A Novel Interior Permanent Magnet Synchronous Motor with High Strength Soft Magnetic Composite Powders as Stator-Rotor Material for Electric Vehicle Application

This paper presents the design of Interior Permanent Magnet Synchronous motor (IPMSM) using Soft Magnetic Composite (SMC) material for Electric Vehicle (EV) applications. In EV, the electric motor is characterized by high power density, high torque, low weight and cost efficient. The high torque, high power to weight ratio and high mechanical strength Synchronous Motor along with the SMC structures will make it suitable candidate for such an EV application. With this focus the new SMC material Somaloy 3P is proposed as a motor core material. The SMC material is made up of iron powder particle coated with an electrically insulated layer which gives a unique 3D flux property. This material provides low eddy current losses because of high material resistance. The benefits of Somaloy 3P material for design of electric motor are compact, high performance, weight reduction and cost efficient. The impacts of Soft magnetic composite in IPMSM have been investigated through Electromagnetic Finite Element Analysis (FEA) static and dynamic characterization with purpose of reducing the iron loss and weight and cost of the motor. Electromagnetic field study is carried out to characterize and compare key advantages of Somaloy 3P material with the conventional silicon steel material. This research may provide guidance for the future prototype.