Among Series-Parallel Hybrid Electric Vehicle (SPHEV) powertrains, the Power-Split architecture with a planetary gear has an exemplary energetic efficiency in mixed driving conditions. Nevertheless, a simple SPHEV architecture can be realized without a planetary gear. It consists of 2 Electric Machines (EM) mounted on the engine shaft and separated by a clutch. With no power-split operation, this architecture allows the vehicle to operate in pure electric, or series hybrid, or parallel hybrid mode. It was proven to be less efficient than a reference Power-Split SPHEV: the Toyota Hybrid System (THS). The aim of this paper is to investigate the potential of efficiency improvement of the simple SPHEV powertrain by topology modification: the addition of gears for the components or a gearbox with few number of ratios. Two new variants of SPHEVs are proposed. The versions of SPHEVs and the reference THS are optimized by a bi-level optimization technique using Genetic Algorithm and Dynamic Programming. Compared to the simple SPHEV, results show an efficiency worsening in one variant and an efficiency improvement in another variant with a fuel consumption comparable to the one of THS. A global sensitivity study is then performed on the worsened variant. The sensitivities of the added gears are determined and an elimination of some is suggested. A new variant with fewer gears is therefore proposed and optimized. The efficiency is improved but remains less than the one of THS.

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The need of compact machines increased in recent years due to increases in raw materials’ price. Hence, many studies are currently being conducted on high-speed challenges to propose an optimal design methodology. AC losses in windings are often not included in the optimization process and are treated in post-processing by choosing a suitable conductor’s diameter to mitigate skin and proximity effects. This paper presents an optimization and design methodology for high-speed electric machines considering these losses, using models with an interesting trade-off between computation time and accuracy, which is helpful for large-scale optimization, in which more than 9,600,000 machines are evaluated. Optimizations are conducted on 100 kW high-speed one-layer V-shaped interior permanent magnet synchronous machines, widely used in vehicles thanks to their high power density, based on the specifications of the Peugeot e208, for different values of pole pairs and maximum speed. The influence of lamination thickness, fill factor, and maximum current density on the optimal design is also investigated. This paper concludes the utility of increasing speed to achieve high power density and proposes best alternatives regarding automotive constraints. Results show that the number of pole pairs is not always a key parameter in obtaining the lowest volume, especially at high speed.