Research on High-Precision Calculation Method for Permanent Magnet Synchronous Motor Efficiency in Electric Vehicles Across Full Load-Speed Range

Yukuan Li, Huichao Zhao, Sibo Wang (), Wan Huang, Yao Wang, Bo Gao, Wei Pang, Tianxu Zhao and Yuan Cheng
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Yukuan Li: FAW Research and Development Institute, Changchun 130028, China
Huichao Zhao: FAW Research and Development Institute, Changchun 130028, China
Sibo Wang: FAW Research and Development Institute, Changchun 130028, China
Wan Huang: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
Yao Wang: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
Bo Gao: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
Wei Pang: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
Tianxu Zhao: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
Yuan Cheng: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China

Energies, 2025, vol. 18, issue 13, 1-18

Abstract: In order to accurately calculate the efficiency of electric vehicle drive motors in the full speed range during the design phase, this paper proposes a comprehensive motor loss fast calculation method. Firstly, a high-fidelity joint simulation model of control and design was established to simulate the real excitation sources in actual operation. Secondly, detailed modeling was conducted for each loss. Regarding iron loss, this paper considers the effects of PWM harmonics, as well as cutting, welding, and other processes, on the loss based on finite element calculations. This paper proposes a semi-analytical AC copper loss calculation method, which superimposes the effective section and end winding separately. A fast improvement simulation method is proposed for the eddy current loss of permanent magnets, which equivalently combines 2D finite element and 3D finite element, while considering factors such as segmentation. Finally, a loss separation scheme was designed and experimentally verified for each loss and motor efficiency, proving that the efficiency calculation error of most operating points was less than 1.5%.

Keywords: electric vehicle; efficiency; loss calculation; iron core loss; copper loss; eddy current loss (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: 2025
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