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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

Author

Listed:
  • Pedro P. C. Bhagubai

    (IDMEC, Instituto Superior Técnico, Universidade de Lisboa, 1049-001 Lisbon, Portugal)

  • João G. Sarrico

    (Instituto Superior Técnico, Universidade de Lisboa, 1049-001 Lisbon, Portugal)

  • João F. P. Fernandes

    (IDMEC, Instituto Superior Técnico, Universidade de Lisboa, 1049-001 Lisbon, Portugal)

  • P. J. Costa Branco

    (IDMEC, Instituto Superior Técnico, Universidade de Lisboa, 1049-001 Lisbon, Portugal)

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.

Suggested Citation

  • Pedro P. C. Bhagubai & João G. Sarrico & João F. P. Fernandes & P. J. Costa Branco, 2020. "Design, Multi-Objective Optimization, and Prototyping of a 20 kW 8000 rpm Permanent Magnet Synchronous Motor for a Competition Electric Vehicle," Energies, MDPI, vol. 13(10), pages 1-24, May.
    • Handle: RePEc:gam:jeners:v:13:y:2020:i:10:p:2465-:d:357867
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    References listed on IDEAS

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    1. Thanh Anh Huynh & Min-Fu Hsieh, 2018. "Performance Analysis of Permanent Magnet Motors for Electric Vehicles (EV) Traction Considering Driving Cycles," Energies, MDPI, vol. 11(6), pages 1-24, May.
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    Cited by:

    1. Song, Zaixin & Liu, Chunhua, 2022. "Energy efficient design and implementation of electric machines in air transport propulsion system," Applied Energy, Elsevier, vol. 322(C).
    2. Youguang Guo & Lin Liu & Xin Ba & Haiyan Lu & Gang Lei & Wenliang Yin & Jianguo Zhu, 2022. "Measurement and Modeling of Magnetic Materials under 3D Vectorial Magnetization for Electrical Machine Design and Analysis," Energies, MDPI, vol. 16(1), pages 1-11, December.
    3. Pedro P. C. Bhagubai & Luís F. D. Bucho & João F. P. Fernandes & P. J. Costa Branco, 2022. "Optimal Design of an Interior Permanent Magnet Synchronous Motor with Cobalt Iron Core," Energies, MDPI, vol. 15(8), pages 1-21, April.
    4. Marko Merdžan, 2021. "Performance Analysis of High-Speed Electric Machines Supplied by PWM Inverters Based on the Harmonic Modeling Method," Energies, MDPI, vol. 14(9), pages 1-35, May.
    5. Jiongjiong Cai & Peng Ke & Xiao Qu & Zihui Wang, 2022. "Research on the Design of Auxiliary Generator for Enthalpy Reduction and Steady Speed Scroll Expander," Energies, MDPI, vol. 15(9), pages 1-17, April.
    6. João F. P. Fernandes & Pedro P. C. Bhagubai & Paulo J. C. Branco, 2022. "Recent Developments in Electrical Machine Design for the Electrification of Industrial and Transportation Systems," Energies, MDPI, vol. 15(17), pages 1-13, September.
    7. Jiahui Huang & Weinong Fu & Shuangxia Niu & Xing Zhao & Yanding Bi & Zhenyang Qiao, 2022. "A General Pattern-Based Design Optimization for Asymmetric Spoke-Type Interior PM Machines," Energies, MDPI, vol. 15(24), pages 1-14, December.

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