Electromagnetic-Thermo-Mechanical Performance Management of Power Losses from 1 KW Traction Motor System

With increasing fuel demands and environmental issues, electric vehicles are more important in reaching a bearable solution. The driving motor is a vital component of electric vehicles defining the design of electric propulsion, and it has small volume, high efficiency with sufficient power for torque and speed with precise control. To ensure a satisfactory life span of the motor, temperature rise must be controlled within safe operating zone. The sizing parameters, design with magnetism, thermal and mechanical calculations are carried out for a 1016-Watt traction motor system. Effects of variation of torque and speed for the 1016-W Brushless Direct Current (BLDC) motor was performed. Power losses calculated included Winding, Stator & Rotor core losses of around 220Watt from the input power of 1236Watt. BLDC motor with air gap between cores and multi-rotational frames are selected for the above calculations. Finally motor system of 1016W was designed and analysed with electromagnetic-thermal-structural coupling simulations and results were verified for the functional requirements. Study of various input parameters with magnetic force distribution (due to current, voltage for stator winding and permanent magnetism) with system efficiency (losses), temperatures, power and its stress fields performances across the motor components verified with the help of commercial codes which meet capacity requirements.