Design of Quasi-Halbach Permanent-Magnet Vernier Machine for Direct-Drive Urban Vehicle Application

Removing the gearbox from the single-motor configuration of an electric vehicle (EV) would improve motor-to-wheel efficiency by preventing mechanical losses, thus extending the autonomy of the EV. To this end, a permanent-magnet Vernier machine (PMVM) is designed to ensure such operation. This machine avoids the high volume and large pole-pair number of the armature winding since its operating principle resembles that of a synchronous machine with an integrated magnetic gear. Therefore, such a structure achieves low-speed and high-torque operation at standard supply frequencies. From the specification of an urban vehicle, the required specification for direct-drive operation is first determined. On this basis, an initial prototype of a Vernier Machine with permanent magnets in the rotor that can replace the traction part (motor + gearbox) is designed and sized. This first prototype uses radial contiguous surface-mounted magnets and its performance is then analyzed using finite element analysis (FEA), showing a relatively high torque ripple ratio. The rotor magnets are then arranged in a quasi-Halbach configuration and simulations are performed with different stator slot openings and different ratios of the tangential part of the magnet in order to quantify the effect of each of these two quantities in terms of average torque, torque ripples and harmonics of the back-electromotive force at no load. Since the design and optimization of this motor is finite element-assisted, a coupling process between FEA Flux software and Altair HyperStudy is implemented for optimization. This method has the advantages of high accuracy of the magnetic flux densities and electromagnetic torque estimates, and especially the torque ripples. The optimization process leads to a prototype with an average torque value that meets the specification, along with a torque ripple ratio below 5% and a high power factor, while keeping the same amount of magnet and copper.