Design and manufacturing considerations of flux-switching permanent magnet motors for mass productions used in EVs and HEVs

Abstract

Published researches on flux-switching permanent magnet (FSPM) motors are focused on the analysis methods of electromagnetic performance, optimization design of lamination dimensions, combinations of stator slots and rotor poles, different kinds of field-excitations, and mechanical stability, etc. However, the manufacturing considerations for mass productions and their influences on the electromagnetic performances of FSPM motors, especially for the applications of electric vehicles (EVs) and hybrid electric vehicles (HEVs), have not been covered in previous works, which instead, are the main contributions of this paper. The complex stator structure of FSPM motors give challenges not only on mass production, but also on the cooling systems, since the permanent magnets (PMs) are surrounded by concentrated armature coils which contain the main heat source. Hence, the modular manufacturing methods are proposed and investigated. Then, a water-cooling system and the idea of an improved real time control scheme taking into account temperature variations are proposed and implemented. Moreover, inaccurate concentricity problems and unbalanced radial forces on rotor are also introduced considering the EVs/HEVs applications.

Modeling of Insulation Paper Damage in the Assembly of a Solid Slot Winding

“…For the data in the 3 rd column of the Table 4, one calculates the total sum of squares SS T from (14), the sum of squares of the parameters SS A , SS B , SS C , and SS D from (15) and the sum of squares of error SS ERR from (19). Corresponding variance ratios expressed in the sums of squares (14), (15), are as follows:…”

“…High torque at fixed motor diameter requires narrow slots and short overhangs. Reference [14] introduces challenges of manufacturing into holistic motor optimization. The goal is modular design for scalable solutions.…”

“…The goal is modular design for scalable solutions. Reference [14] presents a permanent magnet motor for electric vehicle propulsion, but it is not an in-wheel motor.…”

Performance modifications and design aspects of rotating flux switching permanent magnet machines: a review

“…A new modular‐rotor non‐modular stator FSPM has been proposed in [27], in which the rotor does not host PMs, and hence offers relatively simpler fabrication. A new modular fabrication method is proposed in [145] (Fig. 23 a ).…”

“…Stator modular fabrication on FSPMs:(a) New, (b) Traditional FSPM stator modules studied in[145] Additional iron bridge in FSPMs stator core to simplify the fabrication process[146] 12IET Electr. Power Appl., 2020, Vol.…”