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With the emphasis of electrification in automotive industry, tremendous efforts are made to develop electric motors with high efficiency and power density, and reduce noise, vibration and harshness (NVH). A multiphysics simulation workflow is used to predict the eccentricity-induced noise for GM’s Bolt EV motor. Both static and dynamic eccentricities are investigated along with axial tilt. Analysis results show that these eccentricities play a critical role in the NVH behavior of the motor assembly. Transient electromagnetic (EM) analysis is performed first by extruding 2D stator and rotor sections to form 3D EM models. Sector model is duplicated to form full 360-degree model. Stator is split into three rotated sections to characterize stator skew, and the skew between two sections of rotor and magnets are also modelled. Sinusoidal current is applied and lumped-sum forces on each stator tooth are computed.

In electric vehicle applications, the majority of the traction motors can be categorized as Permanent Magnet (PM) motors due to their outstanding performance. As indicated in the name, there are strong permanent magnets used inside the rotor of the motor, which interacts with the stator and causes strong magnetic pulling force during the assembly process. How to estimate this magnetic pulling force can be critical for manufacturing safety and efficiency. In this paper, a full 3D magnetostatic model has been proposed to calculate the baseline force using a dummy non-slotted cylinder stator and a simplified rotor for less meshing elements. Then, the full 360 deg model is simplified to a half-pole model based on motor symmetry to save the simulation time from 2 days to 2 hours. A rotor position sweep was conducted to find the maximum pulling force position. The result shows that the max pulling force happens when the rotor is 1% overlapping with the stator core.

Electric motor noise mitigation is a challenge in electric vehicles (EVs) due to the lack of engine masking noise. The design of the electric motor mounting configuration to the motor housing has significant impacts on the radiated noise of the drive unit. The stator can be bolted or interference-fit with the housing. A bolted stator creates motor whine and vibration excited by the motor torque ripple at certain torsional resonance frequencies. A stator with interference fit configuration stiffens the motor housing and pushes resonances to a higher frequency range, where masking noise levels are higher at faster vehicle speeds. However, this comes with additional cost and manufacturing process and may impact motor efficiency due to high stress on stators. In this paper, a thin sheet metal NVH ring is developed as a tunable stiffness device between the stator and the motor housing. It is pre-compressed and provides additional torsional rigidity to mitigate torsional excitations.