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Magnetic Circuit With Meandering Double-Multilayer Air Gap Winding and Halbach Array Configuration for Electric Wheel Hub Drives

用于电动轮毂驱动器的具有蜿蜒双层气隙绕组和 Halbach 阵列配置的磁路

基本信息

批准号：
315694745
负责人：
Dr.-Ing. Norman Borchardt
金额：
--
依托单位：
Institut für Mobile Systeme (IMS)
依托单位国家：
德国
项目类别：
Research Fellowships
财政年份：
2016
资助国家：
德国
起止时间：
2015-12-31 至 2016-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/315694745?language=en
关键词：
Magnetic Circuit Meandering Double Multilayer

项目摘要

Today's electric motors are not necessarily optimal suited for mobile systems. Standard direct current machines, synchronous machines and asynchronous machines have slotted stators with massive iron poles and voluminous copper windings. This results in high motor masses and construction volumes. In fact, potential for lightweight constructions is limited. Because of this, there are a lot of research activities on alternative motor designs.In a first invention a magnetic circuit with air gap winding was developed and patented. This design already allows a so far unrivaled power density of 2 kW/kg for wheel hub motors. During this development period many other innovative ideas, which can improve the power density again, emerged. Because of this, a novel magnetic circuit design with meandering double-multilayer air gap winding and Halbach array configuration for wheel hub drives should be develop with the requested grant.Six aims are defined that build on each other methodically. (1) First, a new magnetic circuit with multi-layer air-gap winding is to develop. Therefore, a meandering multi-layer winding will be mounted on a thin back iron. This meandering structure enables a simultaneous utilization of all magnetic poles. To analyze the new conversion behavior, a static and transient 3D model is built in ANSYS/Maxwell. Previously, this novel magnetic circuit design is getting modeled analytically. A torque increase of approximately 50%, with minimal mass increase, is expected. (2) In the second step, a double rotor with double-multilayer air gap winding is to develop. Two separate multi-layer windings can be used for the electromechanical conversion for the first time. Another torque increase of about 90% is expected. (3) Next, a Halbach array is intended. For the first time, this well-known configuration is to design for the novel magnetic circuit layout. The increased magnetic field inside the air gap enables a torque benefit of approximately 10%. The field reduction inside the back iron allows a further reduction of iron mass. (4) In order to analyze the dynamic behavior of the new magnetic circuits, a sensor-controlled commutation (by using two analog Hall switches) and a sensorless commutation (by using the angle-dependent inductance) is to develop by using Matlab/Simulink. (5) In parallel an analytical dimensioning script for all developed magnetic circuits is to develop in the software Maple. The aim is to be able to calculate promptly the novel magnetic circuits energy-optimized, torque-optimized and weight-optimized. (6) Finally, test patterns will be used to validate the innovative magnetic circuits and to verify the developed models.With these novel magnetic circuit designs, extremely high power densities of more than 3 kW/kg can be realized for wheel hub motors. Furthermore, gained results will be patented and published.

今天的电动马达不一定最适合移动系统。标准的直流电机、同步电机和异步电机都有开槽的定子，带有巨大的铁极和大量的铜绕组。这会导致电机质量和建筑体积较大。事实上，轻量级建筑的潜力是有限的。正因为如此，有许多关于替代电机设计的研究活动。在第一项发明中，一种气隙绕组的磁路被开发出来并获得专利。这种设计已经为轮毂电机提供了到目前为止无与伦比的2kW/kg的功率密度。在这一发展时期，又涌现出了许多可以再次提高功率密度的创新想法。基于此，提出了一种新型的轮毂磁路设计方案，即采用双多层气隙绕组和Halbach阵列结构的轮毂传动方案。(1)首先研制了一种多层气隙绕组的新型磁路。因此，一个蜿蜒的多层绕组将安装在薄薄的背铁上。这种曲折的结构使得能够同时利用所有磁极。为了分析新的转换行为，在有限元分析软件Ansys/Maxwell中建立了静态和动态的三维模型。以前，这种新颖的磁路设计是以解析的方式建模的。扭矩增加约50%，而质量增加最小。(2)研制了双转子双多层气隙绕组。首次将两个独立的多层绕组用于机电转换。预计还会有大约90%的扭矩增加。(3)接下来，设计了Halbach阵列。第一次，这种众所周知的配置是为了设计出新颖的磁路布局。气隙内磁场的增加使扭矩增加了约10%。背面铁内部的磁场减少允许进一步减少铁的质量。(4)为了分析新型磁路的动态行为，利用MatLab/Simulink开发了传感器控制换向(使用两个模拟霍尔开关)和无传感器换向(使用角度相关电感)。(5)在软件Maple中并行开发所有已开发的磁路的分析尺寸标注脚本。其目的是能够快速计算出能量优化、扭矩优化和重量优化的新型磁路。(6)最后用测试图形验证了创新的磁路和所开发的模型，在这些新颖的磁路设计下，轮毂电机可以实现超过3kW/kg的极高功率密度。此外，已取得的成果将获得专利并发表。