Design and Analysis of an IE6 Hyper-Efficiency Permanent Magnet Synchronous Motor for Electric Vehicle Applications

Hayatullah Nory (), Ahmet Yildiz, Serhat Aksun and Cansu Aksoy
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Hayatullah Nory: Volt Weg Group, Izmir 35735, Turkey
Ahmet Yildiz: Department of Mechatronics Engineering, Faculty of Engineering, Firat University, Elazig 23119, Turkey
Serhat Aksun: Volt Weg Group, Izmir 35735, Turkey
Cansu Aksoy: Volt Weg Group, Izmir 35735, Turkey

Energies, 2025, vol. 18, issue 17, 1-14

Abstract: In this study, a high-efficiency permanent magnet synchronous motor (PMSM) was designed for a geared electric vehicle. The motor was developed for use in an L-category electric vehicle with four wheels and a two-passenger capacity. During the design process, application-specific dimensional constraints, electromagnetic requirements, and material limitations were taken into consideration. A spoke-type rotor structure was adopted to achieve both mechanical robustness and high efficiency with minimized leakage flux. In addition, the combination of a 12-stator slot and a 10-rotor pole was selected to suppress low-order harmonic components and improve torque smoothness. The motor model was analyzed using Siemens Simcenter SPEED software (Product Version 2020.3.1), and an efficiency above 94% was achieved, meeting the IE6 efficiency class. Magnetic flux analysis results showed that the selected core material operated within the magnetic saturation limits. The findings demonstrate that a compact and high-efficiency PMSM design is feasible for electric vehicle applications.

Keywords: electric vehicle; hyper efficiency; IE6 efficiency class; permanent magnet synchronous motor; spoke rotor structure (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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