A high torque density, direct drive in-wheel motor for electric vehicles

The use of in-wheel motors as a source of propulsion for electric vehicles is particularly attractive because they offer new levels of controllability in the vehicle, whilst also freeing up space within the main body of the car. The in-wheel motor is housed in the rim, alongside existing mechanical brakes and suspension systems. This produces tight space constraints, so that the motor and drive electronics must both be power dense and compact. The motor must also offer high efficiency, low cogging torque and be intrinsically fail safe. This paper examines the design options for a direct drive in-wheel motor for use in passenger and light commercial vehicles. The study focuses on achieving high torque density whilst considering magnetic, mechanical, electrical and physical limitations posed on the motor. (6 pages)

[1]  Barrie Mecrow,et al.  Operation of fault tolerant machines with winding failures , 1997, 1997 IEEE International Electric Machines and Drives Conference Record.

[2]  Geraint W. Jewell,et al.  Multiphase Flux-Switching Permanent-Magnet Brushless Machine for Aerospace Application , 2008, IEEE Transactions on Industry Applications.

[3]  J.A. Ferreira,et al.  Selecting an optimum number of system phases for an integrated, fault tolerant permanent magnet machine and drive , 2009, 2009 13th European Conference on Power Electronics and Applications.

[4]  Z. Rahman,et al.  Evaluating radial, axial and transverse flux topologies for 'in-wheel' motor , 2004, Power Electronics in Transportation (IEEE Cat. No.04TH8756).

[5]  D. J. Adams,et al.  Nature and assessments of torque ripples of permanent-magnet adjustable-speed motors , 1995, IAS '95. Conference Record of the 1995 IEEE Industry Applications Conference Thirtieth IAS Annual Meeting.

[6]  B. K. Gupta,et al.  Use of thermal cycling as type test for turn insulation in motor coils , 1994, Proceedings of 1994 IEEE International Symposium on Electrical Insulation.

[7]  J.X. Shen,et al.  Influence on Rotor Eddy-Current Loss in High-Speed PM BLDC Motors , 2006, Proceedings of the 41st International Universities Power Engineering Conference.

[8]  Ambarish Kulkarni,et al.  Design procedure for low cost, low mass, direct drive, in-wheel motor drivetrains for electric and hybrid vehicles , 2011, IECON 2011 - 37th Annual Conference of the IEEE Industrial Electronics Society.

[9]  R. Spee,et al.  The design and development of an axial flux permanent magnet brushless DC motor for wheel drive in a solar powered vehicle , 1994, Proceedings of 1994 IEEE Industry Applications Society Annual Meeting.

[10]  M. D. McCulloch,et al.  Axial flux permanent magnet machines: A new topology for high performance applications , 2006 .

[11]  David G. Dorrell,et al.  Comparison of different motor design drives for hybrid electric vehicles , 2010, 2010 IEEE Energy Conversion Congress and Exposition.

[12]  Jing Zhao,et al.  Investigation of a Novel Five-Phase Modular Permanent-Magnet In-Wheel Motor , 2011, IEEE Transactions on Magnetics.

[13]  Tadashi Ashikaga,et al.  Novel motors and controllers for high-performance electric vehicle with four in-wheel motors , 1997, IEEE Trans. Ind. Electron..

[14]  F. Crescimbini,et al.  Application of direct drive wheel motor for fuel cell electric and hybrid electric vehicle propulsion system , 2004, Conference Record of the 2004 IEEE Industry Applications Conference, 2004. 39th IAS Annual Meeting..

[15]  Z. Zhu,et al.  Influence of design parameters on cogging torque in permanent magnet machines , 1997 .

[16]  Wilfried Hofmann,et al.  Design optimization of permanent magnet motors by evolution strategies and finite element analysis , 1999, IEMDC 1999.

[17]  K. Sitapati,et al.  Performance comparisons of radial and axial field, permanent magnet, brushless machines , 2000, Conference Record of the 2000 IEEE Industry Applications Conference. Thirty-Fifth IAS Annual Meeting and World Conference on Industrial Applications of Electrical Energy (Cat. No.00CH37129).

[18]  Shumei Cui,et al.  A comparative study of the interior permanent magnet electrical machine’s rotor configurations for a single shaft hybrid electric bus , 2008, 2008 IEEE Vehicle Power and Propulsion Conference.

[19]  M.J. Kamper,et al.  Design and Performance Evaluation of Concentrated Coil Permanent Magnet Machines for In-Wheel Drives , 2007, 2007 IEEE International Electric Machines & Drives Conference.

[20]  Barrie Mecrow,et al.  Fault-tolerant permanent magnet machine drives , 1995 .

[21]  Myung-Ryul Choi,et al.  Effect of Pole and Slot Combination on Noise and Vibration in Permanent Magnet Synchronous Motor , 2010, IEEE Transactions on Magnetics.

[22]  R.A. Hanna,et al.  Failure Analysis of Three Slow-Speed Induction Motors for Reciprocating Load Application , 2007, IEEE Transactions on Industry Applications.

[23]  Nicola Bianchi,et al.  Thermal Analysis of a Five-Phase Motor Under Faulty Operations , 2013, IEEE Transactions on Industry Applications.

[24]  D. Howe,et al.  Influence of slot number and pole number in fault-tolerant brushless dc motors having unequal tooth widths , 2005 .

[25]  Xia Jing,et al.  Double-Stator Permanent Magnet Synchronous In-Wheel Motor For Hybrid Electric Drive System , 2008 .

[26]  Ayman M. El-Refaie,et al.  Fractional-Slot Concentrated-Windings Synchronous Permanent Magnet Machines: Opportunities and Challenges , 2010, IEEE Transactions on Industrial Electronics.

[27]  Chai Feng,et al.  Double-Stator Permanent Magnet Synchronous in-Wheel Motor for Hybrid Electric Drive System , 2009, IEEE Transactions on Magnetics.

[28]  Ryoji Mizutani,et al.  Optimum design approach for low-speed, high-torque permanent magnet motors , 2001 .

[29]  M.J. Kamper,et al.  Effect of Hub Motor Mass on Stability and Comfort of Electric Vehicles , 2006, 2006 IEEE Vehicle Power and Propulsion Conference.

[30]  Marcelo Godoy Simões,et al.  A high-torque low-speed multiphase brushless machine-a perspective application for electric vehicles , 2002, IEEE Trans. Ind. Electron..

[31]  Ezio Santini,et al.  Multi-stage axial-flux PM machine for wheel direct drive , 1995 .

[32]  A.M. El-Refaie,et al.  Analysis of surface permanent magnet machines with fractional-slot concentrated windings , 2006, IEEE Transactions on Energy Conversion.

[33]  Thomas A. Lipo,et al.  Field Weakening in Buried Permanent Magnet AC Motor Drives , 1985, IEEE Transactions on Industry Applications.

[34]  N. Bianchi,et al.  Magnetic Loading of Fractional-Slot Three-Phase PM Motors With Nonoverlapped Coils , 2008, IEEE Transactions on Industry Applications.

[35]  Hyun-Kyo Jung,et al.  A Research on Iron Loss of IPMSM With a Fractional Number of Slot Per Pole , 2009, IEEE Transactions on Magnetics.

[36]  Iqbal Husain,et al.  Design, Modeling and Simulation of an Electric Vehicle System , 1999 .

[37]  Hamid A. Toliyat,et al.  Fault-Tolerant Interior-Permanent-Magnet Machines for Hybrid Electric Vehicle Applications , 2007, IEEE Transactions on Vehicular Technology.

[38]  Zi-Qiang Zhu,et al.  Electrical Machines and Drives for Electric, Hybrid, and Fuel Cell Vehicles , 2007, Proceedings of the IEEE.

[39]  R. Nilssen,et al.  Performance Comparisons Among Radial-Flux, Multistage Axial-Flux, and Three-Phase Transverse-Flux PM Machines for Downhole Applications , 2010, IEEE Transactions on Industry Applications.

[40]  A. Emadi,et al.  Comprehensive drive train efficiency analysis of hybrid electric and fuel cell vehicles based on motor-controller efficiency modeling , 2006, IEEE Transactions on Power Electronics.

[41]  Kum-Kang Huh,et al.  Rotor End Losses in Multiphase Fractional-Slot Concentrated-Winding Permanent Magnet Synchronous Machines , 2011, IEEE Transactions on Industry Applications.

[42]  A. G. Jack,et al.  Reliability analysis of fault tolerant drive topologies , 2008 .

[43]  Z.Q. Zhu,et al.  Permanent magnet brushless machines with unequal tooth widths and similar slot and pole numbers , 2004, Conference Record of the 2004 IEEE Industry Applications Conference, 2004. 39th IAS Annual Meeting..

[44]  A. Boglietti,et al.  Solving the more difficult aspects of electric motor thermal analysis in small and medium size industrial induction motors , 2005, IEEE Transactions on Energy Conversion.

[45]  Gan Zhang,et al.  A Novel Hybrid Excitation Flux-Switching Motor for Hybrid Vehicles , 2009, IEEE Transactions on Magnetics.

[46]  Kum-Kang Huh,et al.  Effect of number of layers on performance of fractional-slot concentrated-windings interior permanent magnet machines , 2011, 8th International Conference on Power Electronics - ECCE Asia.

[47]  Bob Brant,et al.  Build Your Own Electric Vehicle , 1993 .

[48]  F. Caricchi,et al.  Influence of magnetic wedges on the no-load performance of axial flux permanent magnet machines , 2010, 2010 IEEE International Symposium on Industrial Electronics.

[49]  P. Viarouge,et al.  Synthesis of High-Performance PM Motors with Concentrated Windings , 2002, IEEE Power Engineering Review.

[50]  Kais Atallah,et al.  Modular Three-Phase Permanent-Magnet Brushless Machines for In-Wheel Applications , 2008, IEEE Transactions on Vehicular Technology.

[51]  C. C. Chan,et al.  The state of the art of electric and hybrid vehicles , 2002, Proc. IEEE.

[52]  Andrés Eduardo Rojas Rojas,et al.  Comfort and Safety Enhancement of Passenger Vehicles with In-Wheel Motors , 2010 .

[53]  Jiabin Wang,et al.  Three-phase modular permanent magnet brushless Machine for torque boosting on a downsized ICE vehicle , 2005, IEEE Transactions on Vehicular Technology.

[54]  Demba Diallo,et al.  Electric Motor Drive Selection Issues for HEV Propulsion Systems: A Comparative Study , 2005, IEEE Transactions on Vehicular Technology.

[55]  Thomas M. Jahns,et al.  Flux-Weakening Regime Operation of an Interior Permanent-Magnet Synchronous Motor Drive , 1987, IEEE Transactions on Industry Applications.

[56]  F. M. Miles,et al.  Principles of fault tolerance , 1996, Proceedings of Applied Power Electronics Conference. APEC '96.

[57]  M. Niemela,et al.  Performance analysis of fractional slot wound PM-motors for low speed applications , 2004, Conference Record of the 2004 IEEE Industry Applications Conference, 2004. 39th IAS Annual Meeting..

[58]  N. Bianchi,et al.  Analysis of a three-phase in-wheel electric motor , 2009, 2009 44th International Universities Power Engineering Conference (UPEC).

[59]  Sheldon S. Williamson,et al.  Suitability analysis of in-wheel motor direct drives for electric and hybrid electric vehicles , 2009, 2009 IEEE Electrical Power & Energy Conference (EPEC).

[60]  M. F. Beavers Determination of Equations and Constants for Life Expectancy Studies for Transformers and Similar Apparatus , 1967 .

[61]  A.G. Jack,et al.  Permanent magnet machines with powdered iron cores and pre-pressed windings , 1999, Conference Record of the 1999 IEEE Industry Applications Conference. Thirty-Forth IAS Annual Meeting (Cat. No.99CH36370).

[62]  X.D. Xue,et al.  Selection of eLECTRIC mOTOR dRIVES for electric vehicles , 2008, 2008 Australasian Universities Power Engineering Conference.

[63]  Barrie Mecrow,et al.  High torque machines for power hand tool applications , 2002 .

[64]  Antonios G. Kladas,et al.  Internal Permanent Magnet Motor Design for Electric Vehicle Drive , 2010, IEEE Transactions on Industrial Electronics.

[65]  Jian Guo Zhu,et al.  Development of a PM transverse flux motor with soft magnetic composite core , 2006, IEEE Transactions on Energy Conversion.

[66]  Bernd Orlik,et al.  Transverse flux machines with distributed windings for in-wheel applications , 2009, 2009 International Conference on Power Electronics and Drive Systems (PEDS).

[67]  Barrie Mecrow,et al.  Design of an in-wheel motor for a solar-powered electric vehicle , 1997 .

[68]  A. Gattozzi,et al.  Challenges in the design of a 100 kw induction motor for a PHEV application , 2009, 2009 IEEE Vehicle Power and Propulsion Conference.

[69]  Nicola Bianchi,et al.  Slot Harmonic Impact on Rotor Losses in Fractional-Slot Permanent-Magnet Machines , 2012, IEEE Transactions on Industrial Electronics.

[70]  T.J. Woolmer,et al.  Analysis of the Yokeless And Segmented Armature Machine , 2007, 2007 IEEE International Electric Machines & Drives Conference.

[71]  Martyn J. Anderson Unsprung Mass with In-Wheel Motors-Myths and Realities , 2010 .

[72]  Shuangxia Niu,et al.  Design and Analysis of a Novel Axial-Flux Electric Machine , 2011, IEEE Transactions on Magnetics.

[73]  Juliette Soulard,et al.  Design Study of Different Direct-Driven Permanent-Magnet Motors for a Low Speed Application , 2004 .

[74]  Hamid A. Toliyat,et al.  Multi-phase fault-tolerant brushless DC motor drives , 2000, Conference Record of the 2000 IEEE Industry Applications Conference. Thirty-Fifth IAS Annual Meeting and World Conference on Industrial Applications of Electrical Energy (Cat. No.00CH37129).

[75]  Rukmi Dutta,et al.  An investigation of a segmented rotor interior permanent magnet (IPM) machine for field weakening , 2003, The Fifth International Conference on Power Electronics and Drive Systems, 2003. PEDS 2003..

[76]  N. Bianchi,et al.  Design considerations on fractional-slot fault-tolerant synchronous motors , 2005, IEEE International Conference on Electric Machines and Drives, 2005..

[77]  Yee-Pien Yang,et al.  Design and application of axial-flux permanent magnet wheel motors for an electric vehicle , 2009, AFRICON 2009.

[78]  T. M. Jahns,et al.  Design, analysis and fabrication of a high-performance fractional-slot concentrated winding surface PM machine , 2010, 2010 IEEE Energy Conversion Congress and Exposition.

[79]  J. S. Hsu REPORT ON TOYOTA/PRIUS MOTOR TORQUE CAPABILITY, TORQUE PROPERTY, NO-LOAD BACK EMF, AND MECHANICAL LOSSES , 2004 .

[80]  Z.Q. Zhu,et al.  Comparison of PM brushless motors, having either all teeth or alternate teeth wound , 2006, IEEE Transactions on Energy Conversion.

[81]  J. Lichtblau,et al.  World oil outlook , 1985 .

[82]  H.A. Toliyat,et al.  Five-Phase Interior Permanent-Magnet Motors With Low Torque Pulsation , 2005, IEEE Transactions on Industry Applications.

[83]  B. C. Mecrow,et al.  Three-Phase Modulated Pole Machine Topologies Utilizing Mutual Flux Paths , 2012, IEEE Transactions on Energy Conversion.

[84]  B. Mecrow,et al.  A wound-field three-phase flux-switching synchronous motor with all excitation sources on the stator , 2009, 2009 IEEE Energy Conversion Congress and Exposition.

[85]  John James Anthony Cullen,et al.  Implications of shorted turn faults in bar wound PM machines , 2004 .

[86]  Ali Emadi,et al.  Novel Switched Reluctance Machine Configuration With Higher Number of Rotor Poles Than Stator Poles: Concept to Implementation , 2010, IEEE Transactions on Industrial Electronics.

[87]  Makoto Abe,et al.  Development of High Response Motor and Inverter System for the Nissan LEAF Electric Vehicle , 2011 .

[88]  King Jet Tseng,et al.  Computer-aided design and analysis of direct-driven wheel motor drive , 1997 .

[89]  Barrie Mecrow,et al.  A comparative study of permanent magnet and switched reluctance motors for high-performance fault-tolerant applications , 1995 .

[90]  Tao Fan,et al.  Lifetime model research of motor drive system for electric vehicles , 2007, 2007 International Conference on Electrical Machines and Systems (ICEMS).

[91]  B.C. Mecrow,et al.  Design and testing of a four-phase fault-tolerant permanent-magnet machine for an engine fuel pump , 2004, IEEE Transactions on Energy Conversion.

[92]  T.A. Lipo,et al.  Fault tolerant three-phase AC motor drive topologies: a comparison of features, cost, and limitations , 2003, IEEE Transactions on Power Electronics.

[93]  John James Anthony Cullen,et al.  Favourable slot and pole number combinations for fault-tolerant PM machines , 2004 .

[94]  C. V. D. Linde,et al.  The Organization of the Petroleum Exporting Countries , 1991 .

[95]  Hans Bernhoff,et al.  Electrical Motor Drivelines in Commercial All-Electric Vehicles: A Review , 2012, IEEE Transactions on Vehicular Technology.

[96]  Charles R. Sullivan,et al.  Computationally efficient winding loss calculation with multiple windings, arbitrary waveforms, and two-dimensional or three-dimensional field geometry , 2001 .

[97]  N. Ertugrul,et al.  Effect of pole and slot number changes on the performance of a surface PM machine , 2012, 2012 XXth International Conference on Electrical Machines.

[98]  Munehiro Kamiya,et al.  Development of Traction Drive Motors for the Toyota Hybrid System , 2006 .

[99]  Marco Villani,et al.  High Reliability Permanent Magnet Brushless Motor Drive for Aircraft Application , 2012, IEEE Transactions on Industrial Electronics.

[100]  Hamid A. Toliyat,et al.  Propulsion system design of electric and hybrid vehicles , 1997, IEEE Trans. Ind. Electron..

[101]  Liwei Song,et al.  Study on Improving the Performance of Permanent Magnet Wheel Motor for the Electric Vehicle Application , 2007, IEEE Transactions on Magnetics.

[102]  Zheng Zhang,et al.  Axial flux machines drives: a new viable solution for electric cars , 1997, IEEE Trans. Ind. Electron..

[103]  S Bolognani,et al.  An Overview of Rotor Losses Determination in Three-Phase Fractional-Slot PM Machines , 2010, IEEE Transactions on Industry Applications.

[104]  E. Brancato Life expectancy of motors , 1991, IEEE Electrical Insulation Magazine.

[105]  M.T. Abolhassani,et al.  A novel multiphase fault tolerant high torque density permanent magnet motor drive for traction application , 2005, IEEE International Conference on Electric Machines and Drives, 2005..

[106]  B. C. Mecrow,et al.  Application of fractional slot concentrated windings to synchronous reluctance machines , 2013, 2013 International Electric Machines & Drives Conference.

[107]  Phil Mellor,et al.  Faulted behaviour of permanent magnet electric vehicle traction drives , 2003, IEEE International Electric Machines and Drives Conference, 2003. IEMDC'03..

[108]  Duane C. Hanselman,et al.  Brushless Permanent-Magnet Motor Design , 1994 .