Highly Efficient Dual-Rotor Electric Drives: Setting New Standards in Performance and Cost Efficiency

Authors

A. Rosen, S. Ender, Z. Weicherding, R. Weingart, DeepDrive GmbH, Garching/Munich

Year

2025

Print Info

Production/Publication ÖVK

Summary

This paper introduces a novel Dual-Rotor radial flux motor technology, which significantly improves the efficiency of electric drives while reducing material and manufacturing costs. By replacing the stator yoke with a second rotor, the Dual-rotor topology eliminates core losses in the stator yoke, increases torque density, and enhances efficiency, particularly in real-world driving cycles. 

Key innovations include a torsionally stiff, self-supporting wave winding, which enhances mechanical stability and cooling efficiency, as well as an axially integrated cooling system that efficiently dissipates heat from both the electric machine and the inverter. The motor design enables the use of grain-oriented electrical steel, further reducing iron losses and improving magnet utilization. 

The integrated SiC-based three-level T-type inverter improves system efficiency by reducing PWM-induced losses while maintaining cost-effectiveness. Additionally, the Dual-rotor concept allows for significant material savings, including over 80% less electrical steel usage and a drastic reduction in magnet mass. 

Prototypes of the electric machine and inverter have been built and tested on a drivetrain test bench, confirming high simulation accuracy and demonstrating superior efficiency in driving cycles. The technology is well-suited for central drive applications in electric vehicles, offering a cost-effective, high-performance alternative to traditional PSMs.

ISBN

978-3-9504969-4-9

DOI

https://doi.org/10.62626/4gym-cmp5 Copy link

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