Methodology for designing traction motor for an Electric Vehicle with tandem application of vehicle system 1D simulation and electromagnetic simulation

This paper presents a comprehensive methodology for sizing a machine for a given vehicle performance target and analyzing the machine performance at different operating zones of the electric vehicle. Designing the powertrain of an electric vehicle starts with understanding the on-road performance requirements of the vehicle relevant to the application such as top speed, gradient and acceleration targets. It is critical to define the operating performance boundary of the vehicle based on end user preference. This paper illustrates a comprehensive approach of implementing 1D simulation tool namely GT-Suite to simulate the vehicle model for different on-road performance targets so as conclude the traction motor specifications. These specifications along with the other boundaries of the vehicle such as battery limitations and MCU limitations are taken as input parameters for the electromagnetic simulation assisted by Ansys Motor-CAD to design optimized machine that can meet the application requirements. The methodology also deals with the coupled deployment of Motor-CAD and GT-Suite to analyze the electric vehicle system in terms of different aspects such as efficiency performance and range, thus providing a comprehensive framework for engineers and researchers engaged in developing electric propulsion systems for xEVs fostering innovation and sustainability in the automotive industry.