Multiphysics Analysis of an Axial-Flux In-Wheel Motor With an Amorphous Alloy Stator

Abstract

This paper presents a novel yokeless and segmented armature (YASA) axial-flux in-wheel motor with amorphous magnetic material (AMM) stator cores for a solar-powered electric vehicle. Although this new axial-flux in-wheel motor has many advantages such as high efficiency, shorter axial length, and high power density, its working condition is complicated. In-wheel motors are usually operated in electromagnetic, thermal, and other multiphysics environments. Increasing the performance requirements of in-wheel motors, such as power density, efficiency, and reliability, requires a multiphysics design approach. The focus of this paper is on the analysis of electromagnetic characteristics, losses, temperature distribution, mechanical behavior and other characteristics of the axial-flux in-wheel motor. The back electromotive force (EMF) and electromagnetic torque of the motor with harmonic current are obtained by the 3-D finite element method (FEM). The permanent magnet (PM) eddy-current losses when using different PM shapes are studied. The equivalent thermal model of the tape-wound AMM stator segments and the windings are established, and the temperature distribution of the motor is obtained. The mechanical behavior of the stator segments and the rotor disks when the motor is eccentric and axially offset is analyzed, and the structural strength of the motor is evaluated. Finally, a prototype of the motor is fabricated, and the electromagnetic performance and temperature of the motor are tested to verify the accuracy of the multiphysics design approach.