. CPU time saving is performed by avoiding meshing step and also by a better initialization of iterative resolution. Optimization, movement modeling and transient-state simulation are very efficient and give same results as usual finite element method.

The method is restricted to simple geometry owing to the difficulty of finding spatial mathematical function describing the geometry. Moreover, a compromise between imprecision, caused by the boundary evaluation, and time saving must be found.

The method can be applied to optimize rotating machines design. Moreover, movement modeling is performed by shifting functions corresponding to moving parts.

This paper aims to propose a method to evaluate the information obtained on harmonics calculations and to estimate the precision of results using finite element method for an innovative motor topology in which some well-known meshing rules are difficult to apply.

The same magnetostatic problem is solved with several mesh sizes using both scalar and vector potentials magnetics formulations on a complex topology, an axial claw pole motor (ACPM). The proposed method lies in a comparison between the two weak formulations to determine what information is obtained on harmonics calculations and to estimate its precision. Moreover, an original mesh method is applied in the air gap to improve the numerical results.

The precision on harmonics calculations using finite element method on an ACPM is estimated. For the proposed motor and mesh, only the mean value (even with large mesh) and the first harmonic (with fine mesh) of torque are calculated with a good accuracy. This results confirm that the non-respect of the meshing rules have a strong impact on the results and that scalar and vector potentials magnetics formulations do not give exactly the same results. Before using torque harmonics values in vibration calculations, a finite element model has to be validated by using both fomulations.

This method is time-consuming and only applied on an ACPM in this work.

The axial claw pole motor, for which the classic meshing rules cannot be applied, is a complex topology very under-studied. To improve the calculation of space harmonics, the authors proposed to split the airgap into four parts. Then in the two central parts, the meshing step of the structured mesh is equal to the rotating step.