Analysis and Optimization of Key Dimensions of Co-Axial Dual-Mechanical-Port Flux-Switching Permanent Magnet Machines for Fuel-Based Extended Range Electric Vehicles

In this paper,key dimensions of a co-axial dual-mechanical-port flux-switching permanent magnet(CADMP-FSPM)machine for fuel-based extended range electric vehicles(ER-EVs),including split ratio,stator/rotor pole arcs,rotor yoke thickness,etc.,are analyzed and optimized.Firstly,the topologies and operation principles of an exampled 3-phase CADMP-FSPM are introduced briefly,in which an inner-rotor FSPM machine with 12-stator-slots/10-rotor-poles for high-speed generation and an outer-rotor FSPM machine with 12-stator-slots/22-rotor-poles for low-speed motoring are assembled co-axially.Then,the relationship between the key dimensions and electromagnetic performance,particularly for electromagnetic torque(power),of the CADMP-FSPM machine is studied by 2D-finite element analysis(FEA).Further,the reasonable matches of split ratio,rotor/stator pole arcs and rotor yoke are determined and the original CADMP-FSPM machine is optimized correspondingly.Finally,the static characteristics,including no-load PM flux-linkage,electro-motive-force(EMF),winding inductances,cogging torques and electromagnetic torques,of the original and optimized machines are compared by 2D-FEA.The results verify that the optimized CADMP-FSPM machine can exhibit improved torque characteristics than the original one,i.e.,the torque ripples of the inner and outer machines can be reduced by 22.7%and 4.7%,respectively,and the average torque of the inner and outer machines can be increased by 0.43Nm and 2Nm,respectively.