Optimization and Design of Built-In U-Shaped Permanent Magnet and Salient-Pole Electromagnetic Hybrid Excitation Generator for Vehicles

In this paper, the concept of symmetry is utilized to optimize the structural parameters and output characteristics of the generator design—that is, the construction and solution of the equivalent magnetic circuit method for the hybrid excitation generator are symmetrical. To address the issues of high excitation loss and low power density in purely electrically excited generators, as well as the difficulty in adjusting the magnetic field in purely permanent magnet generators, a new topology for a built-in permanent magnet and salient-pole electromagnetic hybrid excitation generator is proposed. Firstly, an equivalent magnetic circuit model of the generator is established. Secondly, expressions are derived to describe the relationships between the dimensions of the salient-pole rotor and the permanent magnets and the generator’s no-load induced electromotive force, cogging torque, and air gap flux density. These expressions are then used to analyze the structural parameters that influence the generator’s performance. Thirdly, optimization targets are selected through sensitivity analysis, with the no-load induced electromotive force, cogging torque, and air gap flux density serving as the optimization objectives. A multi-objective genetic algorithm is employed to optimize these parameters and determine the optimal structural matching parameters for the generator. As a result, the optimized no-load induced electromotive force increased from 18.96 V to 20.14 V, representing a 6.22% improvement; the cogging torque decreased from 177.08 mN·m to 90.52 mN·m, a 48.88% reduction; the air gap flux density increased from 0.789 T to 0.829 T, a 5.07% improvement; and the air gap flux density waveform distortion rate decreased from 6.22% to 2.38%, a 39.3% reduction. Finally, a prototype is fabricated and experimentally tested, validating the accuracy of the simulation analysis, the feasibility of the optimization method, and the rationality of the generator design. Therefore, the proposed topology and optimization method can effectively enhance the output performance of the generator, providing a valuable theoretical reference for the design of hybrid excitation generators for vehicles.