Design and research of multi-layer built-in permanent magnet synchronous motor for hairpin winding
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.
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