内置悬置的轮毂电机驱动系统动力学特性及结构优化
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摘要
作为下一代纯电驱动系统的关键技术之一，轮毂电机驱动的电动汽车因其在车辆总布置结构、底盘主动控制以及操控方便性方面的明显技术优势，受到业界的高度重视。目前，轮毂电机驱动电动汽车的研发尚处于起步阶段，其研究方向主要集中在电机本体设计与控制系统的集成开发、线控驱动/制动技术、差速控制等方面。轮毂电机驱动的电动轮集电机、轮毂、减速机构、制动器等于一体，非簧载质量增加的同时，不平路面激励下轮胎跳动、载荷不均、轴承磨损及安装误差等都将引起电机气隙不均匀，这将导致轮毂电机引起的振动激励进一步恶化，同时引起定转子及相邻部件的振动，给车辆的平顺性和轮胎接地安全性等带来不利的影响。如何减小甚至消除这种不利影响，已成轮毂电机驱动电动汽车发展所要解决的关键问题之一。
针对上述现有电动轮驱动车辆存在的问题，本文提出了一种具有自主知识产权的新型内置悬置系统的电动轮拓扑结构方案。此方案通过设置弹性悬置元件将轮毂电机作为一个整体与簧下质量进行弹性隔离，悬置元件的设置一方面可以吸收路面传递给电机的振动能量，减小路面激励对电机气隙的影响，另一方面也可以吸收一部分电磁能量，减小传递到车身的电磁激励，削弱路面激励和电磁激励的相互恶化作用，达到改善车辆动力学特性的目的。围绕此新型结构方案，本文进行了建模、仿真及实验研究，主要做了以下几方面的研究工作：
（1）根据拓扑结构方案，在建立新型电动轮车辆振动模型的基础上，对系统车身加速度、车轮相对动载及定转子相对位移量等动力学响应特性指标对路面不平度速度输入的频响函数进行推导，并在频域范围内对新型电动轮结构和现有电动轮结构进行对比分析，从原理上论证了新型结构在垂向动力学特性上的优越性；并分析了车辆动力学响应指标对电机质量、轴承刚度、悬置元件刚度和阻尼等重要结构参数的灵敏度，为后续系统参数优化奠定了基础，对轮毂电机驱动电动汽车减振技术的研究有重要意义；
（2）根据车辆动力学响应指标对悬置元件参数灵敏度的分析结果，结合某实际汽车的车轮结构尺寸对悬置元件进行了结构设计和样件加工；基于静态压缩试验获得了各悬置元件的非线性刚度特性，并利用非线性刚度模型对路面激励下新型系统和现有电动轮系统的振动响应进行了对比分析，对悬置元件结构的设计结果和减振作用进行理论验证，为后续轮毂驱动系统非线性动力学的研究奠定了基础；
（3）应用Maxwell应力张量法，推导出电机的电磁力解析表达式，对气隙均匀/不均匀情况下的电磁力波进行了分析，研究气隙不均匀对轮毂电机电磁力的影响；在得到电机的电磁力表达式后，对其未偏心、静偏心、动偏心及混合偏心下的气隙不均匀情况进行计算，得到各种情况下主要不平衡激振力的激振谐次，并找出影响不平衡电磁激振力的主要因素，为从激振源本身进行振动控制奠定了基础；同时对轮毂定子—支撑架的固有特性进行计算，通过模态分析预测了外部激振源—不平衡电磁力是否会引起系统较大的振动；最后将电磁力表达式代入车辆动力学方程，对路面不平度和电磁复合激励下，车辆的振动响应特性进行了分析；
（4）应用Lagrange方程建立了传动系统的耦合振动模型，利用所建模型进一步分析电磁激励下系统的振动响应特性；在ADAMS/Car中建立了目标车型的双横臂悬架的动力学模型，并将由电动轮传动系统的动力学模型计算得到的因电机不平衡电磁力产生的作用到车轮上的外载荷激振力作为输入，分析了其对车轮外倾角、主销后倾角、主销内倾角和前轮前束等悬架动力学性能评价指标的影响，为轮毂电机驱动系统的设计和振动控制提供理论依据；
（5）采用尺寸优化和拓扑优化相结合的混合优化方法，对轮毂驱动系统进行结构轻量化优化设计，通过直接减少非簧载质量达到改善车辆平顺性和轮胎接地安全性的目的。轮毂驱动系统的混合优化主要包括两部分：①在保证车辆动力性前提下，以轮毂电机质量最小化为目标，联合有限元（FEM）、响应面（RSM）和粒子群优化算法（PSO）对轮毂电机进行了结构优化设计，并对优化前后轮毂电机的磁场分布和转矩特性进行对比分析，对优化结果进行了验证；②根据第①步的优化结果，对定子支撑架尺寸进行调整，并利用变密度法对其进行应力约束下的拓扑优化，通过对优化后的结构进行应力分析，对优化结果进行了校核；
（6）完成新型电动轮样机系统的研制工作，通过前期样机功能实验，验证了新型内置悬置的轮毂电机驱动电动轮结构对解决路面激励引起的电机气隙不均匀问题的可行性。
As one of the key technologies of the next generation of pure electric drive system，in-wheel motor driven electric vehicles have gained great importance in the industry due to itsobvious technical advantages in vehicle’s overall arrangement, chassis active control andhandling convenience. Currently, the research and development of in-wheel motor drivenelectric vehicles are still in their infancy, research interests are mainly focused on the designof motor itself with integrated development of control system, drive-by-wire/brake-by-wire,speed differential control, etc. The electric wheel driven by in-wheel motor integrates themotor, wheel hub, reducing gearbox and brake as a whole, which increases the unsprung mass,meanwhile, tyre runout under the excitation of uneven road, non-uniform load, bearing wearand installation error will cause the motor air gap non-uniform, which will worsen thevibration excitation induced by the in-wheel motor, cause the vibration of stator and rotor aswell as adjacent parts, and bring adverse effects on vehicle’s ride and ride comfort. How toreduce or even eliminate these adverse effects has become one of the key problems to besolved in the development of in-wheel motor driven electric vehicles.
Focusing on the existing problems in current in-wheel driven vehicles, this articleproposes a novel topology scheme with autonomous intellectual property rights for electricwheel with embedded mount system. This scheme elastically isolates the in-wheel motor as awhole from the unsprung mass by setting elastic elements, converts the motor to a parallelmass of the sprung mass. Meanwhile, to utilize the elastic elements to absorb the vibrationenergy passed to the motor from the ground to minimize the effect on the motor air gap due toroad excitation in order to improve the vehicle’s dynamic characteristics. Around this novelstructure scheme, this article mainly carried out research in the following aspects:
(1) Based on the vibration model of the novel in-wheel vehicle established according tothe topology scheme, to derive the frequency response function of vehicles’ ride performanceindicator such as body acceleration, wheel’s relative dynamic load and relative displacementbetween stator and rotor with respect to road roughness’s velocity input, and then perform thefrequency response analysis for the novel in-wheel structure as well as current electric-wheelstructure in frequency domain, to prove the superiority of the novel structure in verticaldynamic characteristics by principle; to perform the sensitivity analysis of vehicles’ rideperformance indicator with respect to some important structural parameters such as motormass, bearing stiffness, mount element stiffness and damping in order to realize the systemparameters’ effect on vibration response, which make great significance in vibration damping vibration damping for in-wheel motor driven cars as well as building foundation forsubsequent system parameters optimization;
(2) According to the result of sensitivity analysis of vehicles’ ride performance indicatorwith respect to mount elements’ parameters, combined with the actual wheel structural size todesign and make prototype for mount elements, and then to gain the nonlinear stiffness modelfor every mount element based on static compression test, and utilizes the nonlinear stiffnessmodel to make comparative analysis for the vibration response under road excitation of thenovel and current electric wheel system, to verify the structural design result and dampingeffect of the mount elements, building foundation for the subsequent research on nonlineardynamics of in-wheel driven system.
(3) From the constitutive structure of this study’s in-wheel motor prototype, Maxwell’sstress tensor is used to derive the analytical expression of the motor’s electromagneticmoment, the electromagnetic force wave is to be analyzed under uniform/non-uniform air gapcondition, and then research into the effect on in-wheel motor’s electromagnetic force by airgap unevenness, at the same time, the dynamic characteristics of the novel in-wheel motordriven vehicle under uniform/non-uniform air gap will be analyzed in the following aspect:nonlinear vibration response characteristics of vehicle under simultaneous acting of roadexcitation and electromagnetic excitation;
(4) Building the physical model of in-wheel motor system, and then general Lagrangeequation is used to build the system’s electromechanical coupling dynamics model with thehelp of energy principle, the vibration response of motor in-wheel motor system is analyzedunder the electromagnetic excitation. The research work in this chapter can providetheoretical basis of the design and vibration control of in-wheel motor driven system.
(5) To perform the lightweight design of the in-wheel motor driven system with outerrotor and inner stator. Direct reduction of unsprung mass is used to improve the ride and ridecomfort. Lightweight design mainly include two aspects:○1under the premise of ensuringvehicles’ dynamic performance, lightweight design of in-wheel motor is performed bycombining Finite Element Method (FEM), Response Surface Method (RSM) and ParticleSwarm Optimization (PSO) algorithm, to minimize the mass of in-wheel motor, and thenmake comparative analysis of in-wheel motor’s magnetic field distribution and torquecharacteristics before and after optimization to verify the result of optimization;②according to the result of optimization in step○1, to modify the size of stator bracket andperform topology optimization under stress constraint by using variable density method, and then verify the result of optimization by performing stress analysis to the structure afteroptimization.
(6) Completing the development of the novel electric wheel prototype system, functionaltest will be performed to the pre-prototype, and then preliminary feasibility verification of theability of this novel electric wheel structure of in-wheel motor drive system with embeddedmount to solve the non-uniform air gap problem due to road excitation will be performed.
针对上述现有电动轮驱动车辆存在的问题，本文提出了一种具有自主知识产权的新型内置悬置系统的电动轮拓扑结构方案。此方案通过设置弹性悬置元件将轮毂电机作为一个整体与簧下质量进行弹性隔离，悬置元件的设置一方面可以吸收路面传递给电机的振动能量，减小路面激励对电机气隙的影响，另一方面也可以吸收一部分电磁能量，减小传递到车身的电磁激励，削弱路面激励和电磁激励的相互恶化作用，达到改善车辆动力学特性的目的。围绕此新型结构方案，本文进行了建模、仿真及实验研究，主要做了以下几方面的研究工作：
（1）根据拓扑结构方案，在建立新型电动轮车辆振动模型的基础上，对系统车身加速度、车轮相对动载及定转子相对位移量等动力学响应特性指标对路面不平度速度输入的频响函数进行推导，并在频域范围内对新型电动轮结构和现有电动轮结构进行对比分析，从原理上论证了新型结构在垂向动力学特性上的优越性；并分析了车辆动力学响应指标对电机质量、轴承刚度、悬置元件刚度和阻尼等重要结构参数的灵敏度，为后续系统参数优化奠定了基础，对轮毂电机驱动电动汽车减振技术的研究有重要意义；
（2）根据车辆动力学响应指标对悬置元件参数灵敏度的分析结果，结合某实际汽车的车轮结构尺寸对悬置元件进行了结构设计和样件加工；基于静态压缩试验获得了各悬置元件的非线性刚度特性，并利用非线性刚度模型对路面激励下新型系统和现有电动轮系统的振动响应进行了对比分析，对悬置元件结构的设计结果和减振作用进行理论验证，为后续轮毂驱动系统非线性动力学的研究奠定了基础；
（3）应用Maxwell应力张量法，推导出电机的电磁力解析表达式，对气隙均匀/不均匀情况下的电磁力波进行了分析，研究气隙不均匀对轮毂电机电磁力的影响；在得到电机的电磁力表达式后，对其未偏心、静偏心、动偏心及混合偏心下的气隙不均匀情况进行计算，得到各种情况下主要不平衡激振力的激振谐次，并找出影响不平衡电磁激振力的主要因素，为从激振源本身进行振动控制奠定了基础；同时对轮毂定子—支撑架的固有特性进行计算，通过模态分析预测了外部激振源—不平衡电磁力是否会引起系统较大的振动；最后将电磁力表达式代入车辆动力学方程，对路面不平度和电磁复合激励下，车辆的振动响应特性进行了分析；
（4）应用Lagrange方程建立了传动系统的耦合振动模型，利用所建模型进一步分析电磁激励下系统的振动响应特性；在ADAMS/Car中建立了目标车型的双横臂悬架的动力学模型，并将由电动轮传动系统的动力学模型计算得到的因电机不平衡电磁力产生的作用到车轮上的外载荷激振力作为输入，分析了其对车轮外倾角、主销后倾角、主销内倾角和前轮前束等悬架动力学性能评价指标的影响，为轮毂电机驱动系统的设计和振动控制提供理论依据；
（5）采用尺寸优化和拓扑优化相结合的混合优化方法，对轮毂驱动系统进行结构轻量化优化设计，通过直接减少非簧载质量达到改善车辆平顺性和轮胎接地安全性的目的。轮毂驱动系统的混合优化主要包括两部分：①在保证车辆动力性前提下，以轮毂电机质量最小化为目标，联合有限元（FEM）、响应面（RSM）和粒子群优化算法（PSO）对轮毂电机进行了结构优化设计，并对优化前后轮毂电机的磁场分布和转矩特性进行对比分析，对优化结果进行了验证；②根据第①步的优化结果，对定子支撑架尺寸进行调整，并利用变密度法对其进行应力约束下的拓扑优化，通过对优化后的结构进行应力分析，对优化结果进行了校核；
（6）完成新型电动轮样机系统的研制工作，通过前期样机功能实验，验证了新型内置悬置的轮毂电机驱动电动轮结构对解决路面激励引起的电机气隙不均匀问题的可行性。
As one of the key technologies of the next generation of pure electric drive system，in-wheel motor driven electric vehicles have gained great importance in the industry due to itsobvious technical advantages in vehicle’s overall arrangement, chassis active control andhandling convenience. Currently, the research and development of in-wheel motor drivenelectric vehicles are still in their infancy, research interests are mainly focused on the designof motor itself with integrated development of control system, drive-by-wire/brake-by-wire,speed differential control, etc. The electric wheel driven by in-wheel motor integrates themotor, wheel hub, reducing gearbox and brake as a whole, which increases the unsprung mass,meanwhile, tyre runout under the excitation of uneven road, non-uniform load, bearing wearand installation error will cause the motor air gap non-uniform, which will worsen thevibration excitation induced by the in-wheel motor, cause the vibration of stator and rotor aswell as adjacent parts, and bring adverse effects on vehicle’s ride and ride comfort. How toreduce or even eliminate these adverse effects has become one of the key problems to besolved in the development of in-wheel motor driven electric vehicles.
Focusing on the existing problems in current in-wheel driven vehicles, this articleproposes a novel topology scheme with autonomous intellectual property rights for electricwheel with embedded mount system. This scheme elastically isolates the in-wheel motor as awhole from the unsprung mass by setting elastic elements, converts the motor to a parallelmass of the sprung mass. Meanwhile, to utilize the elastic elements to absorb the vibrationenergy passed to the motor from the ground to minimize the effect on the motor air gap due toroad excitation in order to improve the vehicle’s dynamic characteristics. Around this novelstructure scheme, this article mainly carried out research in the following aspects:
(1) Based on the vibration model of the novel in-wheel vehicle established according tothe topology scheme, to derive the frequency response function of vehicles’ ride performanceindicator such as body acceleration, wheel’s relative dynamic load and relative displacementbetween stator and rotor with respect to road roughness’s velocity input, and then perform thefrequency response analysis for the novel in-wheel structure as well as current electric-wheelstructure in frequency domain, to prove the superiority of the novel structure in verticaldynamic characteristics by principle; to perform the sensitivity analysis of vehicles’ rideperformance indicator with respect to some important structural parameters such as motormass, bearing stiffness, mount element stiffness and damping in order to realize the systemparameters’ effect on vibration response, which make great significance in vibration damping vibration damping for in-wheel motor driven cars as well as building foundation forsubsequent system parameters optimization;
(2) According to the result of sensitivity analysis of vehicles’ ride performance indicatorwith respect to mount elements’ parameters, combined with the actual wheel structural size todesign and make prototype for mount elements, and then to gain the nonlinear stiffness modelfor every mount element based on static compression test, and utilizes the nonlinear stiffnessmodel to make comparative analysis for the vibration response under road excitation of thenovel and current electric wheel system, to verify the structural design result and dampingeffect of the mount elements, building foundation for the subsequent research on nonlineardynamics of in-wheel driven system.
(3) From the constitutive structure of this study’s in-wheel motor prototype, Maxwell’sstress tensor is used to derive the analytical expression of the motor’s electromagneticmoment, the electromagnetic force wave is to be analyzed under uniform/non-uniform air gapcondition, and then research into the effect on in-wheel motor’s electromagnetic force by airgap unevenness, at the same time, the dynamic characteristics of the novel in-wheel motordriven vehicle under uniform/non-uniform air gap will be analyzed in the following aspect:nonlinear vibration response characteristics of vehicle under simultaneous acting of roadexcitation and electromagnetic excitation;
(4) Building the physical model of in-wheel motor system, and then general Lagrangeequation is used to build the system’s electromechanical coupling dynamics model with thehelp of energy principle, the vibration response of motor in-wheel motor system is analyzedunder the electromagnetic excitation. The research work in this chapter can providetheoretical basis of the design and vibration control of in-wheel motor driven system.
(5) To perform the lightweight design of the in-wheel motor driven system with outerrotor and inner stator. Direct reduction of unsprung mass is used to improve the ride and ridecomfort. Lightweight design mainly include two aspects:○1under the premise of ensuringvehicles’ dynamic performance, lightweight design of in-wheel motor is performed bycombining Finite Element Method (FEM), Response Surface Method (RSM) and ParticleSwarm Optimization (PSO) algorithm, to minimize the mass of in-wheel motor, and thenmake comparative analysis of in-wheel motor’s magnetic field distribution and torquecharacteristics before and after optimization to verify the result of optimization;②according to the result of optimization in step○1, to modify the size of stator bracket andperform topology optimization under stress constraint by using variable density method, and then verify the result of optimization by performing stress analysis to the structure afteroptimization.
(6) Completing the development of the novel electric wheel prototype system, functionaltest will be performed to the pre-prototype, and then preliminary feasibility verification of theability of this novel electric wheel structure of in-wheel motor drive system with embeddedmount to solve the non-uniform air gap problem due to road excitation will be performed.
引文
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