Design and simulation of an in wheel permanent magnet synchronous motor for an electric vehicle on finite element modeling software tool Ansys Maxwell
In this FYP the group will be designing and simulating the performance of a PMSM for an electric vehicle, on the software ?ANSYS Maxwell? & they will learn about electric machine design in this fyp.
2025-06-28 16:26:25 - Adil Khan
Design and simulation of an in wheel permanent magnet synchronous motor for an electric vehicle on finite element modeling software tool Ansys Maxwell
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryIn this FYP the group will be designing and simulating the performance of a PMSM for an electric vehicle, on the software “ANSYS Maxwell” & they will learn about electric machine design in this fyp.
Project Objectives- Complete motor design & its simulation results presented in the form of an elaborate & comprehensive report, which will be shared with the upcoming EV industry in Pakistan as well as abroad, to secure any joint collaboration between DSU & the EV/HEV industry.
- Conference / journal paper
- A fabricated motor usind design & simulations obtained
For designing & simulation of PMSM we would be using finite element modelling tools Ansys Maxwell. to begin with analytical model would be made on RMXpt considering motor specifications. then it would be exported to maxwell 2d/3d for finite element analysis for flux weakening,mesh refinment,calculate losses & magnet working points. then a thermal model would be made to fing hotspots for cooling.
using these designs & simulations a motor would be fabricated to verfiy results
Benefits of the ProjectThis fyp would contribute to global EV industry where a new technology on in weel PMSM are trending for various electric cars & other electric vehicles. This would also contribute to establish pakistan EV manufacturing sector by developing a working prototype motor to be used in EV specially electrica bikes which we foresee would be comming sooneer then expected.
some benefits for this fyp are stated as follows:
Drive Longer
In-wheel motors remove efficiency losses associated with gear, differential and CV joints situated around the vehicle. Total vehicle weight is also reduced.
This means:
Greater range
Reduced running costs
Lower charge frequency
Better Handling
Individual wheel motors provide torque distribution to different wheels (torque vectoring)
This means:
Improved driver handling
Enhanced stability and control
Improved traction control
Shorter stopping distances
Creative Freedom
In-wheel motors revolutionize car design. No requirement for existing driveline Components
Means vehicle design can unlock opportunities for new services and revenue
Production Efficiency
In-wheel motors with integrated inverters do not require a gear, differential, drive-shafts or external drive electronics.
This means:
Comparable system cost
Reduced development cost
Lower manufacturing cost
More opportunity for modularity
Steering capability
The 360-degree steering capability is made possible by a rotating interface that sits above the corner of main arm. The top of the rotating interface is fixed to the vehicle and the lower interface is fixed to the arm.
Technical Details of Final DeliverableComplete motor design & its simulation results presented in the form of an elaborate & comprehensive report. Design specs for the motor are as follows:
- Three Phase Permanent Magnet Machine, Inner Rotor Topology
- No Of Poles = 8
- Nominal Torque = 170 Nm, Base Speed = 1500 Rpm
- Constant Power Speed Range From 1500 Rpm To 6000 Rpm
- Maximum Outer Diameter = 250 mm
- Maximum Axial Length = 100 mm
- Water Cooled, Maximum Temperature = 60?
- NdFeB Magnets
- Efficiency Goal = 95 %
- Minimum Cost And Easy To Manufacture
Conference / journal paper
A fabricated motor usind design & simulations obtained
Final Deliverable of the Project Software SystemCore Industry TransportationOther Industries Manufacturing Core Technology OthersOther Technologies Clean TechSustainable Development Goals Affordable and Clean EnergyRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 80000 | |||
| stator | Equipment | 1 | 20000 | 20000 |
| rotor | Equipment | 2 | 10000 | 20000 |
| windings | Equipment | 1 | 5000 | 5000 |
| NdFeB radial magnets | Equipment | 8 | 2500 | 20000 |
| insulations | Equipment | 1 | 5000 | 5000 |
| variable frequency drive | Miscellaneous | 1 | 10000 | 10000 |