Thermal and Vibration Analysis of a Dual Stator Consequent-Pole Vernier PM Machine with High Torque Density for application in Electric Vehicles

The Vernier PM machine is known as a machine with high torque and low speed, which has several advantages such as higher torque density, lower PM material volume, lower gear torque, improved performance and simpler and more durable structure compared to other structures based on the magnet is permanent. These machines are a good option for use in electric vehicles. One of the proposed structures that is suitable for this purpose is the structure of the Dual-Stator Consequent-Pole Vernier PM machine, which has high torque density, optimal functional characteristics and lower magnet consumption. But for the complete design of this structure, mechanical studies including thermal and vibration studies must be done on the designed electromagnetic structure. This is important because of the different geometry of conventional radial flux machines, unbalanced magnetic forces, and mechanical and thermal constraints. In this paper, the design of heat transfer system and mechanical structure of DS-CP-VPM machine has been done and thermal and vibration studies have been performed. Design variables were selected based on sensitivity analysis using the finite element method. Several design limitations in geometric dimensions, current density and magnetic flux density in different areas and mechanical forces have been considered. The results are confirmed for a 10 kW car with a torque of 2 KN for the application of an electric vehicle using the three-dimensional finite element method. In this paper, the thermal-mechanical analysis of the engine is performed and the simulation results in Comsol software are evaluated.