Design, Multi-Objective Optimization, and Prototyping of a 20 kW 8000 rpm Permanent Magnet Synchronous Motor for a Competition Electric Vehicle

Abstract

A high-performance 20 kW, 20 Nm, 8000 rpm, spoke-type interior permanent magnet motor to be integrated into a FormulaStudent electric car’s powertrain has been designed to meet demanding performance requirements for its driving cycle. This paper describes key steps in the design optimization, analysis, fabrication, and testing of this machine. Design optimization used the non-dominated sorting genetic algorithm II (NSGA-II) coupled with a hybrid analytical/finite element model to reduce the computational time, achieving a torque and efficiency of 20 Nm and 98.6%, respectively. A prototype has been constructed. The final motor design has been tested, where experimental nominal torque and efficiency have reached 18.2 Nm and 90%, respectively. Design challenges regarding the manufacturing are presented, justified, and discussed in detail. Test results were conducted to evaluate reliability and motor temperatures with and without water refrigeration at nominal current. Despite those adjustments in the optimized design, one shows that the impact on the car’s lap time was low, going from 77.3 s for the ideal optimized motor to 78.9 s for the prototyped motor.