Soomro, Irfan Ali (2023) Design of compact modular rotor permanent magnet flux switching machine for electric vehicles. Doctoral thesis, Universiti Tun Hussein Onn Malaysia.

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Abstract

Permanent magnet flux switching machines (PMFSM) have attracted considerable interest in recent years. Amongst all designs, AlCiRaF PMFSM with salient rotor has been introduced for electric vehicle applications. Although it has less PM volume and less flux leakage, the torque and power performance can still achieve 47 Nm and 11 kW, respectively, higher than the conventional C-core 12S-10P PMFSM. However, the salient rotor and stator of PMFSM with single-tooth winding have inherited longer flux paths and high iron losses, affecting the motor's torque and efficiency. In this research a modular rotor PMFSM with higher flux linkage is proposed and design using 2D finite element analysis (2D-FEA) JMAG designer software version 18.1. The Deterministic Optimization Method (DOM) is executed by treating sensitive design parameters defined in the rotor segments, stator, armature slot and PM to improve the motor's performance. Consequently, the optimized design has 20% better flux linkage compared to initial design along with 39.89%, 60% and 6% increments in torque, power, and efficiency respectively. Moreover, flux linkage and torque characteristics analysis of the proposed design are examined and compared with existing sandwich PMFSM topologies under similar dimensions. Accordingly, the optimized PMFSM modular rotor can achieve improved torque and power values of 57.29 Nm and 23.23 kW, respectively, which are higher than the target values. Thus, sizing optimization technique has been employed by altering the stator outer radius and stack length until the target torque and power of 47 Nm and 11 kW are achieved. As a result, the motor size has been reduced to 0.86 kg, which is 10.39% from the initial size. It can be concluded that the proposed PMFSM modular rotor PMFSM and compact modular rotor PMFSM have shown promising capabilities to achieve higher torque and power at maximum speed ranges

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