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Operating condition of rotor embedded magnet materials for permanent magnet synchronous motor (PMSM) critically affect electric vehicle (EV) range and dynamic characteristics. The rotor liquid cooling technique has a deep influence on PMSM performance improvement, and begin to be studied and applied increasingly in EV field. Here, the fluid, thermal, and electromagnetic characteristics of motor with and without hollow-shaft cooling are researched comprehensively based on 100 kW PMSM with housing water jacket (HWJ) and hollow-shaft rotor water jacket (SWJ). The solid models are constructed considering temperature-dependent power loss and anisotropic thermal conductivity. After the fluid models are set up by using Reynolds stress model (RSM), conjugate heat transfer is conducted through computational fluid dynamics (CFD) simulation, and is verified by real PMSM test bench experiments.

In this paper, a novel driver model is proposed to track vehicle speed in MIL (Model-in-the-Loop) test system, which has structural consistency with HIL (Hardware-in-the-Loop) test system. First, the MIL test system which contains models of driver, vehicle and test bench is established. Second, according to the connections of the established models in Matlab/Simulink environment, the vehicle speed is calculated in vehicle model. Emphatically, through the deviation between driving cycle speed and calculated vehicle speed, PI controller in driver model adjusts the vehicle speed to ideal point through sending the torque command to drive motor, the ILC (Iterative Learning Control) controller modifies and stores P value of PI controller. Then, in order to obtain the better modification of PI controller, iterative learning control algorithm is deeply researched in term of types and parameters.