High Efficiency Axial Flux Permanent Magnet Machine Design for Electric Vehicles

Design and optimization of electrical machines for electric vehicle (EV) applications is achallenging task. In response to variable driving circumstances, the machine should be designedto operate in a wide range of speed and torque. This paper aims to optimize a surface-mountedaxial-flux permanent-magnet (AFPM) traction machine taking the influence of the driving cycleinto account. The AFPM motor is designed to maximize the overall efficiency over a predefineddriving cycle. EV requirements and geometric constraints are taken into account in the designprocess. Hundreds of operating points in a driving cycle are reduced to the limited number ofrepresentative points by calculating the energy centre points in the energy distribution curve.Therefore, the number of calculations during the design optimization is significantly reduced. Ananalytical design procedure based on quasi-3D approach is used for accurate modelling of AFPMmachine and genetic algorithm (GA) is implemented to find out the optimal design parameters.Functionality of the proposed approach is validated via comprehensive three-dimensional (3D)finite-element analysis (FEA).

PDF

___

Onori, S., Serrao, L., Rizzoni, G., “Hybrid Electric Vehicles Energy Management Strategies”, Springer, (2016).
Shokri, M., Behjat, V., Rostami, N., “A Wind System Based on FEA of an Axial Flux Permanent Magnet Generator and Modular Multilevel Inverter”, Gazi University Journal of Science, 30(2): 149- 158, (2017).
Lin, Y. S., Hu, K. W., Yeh, T. H., Liaw, Chang-M., “An Electric-Vehicle IPMSM Drive With Interleaved Front-End DC/DC Converter”, IEEE Transactions on Vehicular Technology, 65(6): 4493- 4504, (2016).
Min, M. J., Jae, P. G., Hyeok, S. S., Woo, K. D., Yong, J. S., “Design Characteristics of IPMSM With Wide Constant Power Speed Range for EV Traction”, IEEE Transactions on Magnetics, 53(6): 1-4, (2017).
Dongjae, K., Hongsik, H., Sungwoo, B., Cheewoo, L., “Analysis and Design of a Double-Stator FluxSwitching Permanent Magnet Machine Using Ferrite Magnet in Hybrid Electric Vehicles”, IEEE Transactions on Magnetics , 52(7): 1-4, (2016).
Abdel-Khalik, A. S., Ahmed, S., Massoud, A. M., “A Six-Phase 24-Slot/10-Pole Permanent-Magnet Machine With Low Space Harmonics for Electric Vehicle Applications”, IEEE Transactions on Magnetics, 52(6): 1-10, (2016).
Zhu, Z. Q., and Howe, D., “Electrical Machines and Drives for Electric, Hybrid, and Fuel Cell Vehicles”, Proceedings of the IEEE, 95(4): 746-765, (2007).
Chau, K. T., Chan, C. C., Liu, C., “Overview of permanent-magnet brushless drives for electric and hybrid electric vehicles”, IEEE Transactions on Industrial Electronics, 55(6): 2246-2257, (2008).
Chai, F., Xia, J., Guo, B., Cheng, S., and Zhang, J., “Double-stator permanent magnet synchronous in-wheel motor for hybrid electric drive system”, IEEE Transactions in Magnetics, 45(1): 1-5, (2009).
Parviainen, A., Niemela, M., and Pyrhonen, J., “Modeling axial flux permanent-magnet machines”, IEEE Transactions on Industrial Applications, 40(5): 1333-1340, (2004).
Parviainen, A., “Design of Axial Flux Permanent-Magnet Low-Speed Machines and Performance Comparison between Radial-Flux and Axial-Flux Machines”, PhD Thesis, Lappeenranta University of Technology, Lappeenranta, Finland, (2005).
Rostami, N., Feyzi, M. R., Pyrhönen, J., Parviainen, A., and Behjat, V., “Genetic Algorithm Approach for Improved Design of a Variable Speed Axial-Flux Permanent-Magnet Synchronous Generator”, IEEE Transactions on Magnetics, 48(12): 4860-4865, (2012).
Rostami, N., and Rostami, M., “Analytical Design of AFPM Machines with Cylindrically Shaped Magnets using Quasi-3D Method”, COMPEL - The International Journal for Computation and Mathematics in Electrical and Electronic Engineering, 36(4): 1168-1183, (2017).
Shokri, M., Rostami, N., Behjat, V., Pyrhönen, J., and Rostami, M., “Comparison of Performance Characteristics of Axial-Flux Permanent-Magnet Synchronous Machine with Different Magnet Shapes”, IEEE Transactions on Magnetics, 51(12): 1-6, (2015).
Ju Hyung Kim, Yingjie Li, Bulent Sarlioglu, “Novel Six-Slot Four-Pole Axial Flux-Switching Permanent Magnet Machine for Electric Vehicle”, IEEE Transactions on Transportation Electrification, 3(1): 108-117, (2017).
Lehr, M., Reis, K., and Binder, A., “Comparison of axial flux and radial flux machines for the use in wheel hub drives”, e & i Elektrotechnik und Informationstechnik, 132(1): 25-32, (2015).
Lok, C.L., Vengadaesvaran, B., and Ramesh, S., “Implementation of hybrid pattern search–genetic algorithm into optimizing axial-flux permanent magnet coreless generator (AFPMG)”, Electrical Engineering, 99(2): 751-761, (2017).
Darabi, A., Baghayipour, M., and Mirzahosseini, R., “An Extended Analytical Algorithm for Optimal Designing of a TORUS-type Non-slotted Axial-Flux Permanent Magnet Motor”, Journal of Control, Automation and Electrical Systems, 28(6): 748-761, (2017).
Johansen, P. R., Patterson, D., O’Keefe, C., and Swenson, J., “The use of an axial flux permanent magnet in-wheel direct drive in an electric bicycle”, Renewable Energy, 22(1-3): 151-157, (2001).
Yang, Y. P., and Shih, G. Y., “Optimal Design of an Axial-Flux Permanent-Magnet Motor for an Electric Vehicle Based on Driving Scenarios”, Energies, 9(4): 285, (2016).
Chen, L., Wang, J., Lazari, P., “Influence of driving cycles on traction motor design optimizations for electric vehicles”, Transport Research Arena (TRA) 5th Conference, Paris, (2014).
Sarigiannidis, A. G., Beniakar, M. E., Kladas, A. G., “Fast Adaptive Evolutionary PM Traction Motor Optimization Based on Electric Vehicle Drive Cycle”, IEEE Transactions on Vehicular Technology, 66(7): 5762-5774, (2017).
De Santiago, J., Bernhoff, H., Ekergå andrd, B., Eriksson, S., Ferhatovic, S., Waters, R., and Leijon, M., “Electrical motor drivelines in commercial all-electric vehicles: a review”, IEEE Transactions on Vehicular Technology, 61(2): 475-484, (2012).
S. Kreuawan, F. Gillon, and P. Brochet, “Comparative study of design approach for electric machine in traction application”, International Review of Electrical Engineering, 3(3): 455–465, (2008).
Sulaiman, E., Kosaka, T., and Matsui, N., “Design and Performance of 6-slot 5-pole PMFSM with Hybrid Excitation for Hybrid Electric Vehicle Applications”, International Power Electronics Conference, (2010).
Lazari, P., Wang, J., and Chen, L., “A computationally efficient design technique for electric vehicle traction machines”, Proc. of 20th International Conference on Electrical Machines (ICEM), France, (2012).
Wynen, V., Boureima, F. S., Matheys, J., Van den Bossche, P., and Van Mierlo, J., “Developing applicable driving cycle for retrofitted Plug-In Hybrid Electric Vehicles (PHEVs): environmental impact assessment”, World Electric Vehicle Journal, 3(1): 147-159, (2009).