Design and FEA analysis of hub based dual rotor machine for optimal energy generation in four wheeled electric vehicle application

Abstract

This research article focuses on the design and Finite Element Analysis (FEA) analysis of a hub-based Dual Rotor Machine (DRM). Conventional, electric machines can perform either motoring or generating operations at an instant of time for electric vehicle (EV) applications. However, the proposed DRM can perform both motoring and generating modes of operation simultaneously. For this dual operation, a power rating of 15 kW Brushless DC Machine is selected with outer rotor configuration to achieve high starting torque in motoring operation and a power rating of 6 kW Permanent Magnet Synchronous Machine is considered for generating operation with an inner rotor. Based on theoretical results, the design of DRM is developed and analysed using FEA software programs such as MagNet, Jmag and ThermNet. By using a two-dimensional (2-D) transient solver, the proposed DRM performance is simulated and validated with cogging torque, electromagnetic, thermal and stress analysis. The performance of the proposed DRM model is also tested with drive cycle data of WLTP-II (Worldwide Harmonised Light Vehicle Test Procedure) in ANSYS Motor-CAD software. The simulation results confirm the proposed DRM can consume only 252 Wh over 405 Wh energy consumed by a single rotor machine and ensuring its applicability for EV applications.