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A novel compound-structure transverse-flux permanent-magnet synchronous machine (CS-TFPMSM) is proposed in this paper, which is used in hybrid electric vehicles (HEVs) to fulfill the power-split function. The key component of the CS-TFPMSM is a brushless transverse-flux dual rotor machine (TFDRM). The TFDRM originates from the transverse-flux machines, and is capable of speed adjustment between the transverse-flux rotor and the permanent-magnet rotor without using any brushes. The structure and principle of the TFDRM are described. The torque equations of the TFDRM are deduced, which are different from those of traditional machines. Based on the investigation, the TFDRM tends to have high leakage and a poor power factor. The method to obtain high power factor is discussed. The back electromotive force (BEMF) and torque of the TFDRM are simulated with the variation of parameters, such as pole-pair number, width of the permanent magnets (PMs), and so on. A prototype of a 10kW TFDRM is designed.

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Abstract:The compound-structure permanent-magnet synchronous machine (CS-PMSM) is a power-split device which can enable the internal combustion engine (ICE) to operate at optimum efficiency during all driving conditions by controlling its torque and speed. However, the CS-PMSM has more serious temperature rise and heat dissipation problems than conventional permanent-magnet (PM) machines, especially when the CS-PMSM is running at low speed and under full load conditions. As the thermal resistance of double-layer air gaps is quite big, the hot spot proves to be in the inner winding rotor. To ensure the safe operation of the CS-PMSM, the use of forced-air and water cooling in the inner winding rotor are investigated. The study shows that the water cooling can provide a better cooling effect, but require a complicated mechanical structure. Considering the complexity of the high efficiency cooling system, a real-time temperature monitoring method is proposed and a temperature measuring system which can accurately measure the real-time temperature of multiple key points in the machine is developed to promptly adjust the operating and cooling conditions based on the measured temperature results. Finally, the temperature rise experiment of the CS-PMSM prototype is done and the simulation results are partly validated by the experimental data.

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