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Design, Multi-Objective Optimization, and Prototyping of a 20 kW 8000 rpm Permanent Magnet Synchronous Motor for a Competition Electric Vehicle

Authors: Pedro P. C. Bhagubai; João G. Sarrico; João F. P. Fernandes; P. J. Costa Branco;

Design, Multi-Objective Optimization, and Prototyping of a 20 kW 8000 rpm Permanent Magnet Synchronous Motor for a Competition Electric Vehicle

Abstract

A high-performance 20 kW, 20 Nm, 8000 rpm, spoke-type interior permanent magnet motor to be integrated into a FormulaStudent electric car’s powertrain has been designed to meet demanding performance requirements for its driving cycle. This paper describes key steps in the design optimization, analysis, fabrication, and testing of this machine. Design optimization used the non-dominated sorting genetic algorithm II (NSGA-II) coupled with a hybrid analytical/finite element model to reduce the computational time, achieving a torque and efficiency of 20 Nm and 98.6%, respectively. A prototype has been constructed. The final motor design has been tested, where experimental nominal torque and efficiency have reached 18.2 Nm and 90%, respectively. Design challenges regarding the manufacturing are presented, justified, and discussed in detail. Test results were conducted to evaluate reliability and motor temperatures with and without water refrigeration at nominal current. Despite those adjustments in the optimized design, one shows that the impact on the car’s lap time was low, going from 77.3 s for the ideal optimized motor to 78.9 s for the prototyped motor.

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Keywords

electromagnetic modeling; multi-objective optimization; permanent magnet; synchronous motor, Technology, T, synchronous motor, multi-objective optimization, electromagnetic modeling, permanent magnet

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    15
    popularity
    This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
    Top 10%
    influence
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    This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
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citations
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
15
Top 10%
Average
Top 10%
gold
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