Design and Analysis of a Dual Rotor Multiphase Brushless DC Motor for its Application in Electric Vehicles
Received: 18 July 2021 | Revised: 13 October 2021 | Accepted: 22 October 2021 | Online: 11 December 2021
Corresponding author: A. Ulasyar
Abstract
The main objective of this paper is to study the effect of phase numbers in the dual rotor Brushless DC (BLDC) motor for its application in Electric Vehicles (EVs). The performance of two novel 5-, and 7-phase dual rotor BLDC motors is compared against the standard 3-phase dual rotor BLDC motor. The proposed motors combine the positive characteristics of multiphase BLDC motor and the dual rotor BLDC motor thus achieving better fault tolerance capability, high power density, and less per phase stator current. Finite Element Method (FEM) was used to design the 3-, 5-, and 7-phase dual-rotor BLDC motors. The design parameters and operating conditions are kept the same for a fair comparison. The stator current and torque performance of the proposed motors were obtained with FEM simulation and were compared with the standard 3-phase dual rotor BLDC motor. It is possible to use low power rating power electronics switches for the proposed motor. The simulation results also validate low torque ripples and high-power density in the proposed motors. Finally, the fault analysis of the designed motors shows that the fault tolerance capability increases as the phase number increases.
Keywords:
brushless DC (BLDC), electric vehicle, multiphase, finite element method, dual rotorDownloads
References
P. Zheng, Y. Liu, Y. Wang, and S. Cheng, "Magnetization analysis of the brushless DC motor used for hybrid electric vehicle," IEEE Transactions on Magnetics, vol. 41, no. 1, pp. 522–524, Jan. 2005, https://doi.org/10.1109/TMAG.2004.838746.
J. A. Sanguesa, V. Torres-Sanz, P. Garrido, F. J. Martinez, and J. M. Marquez-Barja, "A Review on Electric Vehicles: Technologies and Challenges," Smart Cities, vol. 4, no. 1, pp. 372–404, Mar. 2021, https://doi.org/10.3390/smartcities4010022.
K. T. Chau, C. C. Chan, and C. Liu, "Overview of Permanent-Magnet Brushless Drives for Electric and Hybrid Electric Vehicles," IEEE Transactions on Industrial Electronics, vol. 55, no. 6, pp. 2246–2257, Jun. 2008, https://doi.org/10.1109/TIE.2008.918403.
W. Cai, X. Wu, M. Zhou, Y. Liang, and Y. Wang, "Review and Development of Electric Motor Systems and Electric Powertrains for New Energy Vehicles," Automotive Innovation, vol. 4, no. 1, pp. 3–22, Feb. 2021, https://doi.org/10.1007/s42154-021-00139-z.
A. Eldho Aliasand and F. T. Josh, "Selection of Motor foran Electric Vehicle: A Review," Materials Today: Proceedings, vol. 24, pp. 1804–1815, Jan. 2020, https://doi.org/10.1016/j.matpr.2020.03.605.
T. A. Zarma, A. A. Galadima, and M. A. Aminu, "Review of Motors for Electric Vehicles," Journal of Scientific Research and Reports, pp. 1–6, Oct. 2019, https://doi.org/10.9734/jsrr/2019/v24i630170.
M. Yildirim, H. Kurum, D. Miljavec, and S. Corovic, "Influence of Material and Geometrical Properties of Permanent Magnets on Cogging Torque of BLDC," Engineering, Technology & Applied Science Research, vol. 8, no. 2, pp. 2656–2662, Apr. 2018, https://doi.org/10.48084/etasr.1725.
Z. Q. Zhu and D. Howe, "Electrical Machines and Drives for Electric, Hybrid, and Fuel Cell Vehicles," Proceedings of the IEEE, vol. 95, no. 4, pp. 746–765, Apr. 2007, https://doi.org/10.1109/JPROC.2006.892482.
T.-Y. Lee, M.-K. Seo, Y.-J. Kim, and S.-Y. Jung, "Motor Design and Characteristics Comparison of Outer-Rotor-Type BLDC Motor and BLAC Motor Based on Numerical Analysis," IEEE Transactions on Applied Superconductivity, vol. 26, no. 4, pp. 1–6, Jun. 2016, https://doi.org/10.1109/TASC.2016.2548079.
M. Dahbi, S. Doubabi, A. Rachid, and D. Oulad-Abbou, "Performance evaluation of electric vehicle brushless direct current motor with a novel high-performance control strategy with experimental implementation," Proceedings of the Institution of Mechanical Engineers, Part I: Journal of Systems and Control Engineering, vol. 234, no. 3, pp. 358–369, Mar. 2020, https://doi.org/10.1177/0959651819854562.
Y. Li, D. Bobba, and B. Sarlioglu, "Design and Optimization of a Novel Dual-Rotor Hybrid PM Machine for Traction Application," IEEE Transactions on Industrial Electronics, vol. 65, no. 2, pp. 1762–1771, Feb. 2018, https://doi.org/10.1109/TIE.2017.2739686.
B. V. R. Kumar and K. S. Kumar, "Design of a new Dual Rotor Radial Flux BLDC motor with Halbach array magnets for an electric vehicle," in International Conference on Power Electronics, Drives and Energy Systems, Trivandrum, India, Dec. 2016, pp. 1–5, https://doi.org/10.1109/PEDES.2016.7914552.
Y.-H. Yeh, M.-F. Hsieh, and D. G. Dorrell, "Different Arrangements for Dual-Rotor Dual-Output Radial-Flux Motors," IEEE Transactions on Industry Applications, vol. 48, no. 2, pp. 612–622, Mar. 2012, https://doi.org/10.1109/TIA.2011.2180495.
A. Dalal and P. Kumar, "Design, Prototyping, and Testing of a Dual-Rotor Motor for Electric Vehicle Application," IEEE Transactions on Industrial Electronics, vol. 65, no. 9, pp. 7185–7192, Sep. 2018, https://doi.org/10.1109/TIE.2018.2795586.
P. Pisek, B. Stumberger, T. Marcic, and P. Virtic, "Design Analysis and Experimental Validation of a Double Rotor Synchronous PM Machine Used for HEV," IEEE Transactions on Magnetics, vol. 49, no. 1, pp. 152–155, Jan. 2013, https://doi.org/10.1109/TMAG.2012.2220338.
G. Boztas, M. Yildirim, and O. Aydogmus, "Design and Analysis of Multi-Phase BLDC Motors for Electric Vehicles," Engineering, Technology & Applied Science Research, vol. 8, no. 2, pp. 2646–2650, Apr. 2018, https://doi.org/10.48084/etasr.1781.
M. Salehifar, R. S. Arashloo, J. M. Moreno-Equilaz, V. Sala, and L. Romeral, "Fault Detection and Fault Tolerant Operation of a Five Phase PM Motor Drive Using Adaptive Model Identification Approach," IEEE Journal of Emerging and Selected Topics in Power Electronics, vol. 2, no. 2, pp. 212–223, Jun. 2014, https://doi.org/10.1109/JESTPE.2013.2293518.
L. Parsa and H. A. Toliyat, "Five-phase permanent-magnet motor drives," IEEE Transactions on Industry Applications, vol. 41, no. 1, pp. 30–37, Jan. 2005, https://doi.org/10.1109/TIA.2004.841021.
H. Lu, J. Li, R. Qu, D. Ye, and Y. Lu, "Fault-Tolerant Predictive Control of Six-Phase PMSM Drives Based on Pulsewidth Modulation," IEEE Transactions on Industrial Electronics, vol. 66, no. 7, pp. 4992–5003, Jul. 2019, https://doi.org/10.1109/TIE.2018.2868264.
E. Levi, "Multiphase Electric Machines for Variable-Speed Applications," IEEE Transactions on Industrial Electronics, vol. 55, no. 5, pp. 1893–1909, May 2008, https://doi.org/10.1109/TIE.2008.918488.
Y. Yuan, W. Meng, X. Sun, and L. Zhang, "Design Optimization and Analysis of an Outer-Rotor Direct-Drive Permanent-Magnet Motor for Medium-Speed Electric Vehicle," World Electric Vehicle Journal, vol. 10, no. 2, Jun. 2019, Art. no. 16, https://doi.org/10.3390/wevj10020016.
C. Oprea, C. Martis, and B. Karoly, "Six-phase brushless DC motor for fault tolerant electric power steering systems," in International Aegean Conference on Electrical Machines and Power Electronics, Bodrum, Turkey, Sep. 2007, pp. 457–462, https://doi.org/10.1109/ACEMP.2007.4510543.
Y. Li, J. Zhao, Z. Chen, and X. Liu, "Investigation of a Five-Phase Dual-Rotor Permanent Magnet Synchronous Motor Used for Electric Vehicles," Energies, vol. 7, no. 6, pp. 3955–3984, Jun. 2014, https://doi.org/10.3390/en7063955.
J. Zhao, X. Gao, B. Li, X. Liu, and X. Guan, "Open-Phase Fault Tolerance Techniques of Five-Phase Dual-Rotor Permanent Magnet Synchronous Motor," Energies, vol. 8, no. 11, pp. 12810–12838, Nov. 2015, https://doi.org/10.3390/en81112342.
Downloads
How to Cite
License
Copyright (c) 2021 M. Hussain, A. Ulasyar, H. Sheh Zad, A. Khattak, S. Nisar, K. Imran

This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors who publish with this journal agree to the following terms:
- Authors retain the copyright and grant the journal the right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after its publication in ETASR with an acknowledgement of its initial publication in this journal.