轴向磁通轮毂电机新型冷却系统涡流损耗优化

doi:10.19562/j.chinasae.qcgc.2021.08.018

Abstract

Abstract:

The internal cooling system of stator yokeless axial flux motor has eddy current loss， which leads to the reduction of motor efficiency and temperature increase. In this paper， a cooling system of a stator yokeless axial flux motor is modeled with a vehicle hub motor as the research object. Through simulating and analyzing the eddy current loss of the cooling system during the operation of the motor， and performing two?dimensional finite element equivalence of the motor， the mechanism of eddy current loss of fins is further investigated. Based on this， the eddy current loss is optimized from three different perspectives， namely， optimizing the stator tooth shape to reduce the magnetic field strength at the fins， optimizing the fin height through magneto?thermal coupling analysis， and slotting the fins to increase the eddy current path resistance， which finally reduces the eddy current loss to 32.7% of the original one. The experimental tests of the prototype are carried out. The results show that the finite element simulation and experimental test results are consistent and the efficiency of the optimized motor is improved at different speeds， with the efficiency of the optimized motor 3.1% higher than that of the unoptimized motor at 4 000 r/min.

Key words: axial flux motor, YASA, fin, eddy current loss, magneto?thermal coupling, tooth shape, slotting

Jiujian Chang,Chen Wang,Xinxin Zheng,Jianping Fang,Xiaolin Wang,Peng Kang. Optimization of Eddy Current Loss of the New Cooling System of Axial Flux Motors[J].Automotive Engineering, 2021, 43(8): 1254-1262.

Figures/Tables 29

References 16

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参数	数值
电机外径 D_O/mm	187
电机内径 D_i/mm	123
电机轴向长度 L_a/mm	66
极对数 p	20
槽数 N_s	18
气隙长度 L_g/mm	1.2
定子高度 h/mm	43.6
额定电压（直流） U_r/V	350
减速比 η	5
峰值功率 P_peak/kW	50
峰值转矩 T_peak/（N·m）	600
额定功率 P_rated/kW	31.4
额定转矩 T_rated/（N·m）	375
最大转速 n_max/（r·min^-1）	1 200
总质量 m/kg	22.5

槽内材料	等效厚度/mm	导热系数/（W·（m·K）^-1）
绝缘纸	0.25	0.26
导线漆膜	0.33	0.15
环氧树脂	3.30	1.1
铜线	2.92	387.6

电机部件	材料	导热系数/（W·（m·K）^-1）
定子铁心	SMC	25
电机壳体	AL6061	155
槽内等效部件	等效后材料	0.93
永磁体	NdFeB	7.7
转子磁轭	SMC	25
水冷壳体	AL6061	155
电机轴	45#钢	48

转速/ （r·min^-1）	优化前电机效率/%	优化前测试效率/%	优化后电机效率/%	优化后测试效率/%
1 000	81.5	80.8	82.1	81.6
2 000	85.7	85.2	86.9	86.3
3 000	89.1	88.5	90.9	90.3
4 000	90.9	90.7	94.0	93.8

参数	原型	优化后
峰值功率/kW	50	65
功率密度/（kW·kg^-1）	2.22	3.02

Optimization of Eddy Current Loss of the New Cooling System of Axial Flux Motors

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