Design of an interior permanent magnet synchronous machine with a wide speed range for electric vehicle applications

Date

2024-1-25

Author

Rezapour, Parisa

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Interior Permanent Magnet Synchronous Machines (IPMSMs) are commonly used for electric vehicle traction applications due to their high power density and efficiency. The maximum speed that an electric machine can achieve is limited by electrical and mechanical constraints. Therefore, the machine's geometry needs to be optimized to achieve a wider speed range considering the voltage and current limits while maintaining its mechanical integrity. This thesis focuses on designing and optimizing a 150 kW 18000 rpm IPMSM with V-shape permanent magnets for a wide speed range. A detailed multi-objective optimization of the electric machine is carried out using MATLAB and ANSYS Maxwell to obtain a design with required power outputs at base speed and maximum speed while minimizing the torque ripple and the machine’s volume. To ensure robustness at high speeds, radial ribs are included in the rotor geometry. However, this negatively impacted the output power due to increased rotor leakage flux. As rib thickness must be accurately set in the optimizations, a new semi-analytical rib thickness calculation method is proposed. In the proposed method, the required thickness of the radial rib is determined as a function of the rotor's parameters and pre-run static mechanical analysis. After obtaining the optimization results, the final design is selected and validated through ANSYS Maxwell and ANSYS Structural. The selected IPMSM is then studied under the Inter-Turn Short Circuit condition to ensure proper functioning under adverse conditions. Finally, a small-scale prototype IPMSM is designed, and its performance is studied under the active short circuit condition.

Subject Keywords

Interior Permanent Magnet Synchronous Machines, Wide speed range, Optimization, Radial rib, Inter-Turn Short Circuit

URI

https://hdl.handle.net/11511/108795

Collections

Graduate School of Natural and Applied Sciences, Thesis