摘要
针对电动汽车驱动电机性能需求日益提升的现状,设计了一种车用发卡绕组多层磁钢内置式永磁同步电机,保证高功率密度、高效率的设计要求。利用有限元方法建立4种发卡绕组多层磁钢内置式永磁同步电机的二维模型,在转子分段斜极优化的基础上,比较4种电机的性能,探究多层磁钢结构中不同永磁体对电机性能的影响,选择最合适的结构进行后续多次优化;利用田口算法对电机磁钢尺寸设计进行优化,通过参数对优化目标影响的比重选出最优组合;对优化后的电机进行Halbach充磁,对每层磁钢分别利用同一角度充磁,进行参数化扫描寻优,选择最合适的一层充磁,并选择最合适的充磁角度及对应的充磁长度获取最优性能。结果表明:多次优化后的电机在保证较高平均转矩的基础上,转矩脉动与齿槽转矩大幅降低,可满足新能源汽车电机的性能需求。
In light of the escalating demands for enhanced performance in electric vehicle(EV)drive motors,this study has pioneered the development of a bespoke hairpin winding multi-layer magnet internal permanent magnet synchronous motor(IPMSM),tailored specifically for automotive applications.The objective of this innovative design is to achieve superior power density and operational efficiency,which are critical benchmarks for the success of EVs in the rapidly evolving market.The inception of this project involved a rigorous theoretical grounding,where the research team delved into the mathematical models and analytical equations governing the behavior of drive motors.Leveraging the sophisticated tool of finite element analysis(FEA),they constructed four distinct two-dimensional models of hairpin winding multi-layer magnet IPMSMs.These models served as the digital blueprints for the subsequent stages of the project.To refine the rotor’s performance,the team implemented a technique known as segmented skew optimization.This approach involves strategically altering the alignment of the rotor segments to mitigate issues such as torque ripple and cogging torque,which can adversely affect the smoothness and responsiveness of the motor.Through meticulous comparison of the four modeled motors,the team scrutinized a suite of critical performance metrics,including average torque,torque ripple,cogging torque,the fundamental amplitude and distortion rate of back electromotive force,and the fundamental amplitude and distortion rate of radial air gap magnetic density.The comparative analysis shed light on the nuanced effects of various permanent magnet configurations within the multi-layer magnet structure,ultimately leading to the identification of the optimal motor architecture—a pivotal stepping stone for future optimizations.Building upon this foundational work,the researchers adopted the Taguchi method,a robust statistical technique renowned for its efficacy in optimizing product designs while minimizing the number of experiments required.The Taguchi method was harnessed to pinpoint the ideal magnet dimension combination that would yield the highest possible average torque while curbing torque ripple to its lowest potential.An experimental orthogonal table was meticulously crafted,and through the calculation of level numbers and delta values,the team conducted a comprehensive assessment of the impact of each design parameter on the overarching optimization goals.This systematic evaluation culminated in the selection of the optimal parameter level values,which were then synthesized to create the most advantageous magnet dimension combination.In the penultimate phase of the project,the team turned their attention to the application of Halbach magnetization to the motor magnets,following a secondary round of optimization.The Halbach array,a clever arrangement of magnets that enhances the magnetic field on one side while diminishing it on the other,was employed with the dual aim of stabilizing torque ripple and reducing cogging torque.The optimization process commenced with the magnetization of each magnet layer at a uniform angle,followed by a parametric scanning optimization to fine-tune the configuration.Upon thorough analysis and comparison of the resultant data,the most efficacious layer of magnet was earmarked for further refinement.The magnetization angle was subsequently adjusted within a defined range,and through iterative optimization,the most propitious magnetization angle and corresponding length were ascertained to unlock the motor’s peak performance capabilities.The findings of this research underscore the profound influence of the V-shaped magnet within the multi-layer magnet structure.Notably,when the V-shaped magnet is endowed with an apt Halbach structure,the motor’s performance undergoes a transformative enhancement.This revelation underscores the immense potential for performance optimization inherent in the strategic manipulation of the V-shaped magnet’s design.Following a sequence of intricate optimization maneuvers,the targeted motor emerged as a paragon of excellence,boasting a high average torque while simultaneously exhibiting markedly reduced torque ripple and cogging torque.The cumulative effect of these refinements catapulted the motor’s overall performance to an extraordinary level,surpassing conventional expectations.Furthermore,the motor’s magnetic path distribution achieved a harmonious uniformity,and the structural integrity and mechanical robustness of the motor were impeccably balanced,aligning seamlessly with the stringent design imperatives for high power density and efficiency in contemporary new energy vehicle motors.In conclusion,this study represents a seminal contribution to the field of EV technology,offering a meticulously engineered solution that addresses the pressing need for advanced drive motor performance.The innovative design and optimization strategies presented herein pave the way for a new generation of EVs that are poised to redefine the boundaries of sustainable transportation.
作者
林涵
张宇航
王仲根
邓天龙
LIN Han;ZHANG Yuhang;WANG Zhonggen;DENG Tianlong(School of Electrical and Information Engineering,Anhui University of Science and Technology,Huainan 232001,China)
出处
《重庆理工大学学报(自然科学)》
CAS
北大核心
2024年第7期228-239,共12页
Journal of Chongqing University of Technology:Natural Science
基金
安徽省自然科学基金项目(1808085QF197)
安徽高校自然科学重点项目(KJ2020A307)。
关键词
发卡绕组
多层内置式永磁同步电机
田口算法
Halbach充磁
参数化扫描
hairpin winding
permanent magnet synchronous motors with built-in multilayer magnets
Taguchi algorithm
Halbach magnetization
parametric scanning