Design, Multi-Objective Optimization, and Prototyping of a 20 kW 8000 rpm Permanent Magnet Synchronous Motor for a Competition Electric Vehicle

Pedro P. C. Bhagubai, João G. Sarrico, João F. P. Fernandes and P. J. Costa Branco
Additional contact information
Pedro P. C. Bhagubai: IDMEC, Instituto Superior Técnico, Universidade de Lisboa, 1049-001 Lisbon, Portugal
João G. Sarrico: Instituto Superior Técnico, Universidade de Lisboa, 1049-001 Lisbon, Portugal
João F. P. Fernandes: IDMEC, Instituto Superior Técnico, Universidade de Lisboa, 1049-001 Lisbon, Portugal
P. J. Costa Branco: IDMEC, Instituto Superior Técnico, Universidade de Lisboa, 1049-001 Lisbon, Portugal

Energies, 2020, vol. 13, issue 10, 1-24

Abstract: A high-performance 20 kW, 20 Nm, 8000 rpm, spoke-type interior permanent magnet motor to be integrated into a FormulaStudent electric car’s powertrain has been designed to meet demanding performance requirements for its driving cycle. This paper describes key steps in the design optimization, analysis, fabrication, and testing of this machine. Design optimization used the non-dominated sorting genetic algorithm II (NSGA-II) coupled with a hybrid analytical/finite element model to reduce the computational time, achieving a torque and efficiency of 20 Nm and 98.6%, respectively. A prototype has been constructed. The final motor design has been tested, where experimental nominal torque and efficiency have reached 18.2 Nm and 90%, respectively. Design challenges regarding the manufacturing are presented, justified, and discussed in detail. Test results were conducted to evaluate reliability and motor temperatures with and without water refrigeration at nominal current. Despite those adjustments in the optimized design, one shows that the impact on the car’s lap time was low, going from 77.3 s for the ideal optimized motor to 78.9 s for the prototyped motor.

Keywords: electromagnetic modeling; multi-objective optimization; permanent magnet; synchronous motor (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2020
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (7)

Downloads: (external link)
https://www.mdpi.com/1996-1073/13/10/2465/pdf (application/pdf)
https://www.mdpi.com/1996-1073/13/10/2465/ (text/html)

Related works:
This item may be available elsewhere in EconPapers: Search for items with the same title.

Export reference: BibTeX RIS (EndNote, ProCite, RefMan) HTML/Text

Persistent link: https://EconPapers.repec.org/RePEc:gam:jeners:v:13:y:2020:i:10:p:2465-:d:357867

Access Statistics for this article

Energies is currently edited by Ms. Agatha Cao

More articles in Energies from MDPI
Bibliographic data for series maintained by MDPI Indexing Manager ().