This contribution deals with the topic of the consistent further development of a wheel\nhub motor for battery electric vehicles (BEV) based on the principle of an outer rotor switched\nreluctance machine (SRM). The research work presented in this paper was founded by the\nERDF.NRW program, Investment for Growth and Employment and the European Regional\nDevelopment Fund. The R&D project was named Switched-Reluctance fo(u)r wheel (SR4Wheel).\nBased on the experience made by first prototype Evolution 0 (EVO 0), developed in the Laboratory\nfor Automation Engineering, Power Electronics and Electrical Drives of the Cologne University of\nApplied Sciences (CUAS), the test results of EVO 1, as well as the redesign, EVO 2 is presented in\nthis paper. The prototype EVO 0, a first proof of concept leads to several optimizations and lessons\nlearned for the predecessor model EVO 1. The overall target of developing such a gearless outer\nrotor wheel hub motor is the full integration of the complete machine including its power electronics\ninto the given space between the original friction brake and the rim. Furthermore, due to the\nadditional integration of the power electronics, great opportunities in terms of new vehicle design\nas well as retrofitting capabilities of already existing vehicle platforms can be achieved. Thereby,\nfurther drive train assembly space like the engine compartment is no longer necessary. The SRM\ndoes not require magnets for torque production which leads to independence from the changeable\ncommodity prices on the rare earth element markets. This paper presents the developing process,\ntesting, and verification of the innovative drive train concept starting with the final CAD of EVO 1.\nDuring the testing and verification process a machine characteristic mapping is performed on a\ndrive train test bench and subsequently the results of a finite element analysis (FEA) are plausibility\nchecked by the test bench results. The process continues with energy conversion test scenarios of\nthe project demonstrator vehicle on a roller test bench focused on noise vibration harshness (NVH)\nbehavior and efficiency. As a conclusion, the gained knowledge by evaluating two EVO 1\nprototypes on the rear axle of the test vehicle, and the design for the front axle drive train EVO 2\nwill be presented. As a major task on the front axle, the limited space due to the large disc brake can\nbe identified and solved.
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