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

今天的电动机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的定子都有巨大的铁极和巨大的铜绕组。这导致高电机质量和施工量。事实上，轻量化结构的潜力是有限的。正因为如此，有很多的研究活动在替代电机的设计。在第一项发明中，开发了一种具有气隙绕组的磁路并获得了专利。这种设计已经允许到目前为止无与伦比的功率密度2千瓦/公斤轮毂电机。在这一发展时期，出现了许多其他能够再次提高功率密度的创新思想。因此，一种具有弯曲双多层气隙绕组和哈尔巴赫阵列结构的新型轮毂驱动磁路设计应该得到要求的资助。定义了六个目标，它们有条理地相互建立。(1)首先，研制了一种多层气隙绕组的新型磁路。因此，一个曲折的多层绕组将安装在一个薄背铁。这种蜿蜒的结构可以同时利用所有磁极。为了分析新的转换行为，在ANSYS/Maxwell中建立了静态和瞬态的三维模型。在此之前，这种新颖的磁路设计已经得到了解析建模。预计扭矩增加约50%，质量增加最小。(2)第二步，研制双转子双多层气隙绕组。首次可采用两个独立的多层绕组进行机电转换。预计扭矩将再增加约90%。(3)下一步，准备一个哈尔巴赫阵列。第一次，这种众所周知的配置是为了设计新颖的磁路布局。气隙内增加的磁场使扭矩收益约为10%。后铁内部的磁场减少允许进一步减少铁质量。(4)为了分析新型磁路的动态特性，利用Matlab/Simulink开发了传感器控制换相（利用两个模拟霍尔开关）和无传感器换相（利用依赖角度的电感）。(5)同时，将在Maple软件中开发所有已开发磁路的分析尺寸脚本。目的是能够及时计算出新型磁路的能量优化、转矩优化和重量优化。(6)最后，将使用测试图对创新磁路进行验证，并对所开发的模型进行验证。通过这些新颖的磁路设计，轮毂电机可以实现超过3 kW/kg的极高功率密度。此外，获得的成果将获得专利并发表。

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.