Performance Analysis and Simulation of a Novel Brushless Double Rotor Machine for Power-Split HEV Applications

A new type of brushless double rotor machine (BDRM) is proposed in this paper. The BDRM is an important component in compound-structure permanent-magnet synchronous machine (CS-PMSM) systems, which are promising for power-split hybrid electric vehicle (HEV) applications. The BDRM can realize the speed adjustment between claw-pole rotor and permanent-magnet rotor without brushes and slip rings. The structural characteristics of the BDRM are described and its magnetic circuit model is built. Reactance parameters of the BDRM are deduced by an analytical method. It is found that the size characteristics of the BDRM are different from those of conventional machines. The new sizing and torque equations are analyzed and the theoretical results are used in the optimization process. Studies of the analytical magnetic circuit and finite element method (FEM) model show that the BDRM tends to have high leakage flux and low power factor, and then the method to obtain high power factor is discussed. Furthermore, a practical methodology of the BDRM design is developed, which includes an analytical tool, 2D field calculation and performance evaluation by 3D field calculation. Finally, different topologies of the BDRM are compared and an optimum prototype is designed.