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Optimization of Dual-Rotor, Radial-Flux Electric Machines based on Surrogate Models

PRESENTER:
Alexander Rosen, DeepDrive

EXPERTISE:
Electromagnetics

Software:
JMAG

Dual-rotor electric machines offer high torque density and efficiency but require advanced electromagnetic simulation due to their unique topology. Oppositely skewed windings, two interacting air gaps and large conductor cross-sections introduce three-dimensional effects that cannot be captured accurately by conventional 2D finite element analysis.

This presentation introduces the simulation workflow used at DeepDrive for the development of automotive dual-rotor electric drives. The focus is on accurate prediction of torque ripple, current displacement effects and permanent magnet demagnetization using transient 3D FE simulation. The limitations of conventional 2D approaches and the resulting computational effort are discussed.

To enable fast design iterations, the 3D simulation results are combined with surrogate models for efficient multi-parameter optimization. The methodology is demonstrated using examples

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