Design Analysis of a Dual Rotor Permanent Magnet Machine driven Electric Vehicle

School of Engineering, Taylor’s University, Malaysia

^* Corresponding author: aravindcv@ieee.org

Abstract

Electric bike in urban countries such as Europe and China commonly used the brushless direct current machine (BLDC) as it able to produce high torque to transport the user from one place to another. However, BLDC torque density can’t be improving due to limitation magnetic flux generated by the permanent magnet. Therefore, the performance of electric bike can’t be improved. Outer rotor BLDC machine design able to improve the torque density of the motor due to increase radius of the motor which can be explained by simple physics equation (Torque = Force x radius). However, an outer rotor machine only generates constant speed, which is not suitable for operating under tractive load condition, especially electric bike. The proposed model is a new novel of double layer outer rotor BLDCPM machine which able to amplify the magnetic flux density and improve the torque density of the machine. The mutual magnetic coupling between the inner and outer rotor of the proposed model increase the magnetic flux intensity as both of them acts as individual parts. Thus, the magnetic flux generated by both rotors are double which resulted in improving the performance of the E-bike. Designing parameters and analysing the performance of the proposed 2D model is done using FEA tools. Evaluation of the conventional and proposed model by comparing torque performance, magnetic flux density and motor constant square density. Other than that, speed torque graph also is evaluated to justify either it can operate similarly to ICE engine with gears. Two model is designed which is Single Outer Rotor Brushless Direct Current (SORBLDC) and Double Outer Rotor Brushless Direct Current (DORBLDC) operated with the same cases of 27 Amp current supplied to it and operate under various speed from 500 rpm to 2000 rpm. The average torque produce by the conventional and proposed model are 2.045439 Nm and 3.102648 Nm. Furthermore, improvement of the proposed model to conventional model in terms of motor constant square density by 24.92%. Therefore, the proposed model able to improve the magnetic flux by amplifying which resulted to increase the torque density of the machine. Furthermore, the speed-torque graph of the proposed machine shows similarity with speed torque graph of ICE engine. Thus, the proposed machine is suitable to operate for bike application