电动汽车用高性能直驱轮毂电机研制

直驱轮毂电机因其作为分布式驱动电动汽车一种动力构型的诸多优点而广受关注。然而轮毂电机技术要求高，且多物理域深度强耦合，设计及制造难度大，我国尚无比肩国际的高性能轮毂电机标杆产品。对标国际一流产品，提出采用机、电、热、磁多物理域联合设计的方法应用于直驱轮毂电机的设计，结合拼块铁心工艺、一体注塑混合绝缘骨架技术、精密排绕线技术、高导热灌封胶及一体化灌封工艺、轻量化结构等先进制造工艺技术研制了一款高性能直驱轮毂电机。该电机的转矩密度和功率密度分别达到了21.3 N·m/kg和2.2 kW/kg，基本接近国际一流水平，验证了所提方法及相关技术的有效性。

Develop of High Performance Direct-driven In-wheel Motor for Electric Vehicle

Direct-driven in-wheel motor is widely concerned because of its advantages as a solution to distributed power vehicles. However, in-wheel motor has high performance requirements and complex multi-field coupling effects which cause the high difficulty on design and manufacturing. There are few high performance in-wheel motors in China. To overcome these challenges, the method of joint design of mechanic, electric, thermal and magnetic multi-physics is proposed to be applied to the design of direct drive hub motor. Through applying the technology of segmented stator core, over-molding technology of the hybrid bobbing, precision winding technology, high thermal conductivity potting technology, integral potting process, lightweight structural design, high line speed oil seal technology, etc., a high performance in-wheel motor was developed. The motor achieved high torque density of 21.3 N·m/kg and high power density of 2.2 kW/kg which can be compared with international advanced level, the result proved the effectiveness of the method and related techniques.