Design, Optimization and Experimental Study of Axial and Hub BLDC Motors in-Wheel Application for Light Electric Vehicles

Abstract

The use of brushless DC (BLDC) motors in electric vehicles have been rapidly increasing. In this study performance analysis was made for BLDC motors used in wheel applications in light electrical vehicles on issues such as efficiency, speed, and power density. In this study, two types of BLDC motors, axial flux (AF) and hub (outer rotor-radial flux) motor were simulated, optimized, and experimented. Both of them were studied considering multi-parameter objectives mainly, stator yoke flux density, rotor yoke flux density, air gap flux density, efficiency, torque/weight, and speed. The credibility of the models performed has been confirmed by comparing the results of simulation and measurement on rated values 10 kW, 72 V (Axial) and 1 kW, 50 V (Hub) 3 phase, star connected motors. To optimize the motor design comprehensively, a genetic algorithm (GA) has been realized for each motor. The design, optimization, and realization of the study are given in detail pointing out some important data on BLDC motors.

Light electric vehicles have come to stay (problems and regulation in Estonia and Latvia)

“…According to an amendment to the Road Traffic Act that entered into force in 2022, the manufacturer's speed of light electric vehicles must not exceed 25 km/h and the maximum engine power must not exceed 1 kW -the capacity limitation does not only apply to balancers (Toker, K., Tosun, O., 2022). Proposals to amend the Road Traffic Act have recently been drafted by the Ministry of Economic Affairs and Communications to introduce a 0.5 drink-drive limit for cyclists and scooter riders, similar to the 0.5 drink-drive limit at sea.…”

Mechanical and Vibration Analysis of a High-Speed Outer Rotor Electric Motor

“…In outer rotor motors, surface-mounted permanent magnets (SPMs) can provide higher torque density than regular PMs [3]. Examples of recent work on outer rotor motors include [4], which investigates the effect of axial length over pitch-pole ratio in outer rotor brushless DC (BLDC) motors, and [5], which reports on the design and optimization of hub BLDC motors.…”

“…They also studied the rotodynamic behavior of the rotor-bearing structure and studied the different modes of vibration. Chen et al [5] and Balachandran et al [21] studied high-speed outer rotor motors and their mechanical challenges; in each of these studies, the rotor was balanced by bearings on both sides. Numerous rotodynamic analyses for inner rotor motors are available in the literature [22], [23], [24], but few such analyses have been performed for highspeed outer rotor PM motors.…”

Optimal Rotor Design and Analysis of Energy-Efficient Brushless DC Motor-Driven Centrifugal Monoset Pump for Agriculture Applications

“…Using the finite element method, a BLDC hub motor is crafted and analyzed for its no-load behavior, load performance characteristics, and cogging torque [39,40]. FEM simulation entails executing a comprehensive design algorithm that incorporates a step-bystep design process, access to data libraries such as standard wire gauges and magnetic material properties, along with interactive input and output capabilities for enhanced functionality [41,42]. The design of a PM motor control system utilizes the MagNet (v7.1.1) software, specifically focusing on enhancing speed control for these motors [43,44].…”