Multi-Attribute, System-Level Design Process for Automotive Powertrain Electric Drives: An Integrated Approach

This article presents an electric drive powertrain design and virtual integration methodology in the context of electric vehicle systems. In the first stage, using the Model-Based System Engineering paradigm, the electric vehicle performance requirements are translated into electric drive target specifications using a system-level vehicle model. Subsequently, a functional electric drive subsystem-level model is developed based on magnetic co-energy and iron losses data obtained from a reference electric machine design. The functional electric drive model is scaled in order to meet the requested specifications, and it is coupled with different 1D (i.e. lumped-parameter) multi-physics sub-models that are later integrated into the electric vehicle system-level model. At the electric drive level the torque ripple and Noise, Vibration and Harshness characteristics are analyzed. At the vehicle level the energy consumption, thermal behavior, and mechanical performances are determined with reduced computational time. The proposed approach allows for early assessment of multiple attributes and enables designers to make decisions supported by accurate system-level simulations.