Optimization and Performance Comparison of Hairpin?Winding PMSM for Electric Vehicles Under Drive Cycle

循环工况下车用扁铜线绕组永磁同步电机性能优化与对比

Aiming at the problem of large AC copper loss caused by skin effects and proximity effects,and low efficiency at high speed of the hairpin-winding permanent magnet synchronous motor(PMSM)for electric vehicles(EVs),this paper firstly established the electromagnetic analytical model of the hairpin winding to calculate AC resistance.And the finite element model(FEM)of the hairpin-winding driving motor is established to calculate the AC characteristic of the hairpin winding at different speeds and temperatures.Then,combining modified particle swarm optimization(MPSO)and FEM,a 60 k W hairpin-winding PMSM is optimized under driving cycle conditions,and the electromagnetic performance and heat dissipation performance are compared with that of the traditional strand-winding motor.Finally,a prototype is made and an experimental platform is built to test the efficiency Map and temperature rise of the hairpin-winding motor over the whole speed range and verify the accuracy of the proposed optimization design method.The results show that the hairpin-winding PMSM not only has higher slot filling rate,high?efficiency range and power density,but also has better heat dissipation performance,which is suitable for application in the field of electric vehicles.

针对车用扁铜线绕组永磁同步电机高速时绕组中交流损耗大、效率低的问题,首先运用电磁场理论建立扁铜线绕组交流电阻的解析模型,得到定子扁铜线绕组交流电阻的解析表达式,并建立电机有限元模型仿真计算扁铜线绕组在不同转速和不同温度下的交流损耗特性。然后,结合有限元模型和改进粒子群优化算法对一台60 k W车用扁铜线绕组永磁同步电机进行循环工况下性能优化设计,并将优化后结果与散线绕组电机进行电磁、散热性能对比分析。最后,制作样机并搭建实验平台,测试了扁铜线绕组电机在全转速下的效率Map和温升等性能。结果表明,扁铜线绕组永磁同步电机不仅具有较高的高效区间和功率密度,还具有较好的散热性能,适合应用于电动汽车驱动领域。