Hostname: page-component-586b7cd67f-l7hp2 Total loading time: 0 Render date: 2024-11-26T05:26:43.988Z Has data issue: false hasContentIssue false
  • English
  • Français

Mechanical Impact on In-Wheel Motor's Performance

Published online by Cambridge University Press:  09 November 2016

M. Biček ,
R. Kunc  and
S. Zupan
M. Biček*
Affiliation:
Elaphe Propulsion Technologies, LTD.Ljubljana, Slovenia
R. Kunc
Affiliation:
Chair of Modelling in Engineering Sciences and MedicineFaculty of Mechanical EngineeringUniversity of LjubljanaLjubljana, Slovenia
S. Zupan
Affiliation:
Chair of Modelling in Engineering Sciences and MedicineFaculty of Mechanical EngineeringUniversity of LjubljanaLjubljana, Slovenia
*
*Corresponding author ([email protected])
Get access

Abstract

In-wheel motors offer a promising solution for novel drivetrain architectures that could penetrate into the automotive industry by locating the drive where it is required, directly inside the wheels. As obtainable literature mainly deals with optimization of electromagnetic active parts, the mechanical design of electromagnetically passive parts that indirectly influence motor performance should also be reviewed and characterized for its effect on performance. The following study uniquely evaluates the impact of mechanical design and its dimensional variations to air-gap consistency between on rotor glued magnets and on stator fitted winding, for the most commonly used layout of an in-wheel motor. To meet the optimal performance of an in-wheel motor, the mechanical design requires optimization of housing elements, thermal management, geometrical and a dimensional tolerance check, and proper hub bearing selection to assure consistent electromagnetic properties. This article covers the correlation between desired electromagnetic parameters and required geometrical limitations for ensuring functionality and high performance operation. Major mechanical contributors have been analyzed with analytical calculations, numerical simulations, and verified with different sets of measurements. The relative change of motor physical air-gap size, between the stator and rotor was correlated with electromagnetic flux density.

Keywords

In-wheel motorStructural impactPerformanceAir-gap size
Type
Research Article
Information
Journal of Mechanics , Volume 33 , Issue 5 , October 2017 , pp. 607 - 618
Copyright
Copyright © The Society of Theoretical and Applied Mechanics 2017 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

1. Roadmap Electrification of Road Transport, 2nd Edition, European Road Transport Research Advisory Council (ERTRAC), European Technology Platform on Smart System Integration (EPOSS), Brussel, Belgium, pp. 1–43 (2012).Google Scholar
2. Trigg, T., Telleen, P., Boyd, R. and Cuenot, F. Global EV Outlook: Understanding the Electric Vehicle Landscape to 2020, International Energy Association (IEA), Paris, France, pp. 7–18 (2013).Google Scholar
3. Proposal for an Electric Vehicle Regulatory Reference Guide - ECE /TRANS/WP.29/GRPE/2014/13, 69th session, United Nations - Economic and Social council, Geneva, Switzerland (2014).Google Scholar
4. Strategic Outlook of Global Electric Vehicle Market in 2015, Frost & Sullivan, Detroit, USA, pp. 4-8 (2014).Google Scholar
5. Khusid, M., “Potential of Electric Propulsion Systems to Reduce Petroleum Use and Greenhouse Gas Emissions in the US Light-Duty Vehicle Fleet,” M.S. Thesis, Department for System Design and Management, Massachusetts Institute of Technology, Massachusetts, U.S.A. (2010).Google Scholar
6. Vallance, A., “Advanced In-Wheel Electric Propulsion Technology,” The Eco-Innovation Workshop Center For Sustainable Design, Protean electric, Surrey, England, (2010).Google Scholar
7. Perovic, D. K., “Making the Impossible, Possible – Overcoming the Design Challenges of In Wheel Motors,” EVS26 International Battery, Hybrid and Fuel Cell Electric Vehicle Symposium, Los Angeles, USA (2012).Google Scholar
8. Watts, A., Vallance, A., Whitehead, A., Hilton, C. and Fraser, A., “The Technology and Economics of In-Wheel Motors,” SAE International Journal of Passenger Cars - Electronic and Electrical Systems, DOI:10.4271/2010-01-2307 (2010).Google Scholar
9. Ifedi, C. J., et al., “Fault tolerant in-wheel motor topologies for high performance electric vehicles,” 2011 IEEE International Electric Machines & Drives Conference (IEMDC), Niagara Falls, USA (2011).Google Scholar
10. Cakir, K., “In-wheel motor design for electric vehicles,” 9th IEEE International Workshop on Advanced Motion Control, Istanbul, Turkey (006).Google Scholar
11. Pagerit, S., Sharer, P. and Rousseau, A. “Fuel Economy Sensitivity to Vehicle Mass for Advanced Vehicle Powertrains,” Advanced Hybrid Vehicle Powertrains - SAE 2006 World Congress & Exhibition, Warrendale, USA (2006).Google Scholar
12. Gruber, W., Back, W., Amrhein, W. and Bäck, W. “Design and implementation of a wheel hub motor for an electric scooter,” 2011 IEEE Vehicle Power and Propulsion Conference, Chicago USA (2011).Google Scholar
13. Pérez, S. R., “Analysis of a light permanent magnet in-wheel motor for an electric vehicle with autonomous corner modules,” M.S. Thesis, Royal Institute of Technology (KTH), Stockholm, Sweden (2011).Google Scholar
14. Heim, R., Hanselka, H. and El Dsoki, C., “Technical potential of in-wheel motors for Electric Vehicles,” ATZ - Worldwide, 114, pp. 4–9 (2012).Google Scholar
15. Wong, J. Y., Theory of Ground Aehicle, 3rd Edition, John Wiley & SONS Inc., New York, pp. 126–148 (2001).Google Scholar
16. Wang, R. and Wang, J., “Fault-Tolerant Control With Active Fault Diagnosis for Four-Wheel Independently Driven Electric Ground Vehicles,” IEEE Transactions on Vehicular Technology, Columbus, USA (2011).Google Scholar
17. Vos, R., “Influence of in-wheel motors on the ride comfort of electric vehicles,” M. S. Thesis, Department of Mechanical Engineering, Eindhoven University of Technology (2010).Google Scholar
18. Fraser, A., “In-Wheel Electric Motors,” 10th International CTI Symposium, Berlin, Germany (2011)Google Scholar
19. Nagaya, G., Wakao, Y. and Abe, A., “Development of an in-wheel drive with advanced dynamic-damper mechanism,” Japan Society of Automotive Engineering - JSAE, DOI:10.1016/S0389-4304(03)00077-8 (2003).Google Scholar
20. Biček, M., Gotovac, G., Miljavec, D. and Zupan, S., “Mechanical Failure Mode Causes of In-Wheel Motors,” Strojniški Vestnik - Journal of Mechanical Engineering, DOI:10.5545/sv-jme.2014.2022 (2015).Google Scholar
21. Kasgen, J. and Heim, R., “Product Development & Testing Requirements For Electric Wheel Hub Motors”, Fraunhofer Systemforschung Elektromobilität, Darmstadt, Germany (2011).Google Scholar
22. Geissinger, J. M. and Ag, S., “The Future Powertrain – Challenge between Internal Combustion Engine and Electric Mobility,” 33rd International Vienna Motor Symposium, Vienna, Austria (2012).Google Scholar
23. Altenbach, H., Altenbach, J. and Rikards, R., Einfuhrung in die Mechanik der Laminat- und Sandwichtragwerke, 1st Edition, Deutscher Verlag fur Grundstoffindustrie, Stuttgart (1996).Google Scholar
24. Rameshol, I., Henneberger, G., Kuppers, S. and Hadrys, W., “Three dimensional calculation of magnetic forces and displacements of a clawpole generator,” IEEE Transactions on Magnetics, 32, pp. 1685–1688 (1996).Google Scholar
25. Tang, Z., Pillay, P., Omekanda, A., Li, C. and Cetinkaya, C., “Young's modulus for laminated machine structures with particular reference to switched reluctance motor vibrations,” IEEE Transactions on Industry Applications, 40, pp. 748–754 (2004).Google Scholar
26. van der Giet, M., Kasper, K., De Doncker, R. W. and Hameyer, K., “Material parameters for the structural dynamic simulation of electrical machines,” XXth International Conference on Electrical Machines (ICEM), pp. 2994–3000, Marseille, France (2012).Google Scholar
27. Datasheet for Epoxy Elantas MC622LV/W58, Elantas - Alanta group, Elan-tron product information, Wesel (2012).Google Scholar
28. Muncaster, R., A-level Physics, 4th Edition. Nelson Thornes Ltd., Cheltenham (1993).Google Scholar
29. Kaufman, J. G. and Rooy, E. L., Aluminum Alloy Castings: Properties, Processes, and Applications, 1st Edition, ASM International, Ohio (2004).Google Scholar
30. Gentle, R., Edwards, P. and Bolton, W., Mechanical Engineering Systems, 1st Edition, Newnes & ASM International, Ohio (2001).Google Scholar
31. Gotovac, G., “Dynamic thermal model of a multipole permanent magnet synchronous motor,” Ph.D. Dissertation, Department of Electrical machines, Faculty of Electrical Engineering, University of Ljubljana, Slovenia (2014).Google Scholar
32. Yang, M., “A Study on the Lateral Stiffness of the Passenger Car Suspension,” 2012 SIMULIA Customer Conference, Providence, USA (2012).Google Scholar
33. Gianini, C., “Formula One Car Wheel Bearings: an FE Approach,” 2007ABAQUS Users’ Conference, Paris, France (2007)Google Scholar
34. Koyama, T., “Applying FEM to the Design of Automotive Bearings,” NSK Technical Journal Motion & Control No. 2, pp. 23–30 (1997).Google Scholar
35. Kajihara, K., “Improvement of Simulation Technology for Analysis of Hub Unit Bearing,” Koyo Engineering Journal English Ed., 168E, pp. 8–13, (2005).Google Scholar
36. Hub bearings - CAT. No. 4601/E, NTN America, http://www.ntnamericas.com/en/website/documents/brochures-and-literature/catalogs/hub_bearings_4601.pdf (2014).Google Scholar
37. Lee, I., et. al., “Development of Stiffness Analysis Program for Automotive Wheel Bearing,” 2012 SIMULIA Customer Conference, Providence, USA (2012).Google Scholar
38. Gunduz, A. and Singh, R., “Stiffness matrix formulation for double row angular contact ball bearings: Analytical development and validation,” Journal of Sound and Vibration, 332, pp. 5898–5916 (2013).Google Scholar
39. Heuler, P. and Klatschke, H., “Generation and use of standardised load spectra and load–time histories,” International Journal of Fatigue, 27, pp. 974–990 (2005).Google Scholar
40. Heuler, P., Bruder, T. and Klätschke, H., “Standardised load-time histories - a contribution to durability issues under spectrum loading,” Materialwissenschaft und Werkstofftechnik, 36, pp. 669–677 (2005).Google Scholar
41. Gerhard, F. and Grubisić, V., “Biaxial Wheel/Hub Test Facility Report No. TB-221,” Proceeding of the 5th International User Meeting, Darmstadt, Germany (2001).Google Scholar
42. Mazur, M., “Tolerance analysis and synthesis of assemblies subject to loading with process integration and design optimization tools,” Ph.D. Dissertation, Mechanical and Manufacturing Engineering, School of Aerospace, RMIT University Melbourne, Australia (2013).Google Scholar
43. Mihalič, P., “Measuring the width of the air gap in the in-wheel electric motors,” M.S. Thesis, Faculty of Mechanical Engineering, University of Ljubljana, Slovenia (2015).Google Scholar