The Design, Optimization, and Experimental Study of Hub and Axial Flux BLDC Motor Under Operating Conditions For Light Electric Vehicles

Abstract

In this study, we conducted an experimental study and efficiency optimization of the outer rotor (hub) BLDC (brushless direct current) motor and axial BLDC motor for light electric vehicles. Both motors were investigated in the simulation environment and experimentally. The axial flux BLDC motor had a rated power of 10 KW, and a rated speed of 4550 rpm, while the outer rotor (hub) BLDC motor had a rated power of 1 KW and a rated speed of 300 rpm. The speed, efficiency, torque, and weight values of both motors were examined comparatively. The torque/volume values of the hub motor and axial flux motor were used as references for analysis. The hub motor and axial flux motors, with equal volume values, were simulated using ANSYS Electronics Desktop software. The simulation data were also compared with experimental studies. To optimize these motors using a genetic algorithm (GA), lower and upper limit values were determined for various parameters such as the outer and inner diameter of the stator, the outer diameter of the rotor, air gap length, slot height, axial length, air gap flux density, magnet thickness, and tooth width in the hub motor. Similarly, in the axial flux motor, parameters such as the outer and inner diameter of the stator, air gap length, slot height, air gap flux density, magnet thickness, tooth width, stator length, and rotor length were optimized using the GA method. The application of GA optimization has led to a 1.91% increase in the hub motor efficiency and a 3.45% increase in the axial motor efficiency.