Axial Flux PM In-Wheel Motor for Electric Vehicles: 3D Multiphysics Analysis

Abstract

The Axial Flux Permanent Magnet (AFPM) motor represents a valid alternative to the traditional radial flux motor due to its compact structure; it is suitable for in-wheel applications so that the transmission gear can be suppressed. The modeling of the motor is a purely Three-Dimensional (3D) problem and the use of 3D finite element tools allows the attainment of accurate results taking also into account the effects of the end-windings. Moreover, a 3D multiphysics analysis is essential to evaluate not only the motor performance and its thermal behavior, but also the electromagnetic forces acting on the surfaces of the stator teeth and of the magnets that face the air gap. Moreover, as the vehicle’s motors often work in variable-speed conditions, the prediction of vibrations and noise for electric motors over a wide speed range is usually necessary. The paper presents a double-sided AFPM motor for a small pure electric vehicle; the basic drive architecture includes four axial flux motors installed directly inside the vehicle’s wheels. The aim is to propose advanced and integrated electromagnetic, vibroacoustic and thermal analyses that allow the investigation of the axial flux motor behavior in a detailed and exhaustive way.