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Influence of Electric Motor Manufacturing Tolerances on End-of-Line Testing: A Review

Author

Listed:
  • Nusrat Rezwana Shahreen Popsi

    (Department of Electrical and Computer Engineering, University of Windsor, Windsor, ON N9B 3P4, Canada)

  • Animesh Anik

    (Magna International Inc., Aurora, ON L4G 7L6, Canada)

  • Rajeev Verma

    (Data Simulation and IoT, Corporate Engineering and R&D, Magna Services of America, Inc., Troy, MI 48098, USA)

  • Caniggia Viana

    (Department of Electrical and Computer Engineering, University of Windsor, Windsor, ON N9B 3P4, Canada)

  • K. Lakshmi Varaha Iyer

    (Advanced Powertrain-Chassis Americas, Corporate Engineering and R&D, Magna International Inc., Troy, MI 48098, USA)

  • Narayan C. Kar

    (Department of Electrical and Computer Engineering, University of Windsor, Windsor, ON N9B 3P4, Canada)

Abstract

Electric vehicles (EVs) are propelled by electric traction drive systems (ETDSs), which consist of various components including an electric motor, power electronic converter, and gear box. During manufacturing, end-of-line testing is the ultimate step for ensuring the quality and performance of electric motors in electric vehicle (EV) traction drive systems (ETDSs). The outcome of end-of-line testing of electric motors is significantly influenced by the tolerances of their structural parameters, such as stator inner and outer diameters, magnet dimensions, air gaps, and other geometric parameters. The existing literature provides insights into parametric sensitivity, offering guidance for enhancing the reliability of end-of-line testing. In this manuscript, the importance of end-of-line testing and the role of manufacturing tolerances of e-motor structural parameters in the manufacturing process of ETDSs are discussed. The impact of tolerances of e-motor structural parameters on the test results, such as torque, efficiency, back EMF, and e-NV (noise and vibration), is investigated. Finally, key challenges and research gaps in this area are identified, and recommendations for future research to mitigate the drawbacks of end-of-line testing are provided.

Suggested Citation

  • Nusrat Rezwana Shahreen Popsi & Animesh Anik & Rajeev Verma & Caniggia Viana & K. Lakshmi Varaha Iyer & Narayan C. Kar, 2024. "Influence of Electric Motor Manufacturing Tolerances on End-of-Line Testing: A Review," Energies, MDPI, vol. 17(8), pages 1-12, April.
    • Handle: RePEc:gam:jeners:v:17:y:2024:i:8:p:1913-:d:1377367
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    References listed on IDEAS

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    1. Cha-Seung Jun & Byung-Il Kwon & Ohbong Kwon, 2018. "Tolerance Sensitivity Analysis and Robust Optimal Design Method of a Surface-Mounted Permanent Magnet Motor by Using a Hybrid Response Surface Method Considering Manufacturing Tolerances," Energies, MDPI, vol. 11(5), pages 1-16, May.
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