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With Increasing environmental concerns and high fuel prices, the automotive industry is shifting its focus to electric vehicles (EVs). Electric motor being the heart of an electric vehicle, faces a major design challenge to have optimum performance and structural strength at an affordable cost. Synchronous reluctance motor offers higher power density at low cost since the rotor is free from rare earth permanent magnets or field excitation. However, torque fluctuations and resulting vibrations are a major concern. This is amended by optimizing the end-barrier width and end-barrier orientation angle in the rotor so as to maximize the torque and minimize the ripple. Simulations are also performed with ferrite magnets assistance to achieve an enhanced torque output. In each case, a structural analysis is done to verify the mechanical strength and rotor deformation considering structural and electromagnetic forces. The analyses are performed using finite element simulations.

BS-VI or equivalent development calls for tremendous efforts in concept investigation and calibration for engine out, after treatment, diagnostic checks, off-cycle emissions, field performance, component safety etc. Achieving calibration quality for all these tasks is very challenging considering development time and cost with conventional physical testing approach. Present article focuses on assessment of testing and calibration using virtual approach. To prove and validate this approach, a six-cylinder heavy duty diesel engine is selected and configured in HiL environment. The engine plant model is built offline and validated with base engine data at steady state and transient operations and RT model is integrated with ECU hardware. Data for plant model corrections is generated with short measurement campaign. Refined real time plant model is prepared for evaluating different calibration strategies on virtual test bed environment.