This paper deals with the design of a 200kW, 20krpm machine for an electric vehicle application. The aim of the research is to design a low cost, rare-earth free magnet electric motor while ensuring mass production feasibility and providing higher performance than currently available technologies. Electromagnetic, thermal and mechanical constraints are considered throughout the machine design process, from the specification to the optimization. Rotor diecasting, oil spray cooling and hairpin winding are among the solutions investigated to fulfill the project requirements. Analytical and numerical methods are adopted for electromagnetic and continuous performance calculations over the machine's full speed range, taking into account the mechanical limits from a stress and modal point of view.

This paper deals with the design of a scalable 200kW/ 370Nm or 75kW/ 200Nm, induction machines for electrical vehicles traction system. Two configurations are considered as low cost rare-earth free magnet electric motor alternatives: inner rotor and outer rotor. Both designs allow mass production while providing higher performance compared to current technologies. The electromagnetic, thermal and mechanical constraints are considered throughout the machine design, from the specifications to the optimization. Rotor diecasting, oil spray cooling and hairpin stator winding are used in the analyzed solutions. Analytical and numerical methods are used for electromagnetic and continuous thermal performance calculation over the full speed range of the machine, along with the mechanical limits from a stress and modal point of view.

This paper deals with the optimisation of a 200kW, 20krpm machine for an electric vehicle application using Motor-CAD and optiSLang software. The main goal of the research is to design a low cost, rare-earth free magnet motor while ensuring mass production feasibility and providing higher performance than current available technologies. The induction motor with copper rotor cage, either die-casted or fabricated, is selected as a potential candidate. The stator winding is of hairpin type and both rotor and stator parts benefit from direct cooling. The machine is optimised electromagnetically and thermally to meet the peak and continuous performance requirements with respect to the project specifications. In particular, the efficiency computation over the typical WLTP3 drive cycle is considered in the optimisation process. The latter is looked into details and uses a meta-model based approach which allows to evaluate thousands of design topologies in a computationally efficient way for a given optimisation scenario.

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