A permanent magnet synchronous motor for an electric vehicle - design analysis

Sammanfattning: This thesis presents the study and the design analysis of apermanent magnet synchronous motor (PMSM) for the tractionapplication of an electric vehicle. An existing inductiontraction motor for an electric forklift benchmarks the expectedperformances of the proposed PMSM design. Further, thepossibility of using the identical stator as the one used inthe induction motor is explored for the fast prototyping. Theprototype motor is expected to be field-weakened and to have aconstant power speed range (CPSR) of 2.5 to 3.A design approach based on the CPSR contour plot in aninterior permanent magnet (IPM) parameter plane is derived toobtain the possible designs that meet all the designspecifications and the targeted CPSR. This study provides thepossible alternative designs for the subsequent futureprototype motors.An analytical approach to estimate the iron loss in PMsynchronous machines is developed and included in the designprocedure. The proposed technique is based on predicting theflux density waveforms in the various regions of the machine.The model can be applied at any specified load condition,including the field-weakening operation region. This model canbe ultimately embedded in the design process for a routine usein loss estimations.The first prototype motor with an inset permanent magnetrotor has been built and the available measurements are used tovalidate the design performance. In particular, the thermalanalyses based both on the lumped-circuit approach and thenumerical method are compared with the measured results. Asecond and possibly a third prototype motor targeting a widerand higher performance will be carried out in the continuingphase of the project.Keywords:Constant Power Speed Range, Electric Vehicles,Field-weakening, Reference Flux Linkage, Iron Loss, PermanentMagnet Synchronous Motor, Thermal Analysis