Design & Validation of Permanent Magnet Synchronous Motor for Automotive Four-Wheeler Through Simulation Based Approach 2021-26-0148

From last few years, many Auto OEMs are started shifting towards Electric Vehicle development from their regular conventional vehicle development, as the main conventional power source engine is changed to an electric motor, many research and developments going on design and validating the E-Motor performance through test and simulation approaches by the majority of Auto OEMs and electric motor manufacturers. The design approach of motors for electric vehicle (EV) application satisfying the high torque, high power, lessweight, and fewer torque ripples are important aspects, but also the efficiency for the full driving cycle, temperature, noise and vibrations are very critical for suitability of the vehicle. This paper is focused on calculating the power requirement for an electric vehicle using empirical formulas. Permanent magnet synchronous motor topology designed based on the duty cycle requirements and validate the Electromagnetic & Thermal performance by simulation tools. To transmit the power & torque generated by the motor to vehicle efficiently a robust Transmission system need to be designed. This paper focus on designing electric drivetrain with single step gear reduction which is widely used in several Automotive two-wheeler and four-wheeler applications. A multibody simulation tool used to validate the design. When compared with IC Engine, the electric motor makes a whistling noise or annoying noise. So structural performance of the electric motor is equally important to reduce the vibrations, noise, at various RPMs, by using EM forces generated from the electromagnetic analysis. Integrated Motor DVPS are discussed and evaluated, which influence the performance of the E-Motor.