CN104331573A - Optimized design method of brushless composite structure motor system - Google Patents
Optimized design method of brushless composite structure motor system Download PDFInfo
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Abstract
The invention relates to an optimized design method of a brushless composite structure motor system. The method comprises the steps: establishing a mathematic model of a brushless claw-pole two-rotor motor, and analyzing parameters and performance of the motor; establishing a three-dimensional finite-element model of the motor, analyzing the distribution situation of an electromagnetic field inside the motor, calculating the parameter and the performance of the motor, adopting a two-dimensional equivalent limit-element model to simulate the three-dimensional finite-element model, analyzing a relation between a torque density and toothed groove torque and main structural parameters of the brushless claw-pole two-rotor motor, and testing a function of a test sample machine by adopting a finite-element simulation method to set the parameter of the sample machine. The brushless claw-pole two-rotor motor is adopted as one part of the brushless composite structure motor system, so that the problems that the rotor windings in the brush composite motor severely produces heat and an electric brush slide ring needs to feed can be solved.
Description
Technical field
The invention belongs to electric motor of automobile technical field, be specifically related to a kind of Optimization Design of brushless composite structure motor system.
Background technology
Energy crisis and environmental pollution are two hang-ups of restriction orthodox car development.In world wide, economic development causes car owning amount to increase fast, and the petroleum consumption that mechanical transport is brought significantly rises, and causes this limited oil storage resource day by day to reduce.On the other hand, containing carbon dioxide, methane and nitrous oxide isothermal chamber gas in the tail gas of motor vehicle emission, manufacture serious exhaust emission, accelerate the climate warming in the whole world.The appearance of problem impels people to use a series of technological means to improve existing automobile driving system, improves the fuel economy of automobile, reduces the emission level of automobile, therefore the study hotspot be developed in order to automotive field in recent years of novel electric vehicle.
The various electric automobiles of current research and development are mainly divided into three types, i.e. pure electric automobile, hybrid vehicle and fuel cell car.Wherein pure electric automobile can realize zero-emission, but is subject to the restriction of storage battery energy density, and distance travelled of once charging is shorter, can only use between the down town of short distance, low speed and community.Fuel cell car has very large development potentiality, but current high cost, its hydrogen-oxygen fuel supply system also also exists technical matters to be solved, is temporarily difficult to industrialization.And hybrid vehicle utilizes electric power process auxiliary drive, can make up the inherent defect that internal combustion engine drive exists, energy source of car can both be optimized utilization under various operating condition, is the ideal scheme of automotive energy-saving emission-reducing under the present art.
Composite structure motor is the most advanced kind for hybrid electric vehicle field---series parallel hybrid power scheme, provides a kind of novel solution route with principle advance and scheme practicality.This technical scheme adopts the composite structure motor with two different rotating speeds output shafts to regulate speed discrepancy between engine and main reducing gear and torque differences, makes internal combustion engine operation in high efficiency region, thus reaches good energy-saving effect.The brush-free claw-pole double-rotor machine studied herein is a kind of motor with novel arrangement, and be different from conventional motors and have a stator and a rotor, it has a stator and two rotors, can coordinate form brushless composite structure motor with another motor.The internal rotor winding that can solve the past has brush composite structure motor scheme to exist seriously generates heat and needs the problem of electric brush slip ring feed, improves the practicality of motor, place system is become be expected to the hybrid power new transmission mechanism of going into operation.
Composite structure motor is that the height of two motors is integrated, as Fig. 1, this motor, as a kind of core component of emerging series-parallel hybrid electric system, can distribute the energy flow of internal combustion engine and accumulator, reaches the object improving VE Vehicle Economy and reduce exhaust emissions.At present in the world to there being the research of brush composite structure motor to be tending towards ripe, existing research work demonstrates feasibility and the advance of the program, but also shows the problem that the program exists internal rotor winding and seriously generates heat and need electric brush slip ring feed.
Summary of the invention
In order to overcome the deficiencies in the prior art, the invention provides a kind of Optimization Design of brushless composite structure motor system.
Technical scheme of the present invention is: a kind of Optimization Design of brushless composite structure motor system, comprises the steps: step one: the mathematical model setting up brush-free claw-pole double-rotor machine; Step 2: the parameter of brush-free claw-pole double-rotor machine and performance evaluation; Step 3: the three-dimensional finite element model setting up brush-free claw-pole double-rotor machine, analyze the magnetic distribution situation of motor internal, calculate parameter and the performance of motor, comprise the calculating of the close analysis of unloaded magnetic, the analysis of no-load back electromotive force, magnetic leakage factor and reactance parameter; Step 4: the three-dimensional finite element model simplifying brush-free claw-pole double-rotor machine, adopts two dimensional equivalent finite element model to emulate three-dimensional finite element model, makes two-dimensional finite element model have the magnetic resistance identical with three-dimensional model and mmf on every section of magnetic flux path; Step 5: adopt analytic method to analyze torque density and the relation between cogging torque and brush-free claw-pole double-rotor machine main structure parameters, then adopt finite element simulation methods analyst permanent magnet rotor structure, number of pole-pairs, physical dimension, gas length and pawl pole shape on the impact of motor torque performance, given model machine parameter determination method.Step 6: analyze motor power factor, the loss of electric machine and efficiency, the analysis of power factor comprises the analysis of magnet size, umber of turn and input current.Step 7: the function of test experiments model machine, if test data meets performance index, terminates, if do not met, returns step 2.Described step one comprises two steps, the first step: the structure simplifying brush-free claw-pole double-rotor machine, and ignore saturation effects, magnetic hysteresis and vortes interference, magnetic circuit is the impact linearly ignoring slot effect and commutation process, ignores frequency and temperature to the impact of winding; Second step: analytic system structure founding mathematical models.Described step 2 comprises magnetic circuit parameters analysis, the analysis of magnetic flux and electromagnetic torque and reactance parameter analysis.The two dimensional equivalent finite element model of described step 4 comprises: equivalent pawl pole, equivalent stator winding, equivalent stator core.In described step 5 model machine parameter be model machine to very 6 to, size than being chosen as 4.5, the span of the equal value 0.8mm of ectonexine gas length, pawl point pole embrace is 0.1 ~ 0.4, the span of radix unguis pole embrace is 1 ~ 1.1.In described step 7, functional test comprises: no-load back electromotive force test, cogging torque test, open circuit loss and efficiency test, current phase angle are on the test of the test of the impact of power factor and rotational speed regulation function.
The present invention has following good effect: the structure parameter optimizing method that The present invention gives brush-free claw-pole double-rotor machine, as a part for brushless composite structure motor system, solve brush composite structure motor internal rotor winding and seriously generate heat and need the problem of electric brush slip ring feed.More, from basic electromagnetic theory, theoretical analysis is carried out to power factor problem, on this basis, inquired into the impact on power factor of magnet size, umber of turn and input current, proposed the effective ways improving power factor.Give the computing method of the various loss of motor afterwards, and the efficiency of motor and power density situation under analyzing rated operation further, for model machine manufacture and design and in electric motor car, application provides theoretical foundation.
Accompanying drawing explanation
Fig. 1 is the structural drawing of specific embodiment of the invention brushless composite structure motor;
Fig. 2 is the experimental platform system block diagram of the brush-free claw-pole double-rotor machine of the specific embodiment of the invention.
Embodiment
Contrast accompanying drawing below, by the description to embodiment, the specific embodiment of the present invention is as the effect of the mutual alignment between the shape of involved each component, structure, each several part and annexation, each several part and principle of work, manufacturing process and operation using method etc., be described in further detail, have more complete, accurate and deep understanding to help those skilled in the art to inventive concept of the present invention, technical scheme.
Brushless composite structure motor of the present invention is brush-free claw-pole double-rotor machine, brush-free claw-pole double-rotor machine based on claw-pole motor principle propose, it analytical approach with study a question on there is a lot of identical points with traditional claw-pole motor.This motor and conventional radial flux motors have larger different, it relies on the effect of pawl pole that the radial flux in motor is converted to axial magnetic flux, thus the main flux path of motor spatially presents distributed in three dimensions, and the Magnetic fluxleakage distribution situation also more complicated of whole motor.Special construction makes the operation mechanism of this kind of motor and method for designing widely different compared with conventional motor.The Study on topology of claw-pole motor experienced by a development constantly explored, and progressively defines rich and varied structural system.Different according to excitation form, namely claw-pole motor is mainly divided into three types: electric excitation claw-pole motor, permanent magnet claw pole motor and mixed excitation claw-pole motor.
Brush-free claw-pole double-rotor machine can match with the conventional motors of different structure, forms brushless composite structure motor scheme.The program both can realize engine torque rotating speed and independently control, and can solve again puzzle heating in winding in the industry and the problem needing electric brush slip ring feed.
Method step of the present invention is as follows:
The mathematical model of step one, brush-free claw-pole double-rotor machine
The first step, simplification and assumption
To simplify the analysis, suppose during the mathematical model of derivation brush-free claw-pole double-rotor machine:
(1) ignore saturation effects, magnetic hysteresis and vortes interference, magnetic circuit is linear;
(2) motor three-phase windings is symmetrical, and each winding axis is mutual deviation 120o electrical angle spatially, and the mmf produced is along the sinusoidal rule distribution of air gap;
(3) impact of slot effect and commutation process is ignored;
(4) frequency and temperature is ignored on the impact of winding.
Space is there is between brush-free claw-pole double-rotor machine three-stage structure, therefore independent of one another between each phase winding, there is no mutual inductance, its a, b, though c phase winding is not at grade, can regard three-phase same plane not existing mutual inductance as whole apart from winding the angle of power and torque.
The each phase winding of brush-free claw-pole double-rotor machine is not spatially positioned at same plane, the pulsating mmf formed after energising cannot form synthesis rotating mmf, but synthesis electromagnetic torque equation still the same with the electromagnetic torque equation of conventional permanent magnet motor.When system load runs, brush-free claw-pole double-rotor machine and torque adjustment motor produce electromagnetic torque respectively on the rotor of pawl pole, and with load torque acting in conjunction, maintain the steady-state operation of pawl pole rotor.In addition, p-m rotor is subject to the dragging of torque of internal combustion engine and the braking action of brush-free claw-pole double-rotor machine electromagnetic torque, and two kinds of torques maintain the steady-state operation of p-m rotor jointly.
Second step, system architecture
As indicated with 1, whole system is made up of internal combustion engine, brush-free claw-pole compound machine, inverter, battery and control system etc. the mixed power system structure at brush-free claw-pole double-rotor machine place.Wherein brush-free claw-pole compound machine contains the torque adjustment motor being formed brush-free claw-pole double-rotor machine by the first stator, pawl pole rotor, the first p-m rotor and be made up of the second p-m rotor, the second stator.Brush-free claw-pole compound machine is arranged between internal combustion engine and main reducing gear, and the first p-m rotor is connected with internal combustion engine, and pawl pole rotor and the second p-m rotor are connected on main reducing gear jointly by rotating shaft, main reducing gear again Driving Torque to wheel.
The parameter of step 2, brush-free claw-pole double-rotor machine and performance evaluation
The flow direction of brush-free claw-pole double-rotor machine inside presents distributed in three dimensions, comprise circumferential, radial and axial, and it is the same with all claw-pole motors, the leakage flux more complicated of brush-free claw-pole double-rotor machine, leakage path is more, this makes the magnetic structure of brush-free claw-pole double-rotor machine and conventional structure motor have larger difference, is therefore necessary to reanalyse the magnetic circuit model of this motor and analytic formula.
Described parameter and performance evaluation comprise magnetic circuit parameters analysis, the analysis of magnetic flux and electromagnetic torque and reactance parameter analysis.
1, magnetic circuit parameters analysis:
The equivalent magnetic circuit modeling of brush-free claw-pole double-rotor machine is more complicated compared with the magnetic circuit model of conventional motors, and solves the accuracy of equivalent magnetic circuit modeling, depends on the calculating of various magnetic resistance to a great extent.
The calculating of described various magnetic resistance comprises: the calculating that the leakage field between the calculating that the leakage field between the calculating of the calculating of the calculating of pawl pole magnetic resistance, the calculating of knee magnetic resistance, stator core yoke portion magnetic resistance, the calculating of End zone of stator core magnetic resistance, ectonexine air-gap reluctance, calculating that between pawl pole and pawl pole, leakage field hinders, stator end hinders and permanent magnet hinders.
2, the analysis of magnetic flux and electromagnetic torque
Compared with permanent-magnetic outer rotor claw-pole motor magnetic circuit figure, the magnetic circuit figure of brush-free claw-pole double-rotor machine adds one deck air gap, extra clearance will reduce air gap flux density and torque, in order to maintain normal air-gap flux, will reduce main magnetic circuit magnetic resistance as far as possible during design.Because leakage path is more, leakage field to being reduced as far as possible, simultaneously for ensureing air-gap flux, also needing suitably to improve permanent magnet magnetic potential.
Analysis shows: the size of electromagnetic torque is except outside the Pass the factors such as the number of turn and armature supply with the number of phases, number of pole-pairs, winding have, also relevant with the d-axis of motor and quadrature axis magnetic circuit reluctance, permanent magnet magnetic potential.The d-axis of given input and quadrature axis current component, just can calculate the electromagnetic torque of motor.This kind of calculating torque method, without the need to Electromagnetic Calculation, is easy to realize in magnetic circuit calculates, and for design motor provides conveniently, but its accuracy is decided by the accuracy that each parameter calculates.
3, reactance parameter analysis
Brush-free claw-pole double-rotor machine has the magnetic structure different with common permagnetic synchronous motor, compared with traditional permagnetic synchronous motor, brush-free claw-pole double-rotor machine adds a clearance, it also has different winding configurations and more complicated leakage flux path, so original parameter calculation formula is no longer applicable simultaneously.Therefore, be necessary to analyze the reactance parameter characteristic of motor.
Although the analytical formula of reactance parameter can be derived by the analytic expression of equivalent magnetic circuit magnetic resistance, but the magnetic resistance of ferromagnetic material is not a constant in analytic expression, but change along with the change of magnetic flux density, when approximate treatment, can suppose: ferromagnetic material magnetic permeability μ=∞.
Analysis shows: different from common permagnetic synchronous motor, and the reactance of armature reaction and the frequency of brush-free claw-pole double-rotor machine are proportional, so when rated speed works, when design of electrical motor number of poles increases, reactance is corresponding increase also.By analysis, this is mainly because Circular Winding structure makes brush-free claw-pole double-rotor machine winding mmf amplitude be proportional to the number of turn that is often in series, and the mmf amplitude of common permagnetic synchronous motor winding be proportional to every extremely every mutually under effective turns-in-series, the difference of mmf formula result in the difference of reactance formula.
The three-dimensional finite element analysis of step 3, brush-free claw-pole double-rotor machine
Brush-free claw-pole double-rotor machine main magnetic circuit is distributed in three dimensions in space, and simultaneously claw-pole structure ratio that the very complicated and leakage flux of its leakage magnetic circuit is accounted for is bigger than normal, each of which increases the complicacy that electromagnetism calculates.And 3 D electromagnetic field simulation analysis can calculate the magnetic distribution situation of claw-pole motor inside more exactly, thus calculate parameter and the performance of motor exactly.
Comprise: the calculating of the close analysis of unloaded magnetic, the analysis of no-load back electromotive force, the calculating of magnetic leakage factor and reactance parameter.
1, the analysis that unloaded magnetic is close
Under no-load condition, there is the typical time that two different, the distribution situation of brush-free claw-pole double-rotor machine magnetic flux density vector.
1) permanent magnetism magnetic pole overlaps with the center line of pawl pole is the operating typical time of motor, and now motor main magnetic circuit is minimum reluctance, and permanent magnet excitation magnetic flux forms closed-loop path through pawl pole and stator core, and the main flux that stator winding crossed by chain is maximum.
2) permanent magnetism magnetic pole overlaps with pawl clearance between poles is motor another typical time operating, and the magnetic flux now permanent magnet produced closes voluntarily essentially by adjacent pawl pole block, and the magnetic flux that stator winding crossed by chain is close to zero.
2, the analysis of no-load back electromotive force
No-load back electromotive force is an important indicator of magneto, and it has obvious impact to the stable state of motor and dynamic property.When the p-m rotor of brush-free claw-pole double-rotor machine rotates relative to pawl pole rotor, the ectonexine air gap flux density distribution time to time change of motor, the magnetic flux of every phase winding institute interlinkage also changes along with the time simultaneously, and the magnetic flux of change induces the electromotive force of change in winding coil.
Analysis shows: similar to Conventional permanent magnet synchronous motor, and the no-load back electromotive force of brush-free claw-pole double-rotor machine is with relative rotation speed proportional increase substantially.
2, the calculating of magnetic leakage factor
Magnetic leakage factor is an important design parameter of magneto.The calculating of magnetic leakage factor, significant to the optimal design of the determination of motor permanent magnet working point, the accurate calculating of magnetic circuit and structure.For the relatively simple motor of magnetic structure, analytical method can be utilized to calculate equivalent magnetic flux leakage coefficient, and for having the motor of labyrinth, much ratios can be accounted in order to understand useful flux, need to calculate this parameter value by 3 D electromagnetic field.
Analysis shows: armature leakage coefficient and the permanent magnet magnetic leakage factor of brush-free claw-pole double-rotor machine are all larger.Permanent magnet magnetic leakage factor means that more greatly the producing level of permanent magnet is lower, can cause the increase of motor permanent magnet consumption; Armature leakage coefficient greatly then indicates that armature leakage flux is comparatively large, can cause the increase of armature leakage reactance, thus cause the power factor of motor on the low side.
3, the calculating of reactance parameter
Reactance parameter is design motor and the basis analyzing motor performance.Although analytical method can obtain the expression formula of reactance parameter, reactance, by the impact of the factors such as rotor structure, gas length, saturation effects, is difficult to use analysis mode accurate expression, only by means of finite element method, can obtains reactance value more accurately.
The simplification modeling of step 4, brush-free claw-pole double-rotor machine
Three-dimensional finite element model mesh generation number is many, and the calculating of a model just needs to expend a lot of computing times, is difficult to the needs meeting engineering design, is therefore necessary to study more simple finite element model under prerequisite accurately calculating.
Described simplification modeling is on the basis of three dimensional field model, adopts two dimensional equivalent finite element model to emulate brush-free claw-pole double-rotor machine.
The foundation of two dimensional equivalent finite element model derives from the equivalent transformation to three-dimensional model.The principle adopted during equivalent transformation makes two dimensional model have the magnetic resistance identical with three-dimensional model and mmf on every section of magnetic flux path, can the model before and after conversion just can be made basically identical on properties like this.
According to equivalent transformation principle, the two dimensional equivalent finite element model of brush-free claw-pole double-rotor machine comprises:
(1) equivalent pawl pole
Pawl very modal pawl pole shape, pawl pole-face is trapezoidal to p-m rotor side shape, and pawl pole radial section is trapezoidal equally.When determining two dimensional equivalent pawl pole model, can suppose that pawl pole is through appropriate design, magnetic flux density is more or less the same everywhere, so can get three-dimensional pawl pole axis to middle section the equivalent pawl pole-face as two dimensional model.
(2) equivalent stator winding
The annular concentratred winding of brush-free claw-pole double-rotor machine equivalence can become be similar to the whole apart from winding of common permagnetic synchronous motor.In two dimensional equivalent model, coil is placed in along the circumferential direction in equally distributed open slot, and groove number arranges and equals p-m rotor number of poles.Meanwhile, the mmf produced in often pair of pole magnetic circuit due to Circular Winding equals often to be in series the mmf of winding, and identical for ensureing the mmf before and after conversion, every groove conductor number of two dimensional model winding arranges the number of turn N that is often in series equaling triphase flow winding.
(3) equivalent stator core
In two dimensional equivalent model, the stator end of brush-free claw-pole double-rotor machine equivalent can become the stator tooth of fan shape.In order to make magnetic resistance unshakable in one's determination before and after equivalence identical, the core tooth in two dimensional equivalent model keeps the tooth length of magnetic path identical with three-dimensional model, and meanwhile, central angle corresponding to stator core tooth is by determining.
L1 in formula---single-phase core length in three-dimensional model; L2---stator core tooth thickness in three-dimensional model; α---often pair of central angle extremely descending stator core tooth corresponding in three-dimensional model.
After the same method, keep magnetic resistance unshakable in one's determination before and after equivalence identical, the stator yoke of three-dimensional model also equivalence can become the stator yoke of two dimensional model.
(4) other parts
The p-m rotor of two dimensional equivalent model keeps identical with three-dimensional model axial cross section; The axial length of two dimensional equivalent model arranges the live part equaling three-dimensional model magnetic circuit, the overlap length namely between pawl pole and permanent magnet, and the alternate gap portion of motor is got rid of outside the calculating of equivalent model axial length.In addition, for ensureing that air-gap reluctance is identical, the ectonexine air gap radius of two dimensional equivalent model and gas length keep equal with three-dimensional model.
The magnetic flux path of two dimensional model is similar with common permagnetic synchronous motor, magnetic flux with radial direction namely perpendicular to the turning axle direction of motor through air gap, therefore motor can easily perpendicular to motor shaft to two dimensional surface on carry out simulation analysis.
Simulation result shows: the no-load back electromotive force of two and three dimensions finite element simulation and the simulation result of load torque curve relatively, but still also exist some deviations.Through calculating, the no-load back electromotive force of two dimensional model simulation calculation is 114.4V, and it is 106.7V that motor three-dimensional artificial calculates no-load back electromotive force, and its relative deviation is 7.2%; The load torque 27.02Nm of two dimensional model simulation calculation, the torque of motor three-dimensional artificial computational load is 24.98Nm, and its relative deviation is 8.2%.And found by model contrast, producing with the main cause of the upper deviation is owing to simplifying pawl pole shape, pawl pole top surface originally in three-dimensional model and the leakage field between face and pawl pole tip leakage field do not embody in two-dimensional finite element model, and pawl pole magnetic resistance also reduces to some extent, so the pawl pole magnetic that two-dimensional simulation obtains is close, no-load back electromotive force and load torque be all a little more than three-dimensional artificial result.
Effect: in order to verify the accommodation of this short-cut method, compared for again the simulation performance of different three-dimensional models and corresponding two dimensional model.Study in the stator yoke thickness changing corresponding model, pawl point pole embrace, radix unguis pole embrace and several situation of single-phase axial length, two and three dimensions emulation no-load back electromotive force amplitude and average torque versus's situation.Result is presented under various structural parameters situation of change, and two dimensional model and three-dimensional model have close simulation result, thus demonstrates the general applicability of this short-cut method.
The optimal design of step 5, motor torque
Torque performance is the more concerned performance of motor of electric motor car.Electric automobile, due to the restriction in space, wishes that the motor volume that wherein uses is less, weight is lighter, efficiency is higher, namely requires that motor of electric motor car has higher torque density.Meanwhile, for reducing vibration & noise, make vehicle operating more steadily quiet, the Driving Torque stationarity of motor of electric motor car also requires to control in certain scope.
Brush-free claw-pole double-rotor machine has claw-pole structure and Circular Winding structure, and it is larger different that this makes its torque density and cogging torque formula also exist compared with conventional motor, is therefore necessary new analytical expression of again deriving.Meanwhile, when carrying out motor with novel arrangement design, numerical solution more accurately be obtained, need to carry out Calculation of Electrical Motor & Electromagnetic and analysis, by parameter optimization, obtaining electric machine structure and the size value of corresponding optimum torque performance.
First analytic method is adopted to analyze torque density and the relation between cogging torque and brush-free claw-pole double-rotor machine main structure parameters.Then, on the basis of analytical analysis, adopt finite element simulation methods analyst permanent magnet rotor structure, number of pole-pairs, key dimension ratio, gas length and pawl pole shape on the impact of motor torque performance, give the defining method of relevant parameter.
Analysis shows: similar to conventional radial motor, and the torque density of brush-free claw-pole double-rotor machine is directly proportional to the product of magnetic loading to the electric load of motor.But with conventional radial motor unlike, the torque density of brush-free claw-pole double-rotor machine is directly proportional to number of pole-pairs.This is due in brush-free claw-pole birotor, and along with the increase of motor number of pole-pairs, electric frequency f increases, and the magnetic flux of every circle conductor linkage still remains unchanged, and therefore the induction phase electromotive force of motor, electromagnetic torque, torque density to be all directly proportional increase with number of pole-pairs.
Cogging torque is one of peculiar problem of magneto, is the torque that between permanent magnet and armature core, adelphotaxy produces.In brush-free claw-pole double-rotor machine, pawl pole block is equivalent to the tooth of conventional motors, space between the block of pawl pole is equivalent to the groove of conventional motors, pawl pole block and the effect between permanent magnet make pawl pole rotor produce the trend of aliging with p-m rotor along motor circumference tangential direction, and trend creates the cogging torque of oscillation property thus.
Analysis shows: the cogging torque of brush-free claw-pole double-rotor machine is main relevant with the structural parameters of pawl pole rotor and p-m rotor, to arrange with stator core, winding and the factor such as the amplitude of electric current and phase place has nothing to do, therefore, the method weakening cogging torque sums up and can be divided into following two classes:
(1) pawl pole rotor parameter is changed
These class methods mainly comprise change pawl pole shape, adopt magnetic slot-seal, the method such as surface fluting in pawl pole and pawl pole interblock distance not etc.Wherein, by changing pawl pole shape, form skewed slot, be equivalent to groove consecutive mean to be distributed in permanent magnetism magnetic pole surface, make to look vertically, magnetic resistance is all equal everywhere, thus can eliminate teeth groove pulsation.Pawl pole adds the slot wedge with magnetic property in block space, the leakage field between pawl pole can be made greatly to increase, cannot adopt.Although and open auxiliary flute at pawl pole tooth surface and adopt the method for pawl pole interblock distance not etc. can weaken cogging torque, but the former adds effective air gap length, can reduce motor gas-gap magnetic close, latter can cause interpolar magnetic field asymmetric, so they also have larger limitation.
(2) permanent magnet pole parameter is changed
The methods such as these class methods mainly comprise oblique pole, adopt not uniform thickness or not wide permanent magnet, permanent magnetism polar arc coefficient sets conjunction not etc.In this several method, oblique pole makes processing technology complicated, adds production cost, generally just can apply oblique pole when realizing skewed slot.Adopt the method for not uniform thickness or not wide permanent magnet, pole embrace combination not etc., although can weaken cogging torque to a certain extent, this method easily produces unilateral magnetic force, generation vibration & noise when motor is run.
The finite element optimization of motor torque: the selection of p-m rotor form has material impact to whole motor performance.Because claw pole type motor number of poles is generally more, and motor of electric motor car will be convenient to assembling, restriction manufacturing cost, and therefore p-m rotor is not suitable for the magnetic structure adopting the complexity such as built-in U type, W type.
In order to analyze the impact of number of pole-pairs on motor torque performance, establishing the brush-free claw-pole double-rotor machine finite element model that basic size is certain, volume is identical, number of poles is different and analyzing.When motor basic size is constant, back electromotive force amplitude and average torque increase along with the increase of number of pole-pairs, therefore, can improve the torque density of brush-free claw-pole double-rotor machine by increasing number of pole-pairs.Meanwhile, when number of pole-pairs increases to a certain degree, no-load back electromotive force amplitude and average torque increase trend and slow down gradually.This mainly causes the spacing of adjacent pawl pole to become near due to number of pole-pairs increase, and the increase of leakage field limits the further increase of torque density.
Actual when carrying out design of electrical motor, increase the impact on core loss when also needing to consider to be increased to number of pole-pairs.Can find that number of poles increase makes motor running frequency increase, motor iron loss can be caused significantly to increase.In addition, also need to consider that number of pole-pairs too much can cause pawl pole block thinning, physical strength declines.Take into account this several respects, carry out compromise and consider, final experimental prototype is chosen as 6 to pole.
Motor key dimension comparison no-load back electromotive force amplitude and average torque affect relatively large, along with motor key dimension is than the increase of λ, the no-load back electromotive force amplitude of motor and average torque increase gradually, and illustrating that motor profile is relatively elongated can improve torque density.During actual design model machine, also need to consider that motor key dimension increases than undue, the parts such as pawl pole block can be made to become elongated, thus affect physical strength and the operational reliability of motor.Consider various index, the key dimension ratio of final experimental prototype is chosen as 4.5.
Gas length is an important parameter of Design of PM Motor.If gas length is selected excessive, the mmf set up needed for air-gap field increases, and correspondingly requires that the thickness of permanent magnet magnetizing direction in motor also will increase, can cause the increase of permanent magnet consumption and motor manufacturing cost.On the other hand, by the impact of processing technology and mechanical factor, the air gap of motor can not be too little, therefore should comprehensively analyze to determine gas length.In sum, the outer gas length of brush-free claw-pole double-rotor machine only affects no-load back electromotive force amplitude and average torque, and interior gas length not only has impact to no-load back electromotive force amplitude and average torque, but also there is larger impact to torque ripple and cogging torque.When actual model machine manufactures, gas length value is except needs consideration torque performance, and also need the impact considering processing technology and mechanical factor, consider, the equal value of ectonexine gas length of the brush-free claw-pole double-rotor machine of the design is 0.8mm.
Analytically analyze known, pawl pole shape directly has influence on the magnetic flux by air gap and motor winding coupled, and the area suitably increasing pawl pole can increase operating magnetic field flux, is conducive to improving Driving Torque; But pawl is extremely excessive, the leakage field between two adjacent pawl pole blocks also increases, and the Driving Torque of motor can reduce on the contrary.According to the definition of pawl point pole embrace, have chosen respectively span be 0.1 to 0.7 seven prescription cases compare, can find, the optimum valuing range of pawl point pole embrace is between 0.1 ~ 0.4, and the optimum valuing range of radix unguis pole embrace is between 1 ~ 1.1.
The optimal design of step 6, motor power factor and efficiency
Due to the existence of claw-pole structure, brush-free claw-pole double-rotor machine inside also exists many leakage paths, larger leakage flux can cause motor power factor on the low side, if this problem can not get reasonable solution, the factor affecting motor and apply may be become, be therefore necessary to study the measure improving motor power factor.On the other hand, because the starting point of hybrid vehicle research will improve capacity usage ratio exactly, reduce exhaust emissions, the efficiency characteristic therefore calculating motor of electric motor car also seems necessity very.The loss calculating motor is exactly the prerequisite of calculating electric efficiency, and the various compositions studying loss are formed and proportion, all have very important meaning to raising electric efficiency, rationally change structure design, raising stock utilization and global design level.
First from basic electromagnetic theory, theoretical analysis has been carried out to power factor problem, on this basis, inquired into the impact on power factor of magnet size, umber of turn and input current, proposed the effective ways improving power factor.Give the computing method of the various loss of motor afterwards, and the efficiency of motor and power density situation under analyzing rated operation further, for model machine manufacture and design and in electric motor car, application provides theoretical foundation.
(1) analysis of motor power factor
Comprise the impact on power factor of magnet size, umber of turn and input current
(2) calculating of the loss of electric machine and efficiency
Comprise the calculating of copper loss, iron loss, mechanical loss and stray loss.
The loss produced in the brush-free claw-pole double-rotor machine course of work mainly comprises: copper loss, iron loss, mechanical loss and stray loss.In above-mentioned four class losses, the copper loss of winding can be calculated by the resistance value of winding current values and winding.Iron loss and structural parameters unshakable in one's determination, supply frequency and magnetic flux density relevant, Finite Element Method can be adopted to calculate according to separation iron loss model.Mechanical loss is generally calculated by experimental formula, but due to the difference of structure, the mechanical loss formula of brush-free claw-pole double-rotor machine can not indiscriminately imitate the computing formula of conventional motors.And stray loss is generally difficult to accurate Calculation, can refer to the computing method process of conventional motors.
The experimental verification of step 8, actual model machine
Brush-free claw-pole double-rotor machine has inside and outside two-layer air gap, and manufacturing process and the Conventional permanent magnet synchronous motor of model machine also exist very large different.Simultaneously, in order to motor can be applied in hybrid vehicle, realize smoothly commercially producing, the process program of model machine can not design too complicated, so how to adopt efficient, energy-conservation method to produce the model machine of high-quality, just become problem demanding prompt solution in research.In order to investigate the performance characteristics of this kind of structural electromotor, simultaneously also in order to the accuracy that proof theory analysis and electromagnetism calculate, need to carry out performance test to the model machine of development.Brush-free claw-pole double-rotor machine has dual-rotor structure, directly can not copy the method for testing of single-rotor motor mechanically, needs to design new test platform and method of testing according to the feature of motor.
Fig. 2 is respectively the experimental platform system block diagram of brush-free claw-pole double-rotor machine.Due to laboratory condition restriction, adopt two permanent magnet synchronous motors simulation internal combustion engine and road conditions load respectively.Experiment porch three motors are from left to right respectively the load motor of drive motor, brush-free claw-pole double-rotor machine and the simulation road conditions simulating internal combustion engine, wherein drive motor is connected with the p-m rotor of model machine by torque rotational speed meter, and load motor is then connected with the pawl pole rotor of model machine by another torque rotational speed meter.
Described experiment test comprises: the experimental verification of the test that no-load back electromotive force test, cogging torque test, cogging torque test, open circuit loss and efficiency test, current phase angle affect power factor and rotational speed regulation function.
During test no-load back electromotive force, the p-m rotor being dragged model machine by drive motor runs surely with permanent rotating speed, then dragged by the pawl pole rotor operation of sample machine under the every speed needed by load motor, measure the no-load back electromotive force waveform of model machine winding terminal, and record the actual speed of speed discrepancy as motor of two rotors.
Cogging torque is the important technology index affecting motor running stability, and its accurate measurement contributes to the Performance Evaluation of motor and optimizes further.First experiment is tested the cogging torque between p-m rotor and pawl pole rotor.Fixed by the pawl pole rotor of brush-free claw-pole double-rotor machine during test, it is initial position that p-m rotor demarcates a position, then slowly rotates p-m rotor, records the mechanical angle of rotation and the torque tester reading of correspondence.
During open circuit loss test, model machine and frequency converter are disconnected, implement rotating speed to drive motor and load motor to control, two rotors dragging model machine rotate relatively, under making model machine operate in different rotating speeds situation, be now the open circuit loss of brush-free claw-pole double-rotor machine from the difference of the mechanical output of model machine two rotating shaft inputs.Test finds, the torque value of model machine two rotating shafts is substantially identical at each speed, so can get the no-load torque of torque value as model machine of any side.
After prototype structure is determined, change the effective ways that current phase angle is regulating power factor, by experiment this conclusion is verified.During test, rotating speed is implemented to drive motor and load motor and controls, direct torque is implemented to model machine.When keeping model machine input current constant amplitude, changing the phasing degree of input current, being measured the situation of change of model machine power factor and load torque by power analyzer and torque rotational speed meter.
The experimental verification of rotational speed regulation function is to carry out functional verification to model machine, is on existing experiment porch, simulate the operational process of one section of brush-free claw-pole double-rotor machine in hybrid electric vehicle.
If test data meets performance index, design successfully, terminate; If test data does not meet performance index, the problems in the design, returns step 2, continues optimal design.
Above by reference to the accompanying drawings to invention has been exemplary description; obvious specific implementation of the present invention is not subject to the restrictions described above; as long as have employed the improvement of the various unsubstantialities that method of the present invention is conceived and technical scheme is carried out; or design of the present invention and technical scheme directly applied to other occasion, all within protection scope of the present invention without to improve.
Claims (6)
1. an Optimization Design for brushless composite structure motor system, is characterized in that, comprises the steps:
Step one: the mathematical model setting up brush-free claw-pole double-rotor machine;
Step 2: the parameter of brush-free claw-pole double-rotor machine and performance evaluation;
Step 3: the three-dimensional finite element model setting up brush-free claw-pole double-rotor machine, analyze the magnetic distribution situation of motor internal, calculate parameter and the performance of motor, comprise the calculating of the close analysis of unloaded magnetic, the analysis of no-load back electromotive force, magnetic leakage factor and reactance parameter;
Step 4: the three-dimensional finite element model simplifying brush-free claw-pole double-rotor machine, adopts two dimensional equivalent finite element model to emulate three-dimensional finite element model, makes two-dimensional finite element model have the magnetic resistance identical with three-dimensional model and mmf on every section of magnetic flux path;
Step 5: adopt analytic method to analyze torque density and the relation between cogging torque and brush-free claw-pole double-rotor machine main structure parameters, then adopt finite element simulation methods analyst permanent magnet rotor structure, number of pole-pairs, physical dimension, gas length and pawl pole shape on the impact of motor torque performance, given model machine parameter determination method
Step 6: analyze motor power factor, the loss of electric machine and efficiency, the analysis of power factor comprises the analysis of magnet size, umber of turn and input current,
Step 7: the function of test experiments model machine, if test data meets performance index, terminates, if do not met, returns step 2.
2. the Optimization Design of brushless composite structure motor system according to claim 1, it is characterized in that: described step one comprises two steps, the first step: the structure simplifying brush-free claw-pole double-rotor machine, ignore saturation effects, magnetic hysteresis and vortes interference, magnetic circuit is the impact linearly ignoring slot effect and commutation process, ignores frequency and temperature to the impact of winding; Second step: analytic system structure founding mathematical models.
3. the Optimization Design of brushless composite structure motor system according to claim 1, is characterized in that: described step 2 comprises magnetic circuit parameters analysis, the analysis of magnetic flux and electromagnetic torque and reactance parameter analysis.
4. the Optimization Design of brushless composite structure motor system according to claim 1, is characterized in that: the two dimensional equivalent finite element model of described step 4 comprises: equivalent pawl pole, equivalent stator winding, equivalent stator core.
5. the Optimization Design of brushless composite structure motor system according to claim 1, is characterized in that: in described step 5 model machine parameter be model machine to very 6 to, size than being chosen as 4.5, the span of the equal value 0.8mm of ectonexine gas length, pawl point pole embrace is 0.1 ~ 0.4, the span of radix unguis pole embrace is 1 ~ 1.1.
6. the Optimization Design of brushless composite structure motor system according to claim 1, is characterized in that: in described step 7, functional test comprises: no-load back electromotive force test, cogging torque test, open circuit loss and efficiency test, current phase angle are on the test of the test of the impact of power factor and rotational speed regulation function.
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| CN108291939A (en) * | 2015-10-30 | 2018-07-17 | 法拉第未来公司 | Low core loss interior magnet design of electrical motor |
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| CN110378027B (en) * | 2019-07-22 | 2022-09-13 | 合肥工业大学 | Motor no-load loss and electromagnetic torque calculation method considering magnetic flux density axial distribution |
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