Design and Performance Analysis of an Outer Rotor Brushless DC Motor for Single-Phase Integrated Charger

The growing demand for electric vehicles has led to a significant increase in the need for battery chargers. Traditionally, there are two main types of chargers: on-board and off-board. Recently, integrated on-board chargers have garnered interest from researchers, as they make use of components from the propulsion system, namely the motor and it's associated converter for charging purposes. In this type of system, the motor serves not only in propulsion mode but also employs it's windings as a grid filter during charging. This necessitates that the motor design not only focuses on enhancing performance during propulsion but also addresses critical performance parameters in charging mode, such as maximizing winding inductance to meet current quality standards and minimizing core flux density. This study focuses on the design of an outer-rotor brushless DC motor (BLDC) intended to be used as an integrated charger in twowheeler applications. The main aim of the work is to select the voltage rating of the motor to achieve desired inductance required for satisfying the power quality in charging mode. Accordingly, analytical design has been performed followed by finite-element simulation using ANSYS MAXWELL 2D. A laboratory prototype has been fabricated and results obtained have been reported.