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I. INTRODUCTION
For the past few decades, greenhouse gas emission has been
the most crucial problem as they lead to many unpredictable
disasters. In the next 50 years, it is expected that the global
population will increase from 6 billion to 10 billion and the
vehicles they own will increase form 700 million to 2.5
billion [1-2]. One of the most vibrant issues on greenhouse
gas emissions reflects directly on emission gases produced by
gasoline vehicles. Besides, the ever rising concerns on natural
resources has also accelerated the development of automobile
which saves fuel by maximizing energy conservation such as
Electric-Gasoline Hybrid Vehicle and Battery operated
Electric Vehicle (BEV) [3]. Typically for BEV drive train
application, the electric motors deployed should have the
capabilities of high torque at constant power which promotes
towards a highly efficient system which determines the
driving range and performance. A large number of motor
types and technologies were considered, developed and
employed in the past decades. However the choice is limited
by the availability of motor, the electronic control
technologies together with the traction requirements. [1-5].
Currently, Interior Permanent Magnet (IPM) Permanent
Magnet Synchronous Motors (PMSM) have been widely
selected by international automakers such as Toyota, Nissan
and Tesla which they believe the best motor to satisfy BEV
characteristic. Besides, IPM-PMSM have also gained fame
through reliability based on market test for the past few years
[6-11]. However, IPM-PMSM motors are much expensive,
difficult to maintain and often demands high energy source to
produce the desired output which limits the driving range.
Constant
Torque
Constant Power
Reduced Power
Power
0.8
0.6
Torque
0.4
0.2
Base Speed
Critical Speed
3
2
Speed [Per unit]
Design Concepts
PM
Coil
= 0 0
= (1 0 2 )0 2
Airgap
PM
Rotor Motion
Flux Flow
Figure 2. Magnetic Flow Concept
(3)
Rotor
(4)
(1)
Stator
1
0
0
1 +
2
= ()() =
0
(2)
Rotor
2.2
The peak value of the air gap phase EMF for the radial flux
machine is as in Eq. (2).
Stator
Coil
Airgap
(6)
/2
= 2
/2
End Plate
Stator
End Plate
Requirement
Type
Motor volume
Do 129mm x Di 50.8mm x
L 43mm
Cogging torque
Operational
temperature
Drive electronics
80 C
Six pulse PWM drives
= 0.5 (02 2 )
Stator 1
Rotor
(7)
Stator 2
= 0.5 (02 2 )
(8)
(9)
0.5 (02 2 )
0.5 (02 2 )
(10)
(11)
(12)
From the above the turns per slot and the maximum current
density of the machine designed is computed for the specified
sizing of the machine based on the initial design on capability
of the machine which is later used in the simulation study of
the machine using the FEA tool.
3.2 Magnetic Circuit Analysis
The windings are of the two stators are connected in series
therefore the factor of 2 is required in the calculations. With
two stators each having slots per phase, the phase
resistance and the phase inductance can be calculated
as in Eq. (13)- Eq. (14).
= 2 ( + )
(13)
= 2 ( + + )
(14)
g/2
Stator 1
Rs1
2Rg
Airgap 1
2Rg
End Plate
r/2
Rm
2Rm
r/2
2Rm
Magnet
Stator 1
Airgap 2
Stator 2
Rm
2Rg
2Rg
Rs2
g/2
Stator 2
End Plate
th Magnet Section
120
(15)
130 mm
= + 2
= (
Back Iron
(16)
(a). Rotor Magnet Design
Coil Base
= (
(17)
1
1+
2 )
A1
B1 C1
B2
C3
A2
A3
B3 C2
1/4th Magnet
(up side)
Double Sided Coil
1/4th Magnet
(bottom side)
(a)
(b)
Parameters
Rated Speed
Rated Power
Number of phases
Number of magnets
Number of armature core
Magnet type
Motor overall diameter
Motor axial diameter
Number of turns/ phase
Type of winding
Total amp-turns
Conductor Material
Core Material
Term/Values
150 rpm
1 kW
3
12 X 4 sets
9
N40
500 mm
50 mm
1000
Concentrated
12000 A-t
Copper alloy
M22 Steel
Structure
parameters
Structure Modeling
Changes
(c)
Figure 10. Finite Element Analysis
(a) Boundary Element (b) Meshing (c) Magnetic Flux
Density
VI. RESULTS AND DISCUSSIONS
4
3
2
Phase B
Phase A
Phase C
1
0
-1
-2
-3
-40
20
40
60
80 100 120
Rotational Angle [Deg.]
140
160
180
Development of Mesh
0.232
Element Calculation
Material or
current
0.224
Magnetic Analysis
0.216
Result
0.208
No
Acceptable?
Yes
End
0.200
0
20
40
60
80
100
120
140
160
REFERENCES
[1]
[2]
[3]
1
[4]
0
[5]
-1
[6]
-2
[7]
-3
60
80
100
220
240
[8]
[9]
[11]
[10]
[12]
[13]
VII. CONCLUSIONS
The design variations in the axial flux flow pertaining to the
use in EV is presented. A dual axial flux flow through double
rotor (exterior rotor) and sandwiched stator is presented. The
magnetic circuit analysis is done and the designed machine is
modelled, designed and simulated using the standard FEA
tool and the preliminary result on the torque is presented.
Suggestion on the improvement on the design is presented.
500
100 rpm
300
Voltage V [V]
150 rpm
50 rpm
200
100
[17]
[18]
0
-100
[19]
[20]
-200
-300
-400
20
[15]
[16]
400
-500 0
[14]
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