【目的】整数槽扁线电机虽具备高功率密度与效率优势,但其绕组端部用铜量大、铜耗与发热问题突出。为此,本文提出一种双转子电机结构,旨在降低铜耗并提升电机整体效率。【方法】电机定子内外绕组采用径向集中嵌线技术,显著降低了电机端部用铜量及相应的铜耗。与此同时,通过增加永磁体用量并结合有限元法对电机整体性能进行优化,有效提升了功率因数与最大输出功率,并将铁耗的增加控制在最低限度。【结果】研究结果表明:采用扁线径向集中嵌线技术,使端部阻抗参数(电阻/电抗)及铜耗、漏磁同步降低50%;在等体积约束下完成电磁-机械协同优化,功率因数提升的同时,最大输出功率增加;冷却系统设计推动效率峰值提升,实现全工况(含过载)下高效区与高功率因数区重合。【结论】仿真与理论计算结果的高度一致性,验证了该双转子电机在高效率与高功率因数方面具备显著优势,为高密度电机设计提供新范式。

[Objective] Although integer-slot flat-wire motors offer high power density and efficiency, they suffer from significant drawbacks, including high copper usage, substantial copper loss, and severe heat generation in the winding end regions. Therefore, this paper proposes a dual-rotor motor structure designed to reduce copper loss and enhance overall motor efficiency. [Methods] Radial concentrated winding technology was adopted for both the inner and outer stator windings, significantly reducing copper usage and associated losses at the motor ends. Meanwhile, by increasing the amount of permanent magnet material and optimizing the overall motor performance with the finite element method, the power factor and maximum output power were effectively enhanced, while the increase in iron loss was kept to a minimum. [Results] The research findings were as follows: with the flat-wire radial concentrated winding technology, the end impedance parameters (resistance/reactance), copper loss, and magnetic flux leakage were all reduced by 50% synchronously. Furthermore, under the constant-volume constraint, electromechanical co-optimization was achieved, whereby the power factor was enhanced and the maximum output power was increased. The cooling system was designed to elevate the peak efficiency, enabling the coincidence of the high-efficiency and high-power-factor regions across all operating conditions, including overload. [Conclusion] The strong consistency between simulation and theoretical calculations confirms the significant advantages of the dual-rotor motor in terms of high efficiency and high power factor, establishing a new paradigm for the design of high-density motors.

国家自然科学基金(51677058，52207233)