Design and Optimization of Electric Vehicle Traction Motor Considering Rotor Topology and Manufacturing Uncertainty

As one of the key issues of interior permanent magnet (IPM) motors in the matching of electric vehicles (EVs), the design and optimization of the rotor are greatly fundamental. This article performs the design and optimization of IPM motors for EVs considering rotor topology and manufacturing uncertainty. First, the contribution of different rotor topologies to a variety of motor performances is investigated, and the results show that the IPM motor with V-type rotor topology is more satisfying with comprehensive performance competitiveness. Then, robust optimization and design of the V-type motor are carried out to further improve the motor performance robustness. On one hand, the influences of manufacturing uncertainties on motor performance fluctuation are suppressed by using an improved robust optimization algorithm. On the other hand, rotor notch is adopted as an alternative method of rotor skew, to avoid the manufacturing uncertainties introduced by the rotor skew process as well as reduce torque ripple. Finally, based on the simulation results and theoretical explanation, a prototype is assembled and the experimental results verify the validity of the results presented in this article.