Design and Analysis of New Irregular Consequent-Pole Hybrid Magnet Dual-Stator Machines

This article proposes new irregular consequent-pole hybrid magnet dual-stator machines (ICP-HMDSMs) with the merits of high torque density, low torque ripple (TR), and high space utilization, which are applicable to electric vehicles and unmanned aerial vehicles that require lightweight and high torque density drive machines. The proposed ICP-HMDSMs employ two layers of irregular shape consequent poles on inner stator and rotor, in which the irregular permanent magnets (PMs) can be divided into modulation area and excitation expansion area. The excitation expansion area can effectively improve the main flux and PM utilization. Meanwhile, the magnetic field excited by the modulation areas of NdFeB magnets and ferrite magnets is modulated by rotor teeth and inner stator iron poles, respectively, which introduce a bidirectional flux modulation effect to improve torque production. The configuration and design considerations of the proposed ICP-HMDSMs are presented. In addition, the electromagnetic performances of the proposed ICP-HMDSM are evaluated using a finite-element analysis (FEA) and compared with the conventional DSM. The FEA-predicted results show that the proposed ICP-HMDSMs have the merits of high torque density, low TR, and high power factor.