Elektrikli Araç Uygulamaları İçin Doğrudan Tahrikli Bir BLDC Motorunun Kapsamlı Tasarımı ve Testleri

Yıl 2025, Cilt: 6 Sayı: 1, 32 - 48, 19.06.2025

Mücahit Soyaslan , Mohamad Bazazian , Osman Eldoğan

https://doi.org/10.55546/jmm.1590391

Öz

Bu çalışma, hafif bir elektrikli araç (EV) için 2 kW'lık teker içi fırçasız doğru akım (BLDC) motor tasarımını sunmaktadır. EV, elektrikli araç yarışlarında önceden tanımlanmış bir rota için tasarlanmıştır. BLDC motor doğrudan aracın tekerlek jantına monte edilmektedir. Başlangıçta, EV'nin dinamik modeli araç özelliklerine göre hesaplanmıştır. Motorun oluk/kutup oranı 36/32 olarak seçilmiştir. Stator, rotor ve mıknatıslar için tasarımlar daha sonra düşük vuruntu torku ve yüksek verimlilik hedeflenerek motorun sınır boyutlarına göre geliştirilmiştir. Bunu başarmak için stator diş uçları arasındaki mesafe optimize edilmiştir. Tasarım, 2B sonlu elemanlar analizleri ile doğrulanmış ve ardından motorun üretimi gerçekleştirilmiştir. Deneysel kurulumla gerçekleştirilen performans testleri, tasarımın deneysel sonuçlarla örtüştüğünü doğrulamıştır.

Anahtar Kelimeler

BLDC motor , Elektrikli araç , Elektrik motor tasarımı , Dıştan rotorlu , Elektrikli araç dinamik modeli

Comprehensive Design and Testing of a BLDC Motor for Direct Drive EV Applications

Öz

This paper proposes a 2 kW in-wheel brushless direct current (BLDC) motor design for a light electric vehicle (EV). The EV is designed for a predefined route in electric vehicle races. The BLDC motor was directly mounted into the vehicle's wheel rim. Initially, dynamic model of EV was calculated according to vehicle characteristics. The motor's slot/pole ratio was selected as 36/32. The designs for the stator, rotor, and magnets were subsequently developed based on the motor's boundary dimensions, aiming for low cogging torque and high efficiency. To achieve this, the distance between stator tooth tips was optimized. The design was validated through 2D finite element analyses, followed by the motor's production. Performance tests conducted with the experimental setup confirmed that the design matches the experimental results.

Anahtar Kelimeler

Electric vehicle , BLDC motor , Electric motor design , Outer rotor , EV dynamic model

Teşekkür

The authors would like to thank to Sakarya University of Applied Sciences, SUBU-TETRA Electromobile Team and its members for their support.

Kaynakça

• Akar M., Eker M., Akın F., BLDC motor design and application for light electric vehicle. Afyon Kocatepe University, Journal of Science and Engineering 21.2, 326-336, 2021.
• Aliyadin A. Z., Purwadi A., Hidayat S., Performance Analysis and Design of 250 Watt Outer Rotor BLDC Motor for Urban Electric Bicycles, 2022 7th International Conference on Electric Vehicular Technology (ICEVT), Bali, Indonesia, 2022, pp. 195-199, doi: 10.1109/ICEVT55516.2022.9925011.
• Anuja T.A., Doss M.A.N., Reduction of Cogging Torque in Surface Mounted Permanent Magnet Brushless DC Motor by Adapting Rotor Magnetic Displacement. Energies 14 (10), 2861, 2021. https://doi.org/10.3390/en14102861.
• Anuja T.A., Doss M.A.N., Senthilkumar R., Rajesh K.S., Brindha R., Modification of Pole Pitch and Pole Arc in Rotor Magnets for Cogging Torque Reduction in BLDC Motor, IEEE Access, vol. 10, pp. 116709-116722, 2022. doi: 10.1109/ACCESS.2022.3217233.
• Avsar Y., Fenercioglu A., Soyaslan M., Design Optimization of PM Synchronous Motor: Rail Mounted Belt Drive Elevator Systems, IEEE Transactions on Industry Applications, vol. 60, no. 1, pp. 301-311, Jan.-Feb. 2024b. doi: 10.1109/TIA.2023.3311781.
• Avsar, Y., Soyaslan, M., & Fenercioglu, A. PMSM Design for Elevators: Determination of the Basic Topology Affecting Performance. The Eurasia Proceedings of Science Technology Engineering and Mathematics, 28, 342-351, 2024a. https://doi.org/10.55549/epstem.1523527
• Bazazian, M., Design of an outer rotor brushless dc motor used in electric vehicles, Master Thesis. Dept. of Mechatronics Eng., Sakarya University of Applied Sciences, Graduate Education Institute, Sakarya, 2022.
• Cabuk, A. S., Saglam, S., & Ustün, Ö., Investigation on efficiency of in-wheel BLDC motors for different winding structures. Journal of the Faculty of Engineering and Architecture of Gazi University, 34(4), 1975-1985, 2019.
• Cagıslar A. S., İn S., Tiryaki H., Effects of Magnet Type and Thickness on Outer Rotor Brushless Direct Current Motor Designed by Calculating the Required Motor Power for an Electric Vehicle Prototype. Erzincan University Journal of Science and Technology 13(3), 1025-1041, 2020. https://doi.org/10.18185/erzifbed.707837.
• Chawrasia S.K., Das A., Chanda C.K., Banerjee S., Design, analysis and comparative study of Hub motor for an electric bike. Michael Faraday IET International Summit 2020a MFIIS, pp. 242–247, 2020. https://doi.org/10.1049/icp.2021.1179.
• Doss M., Mohanraj K., Vakesan K., Karthik K., Reduction of Cogging Torque by Adapting Bifurcated Stator Slots and Minimization of Harmonics and Torque Ripple in Brushless DC Motor, International Journal of Power Electronics and Drive Systems (IJPEDS), 7(3), 781, 2016. https://doi.org/10.11591/ijpeds.v7.i3.pp781-789.
• Gürdal O., Elektrik Makinalarının Tasarımı, Atlas Yayın Dağıtım, İstanbul, 2001.
• Hussain M., Ulasyar A., Sheh Zad H., Khattak A., Nisar S., Imran K., Design and Analysis of a Dual Rotor Multiphase Brushless DC Motor for its Application in Electric Vehicles, Eng. Technol. Appl. Sci. Res., vol. 11, no. 6, pp. 7846–7852, Dec. 2021.
• Jhankal T., Design and Cogging Torque Reduction of Radial Flux Brushless DC Motors with Varied Permanent Magnet Pole Shapes for Electric Vehicle Application, Transactions on Energy Systems and Engineering Applications, 4(2), 1-13, 2023. https://doi.org/10.32397/tesea.vol4.n2.535.
• Karthick K., Ravivarman S., Samikannu R., Vinoth K., Sasikumar B., Analysis of the Impact of Magnetic Materials on Cogging Torque in Brushless DC Motor, Advances in Materials Science and Engineering, 2021, 1-10. https://doi.org/10.1155/2021/5954967.
• Kim Y., Yang B., Kim C., Noise Source Identification of Small Fan‐BLDC Motor System for Refrigerators," International Journal of Rotating Machinery, 2006(1). https://doi.org/10.1155/ijrm/2006/63214.
• Krasopoulos C.T., Beniakar M.E., Kladas A.G., Velocity and Torque Limit Profile Optimization of Electric Vehicle Including Limited Overload, IEEE Transactions on Industry Applications, vol. 53, no. 4, pp. 3907-3916, July-Aug. 2017, doi: 10.1109/TIA.2017.2680405.
• Lee B.-C., Song C.-H., Kim D.-H., Kim K.-C., Study on Process Derivation and Characteristic Analysis for BLDC Motor Design Using Dual Rotor Structure with High Torque Density. Energies 2020, 13, 6745. https://doi.org/10.3390/en13246745.
• Leitner S., Gruebler H., Muetze A., Cogging Torque Minimization and Performance of the Sub-fractional hp BLDC Claw-pole Motor, IEEE Transactions on Industry Applications, 55(5), 4653-4664, 2019. https://doi.org/10.1109/tia.2019.2923569.
• Mandasari D., Design and Optimization of Brushless DC Motor for Electric Boat Thruster, Evergreen, 10(3), 1928-1937, 2023. https://doi.org/10.5109/7151773.
• Minh D., Quoc V., Huy P., Efficiency Improvement of Permanent Magnet BLDC Motors for Electric Vehicles," Engineering Technology & Applied Science Research, 11(5), 7615-7618, 2021. https://doi.org/10.48084/etasr.4367.
• Murali, N., Ushakumari, S., Mini, V. P., & Varghesee, A. T., Sizing and Performance Analysis of an Electric Motor in an E-rickshaw. IEEE International Conference on Power Systems Technology (POWERCON) (pp. 1-6), Sep., 2020.
• Murat N., Ushakumari S., Mini V.P., Varghesee A.T., Sizing and Performance Analysis of an Electric Motor in an E-rickshaw, 2020 IEEE International Conference on Power Systems Technology (POWERCON), pp. 1-6, Sept. 2020.
• Niessen F., Winding Scheme Calculator, Erişim: 31 Ekim 2019, http://www.bavaria-direct.co.za/scheme/calculator/.
• Ocak C., Tarimer I., Dalcali A., Uygun D., Investigation effects of narrowing rotor pole embrace to efficiency and cogging torque at PM BLDC motor. TEM Journal 5(1), 25, 2016.
• Ozupak Y. Efficiency analysis of BLDC motor for variable magnetic field. MANAS Journal of Engineering,10(1):105-109, 2022. doi:10.51354/mjen.1097668
• Ozupak, Y., & Çınar, M. Design and Co-Analysis of A Permanent Magnet Brushless DC Motor By Using Clonal Selection Principle Based Wound Healing Algorithm and Ansys-Maxwell. Gazi University Journal of Science Part A: Engineering and Innovation, 10(4), 499-510, 2023. https://doi.org/10.54287/gujsa.1371904
• Rupam, S. Marwaha, Mitigation of Cogging Torque for the Optimal Design of BLDC Motor, IEEE 2nd International Conference On Electrical Power and Energy Systems (ICEPES), Bhopal, India, pp. 1-5, 2021, doi: 10.1109/ICEPES52894.2021.9699544.
• Smółka, K. and Firych‐Nowacka, A., Comparison of the design of 3-pole bldc actuators/motors with a rotor based on a single permanent magnet. Sensors, 22(10), 3759, 2022. https://doi.org/10.3390/s22103759
• Soyaslan M., Avşar Y., Fenercioğlu A., Eldoğan O., Cogging Torque Reduction in External Rotor PM Synchronous Motors by Optimum Pole Embrace, 3rd International Symposium on Multidisciplinary Studies and Innovative Technologies (ISMSIT), Ankara, Turkey, 2019, pp. 1-4, doi: 10.1109/ISMSIT.2019.8932915.
• Soyaslan M., Design of an External Rotor Permanent Magnet Synchronous Motor for Elevator Traction Systems, PhD Thesis, Dept. of Mechatronics Eng., Sakarya University, Institute of Natural Sciences, Sakarya, 2020.
• Soyaslan, M., External Rotor BLDC Motor Design for a Light Electric Vehicle: 24 Slot/22 Pole Combination, 18th Conference on Electrical Machines, Drives and Power Systems (ELMA), Varna, Bulgaria, pp. 1-4, 2023, doi: 10.1109/ELMA58392.2023.10202463
• Tosun, O., Serteller, N.F.O., The Design of the Outer-Rotor Brushless DC Motor and an Investigation of Motor Axial-Length-to-Pole-Pitch Ratio. Sustainability 2022, 14, 12743. https://doi.org/10.3390/su141912743.
• Vadde A., Sachin S., Influence of Rotor Design in BLDC Motor for Two-Wheeler Electric Vehicle, 1st International Conference on Power Electronics and Energy (ICPEE), Bhubaneswar, India, 2021, pp. 1-6, doi: 10.1109/ICPEE50452.2021.9358520.
• Zuki, N. A. M., Othman, R. N. F. K. R., Ahmad, S. R. C., & Shukor, F. A. A., Consideration of various constants in double stator permanent magnet brushless DC motor, International Journal of Applied Electromagnetics and Mechanics 63.1, 1-17, 2020.