Design and Development of Interior Permanent Magnet Motor for Electric Traction Applications

Transport sector is responsible of more than 28% of total energy consumption. More specifically, it is consuming approx. 60% of global oil products. Among the transport, road vehicles are consuming the largest energy. Although, improving the efficiency and fuel economy of vehicles are helping in man

Project Title

Design and Development of Interior Permanent Magnet Motor for Electric Traction Applications

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

Transport sector is responsible of more than 28% of total energy consumption. More specifically, it is consuming approx. 60% of global oil products. Among the transport, road vehicles are consuming the largest energy. Although, improving the efficiency and fuel economy of vehicles are helping in managing energy demand, saving money, and minimizing climate and air quality impacts from emissions, it is not enough, especially due to the depletion of natural energy resources and increasing demand of the transport predominantly in Asia. The future solution and need are to shift on the electric vehicle (EV) or hybrid electric vehicle (HEV).

The basic requirements for traction applications, such as, EV, HEV, or in wheel scooter etc include high starting torque, high torque density, a wide constant power speed range (CPSR), and high efficiency. Therefore, permanent magnet (PM) motors are better choice, and it is known that the CPSR is greatly influenced by the PM rotor structures and can be achieved by inserted PM rotor structures. Furthermore, it is possible to improve the CPSR, torque density, emission, and cost by optimizing the rotor design.

In this project, inserted permanent magnet (IPM) motor structure are designed and analysed through 2D finite element method (FEA) and selected IPM motor prototype is developed, and its characteristics will be validated and analysed. The stator of the IPM motors will be identical, airgap, number of poles and rotor outer dimensions are kept same during the 2D FEA, as to reduce the number of design variables, and for the reasonable comparison, however, the rotor shapes, considering the placemen, position, number, and size of the inserted PMs will be modified to compare torque, torque ripple, efficiency, and back EMF.

The key aspects of the aimed project are:

• IPM motor is more suitable for the EVs and HEVs because of their high torque and high torque density, better CPSR, high efficiency, smooth performance, and easy control.
• It reduces the dependance on the fuels, and hence, supports and encourage the affordable clean energy.
• It is aimed to investigate, analyze, and improve the technological performances of the IPM motor for the traction applications.
• Safe and clean traction is critical for the sustainable development and hence it is vital to invest in the electric tractions, which necessitates the investigation on IPM motor structures.

Project Objectives

In this project, IPM motor for the traction application is investigated. Therefore, the main objectives of the project are as under:

1. Technological advancement: As the EVs and HEVs are the future of the automobile industry, therefore:

1.1 Modeling, analyzing, and designing the IPM motor using the 2D FEA will be carried out.

1.2 IPM motor having high starting torque, high torque density, extended speed range will be developed for the traction applications.

1.3 Detailed report will be published for the further advancements.

1. Sustainable development: Actually, transport supports all the sustainable development goals for the social, industrial, and economic development of Pakistan. However, the objective for the selected project is

2.1 Lesser dependance on the fuel consumption and reduction of the pollution and emission.

2.2 Clean and safe electric or hybrid electric traction system.

Project Implementation Method

The project implementation will be based on following flow:

1. Literature review:

1.1 State of the art of the IPM motor structures for any application.

1.2 Machine structure i.e., stator and rotor for the traction applications.

1.3 Commercialized IPM structures for the traction applications.

1. Analysis of the IPM motor using 2D FEA for the traction application

2.1 Select the motor dimensions i.e., stator winding, number of slots and stator structure, number of poles, air gap, and rotor over all dimensions.

2.2 Model the IPM rotor structure by changing the PM placement, position, and its dimensions.

2.3. Analyze the different IPM rotor structure using 2D FEA.

1. Precisely design, model and analyze the selected IPM model by considering the following constraints:

3.1 Required torque, power, and speed.

3.2 At provided motor specifications.

3.3 Precise and fine 2D FEA.

1. Development of the IPM motor prototype for the traction applications

4.1 IPM motor sample prototype will be developed.

4.2 Analysis will be carried out between the 2D FEA model and developed prototype results.

Benefits of the Project

The Design and development of Interior permanent magnet motor for traction applications and its hardware configuration plays a vital role in overall machine’s performance and this project would be intensively beneficial for machine design and techniques for industrial applications.

This project will present design of traction application aimed and satisfying the requirements of exemplary working vehicle and the challenges associated with it. The large, rated torque, an even larger value of stall torque capability will be produced within short period so that vehicle will overcome obstacles along the way.

Although, EVs and HEVs are very expensive, their running cost is heavily reducing due to the growing advancements in the electrical motor technologies. However, huge room of investigation and research is available to boom the technological advancements. It assists in the safe and clean affordable energy by reducing the dependence on the fuel consumption.

Technical Details of Final Deliverable

Different models of the IPM motor are modeled and analyzed using 2D FEA, by principally varying the PM structure in the rotor, such as, position, placement, and PM dimensions. The IPM motor having high starting torque, high torque density, lesser amount of the PM, constant power speed range, higher efficiency, lesser losses is selected for the precise and fine 2D FEA. The FEA results of the selected IPM motor are aimed to be validated by developing the motor prototype.

As, the IPM motor is designed for the traction applications, such as EVs or HEVs, therefore, carbon emissions, fuel consumption, and hence pollution produced by the conventional internal combustion engines (ICE) in the automobile industry will be reduced to provide clean and safe traction to enhance the sustainable industrial and economic growth.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Manufacturing

Other Industries

Core Technology

Artificial Intelligence(AI)

Other Technologies

Sustainable Development Goals

Affordable and Clean Energy, Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Climate Action

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com