Optimized design of a fault-tolerant 12-slot/10-pole six-phase surface permanent magnet motor with asymmetrical winding configuration for electric vehicles

This paper presents a comprehensive methodology for optimizing the design of a 12-slot/10-pole permanent magnet (PM) motor with a six-phase winding configuration tailored for electric vehicles (EVs). The design aims to enhance motor performance under both healthy and fault conditions. While the single neutral configuration offers superior torque during faults, it also introduces zero sequence currents and additional space harmonics, which can lead to increased torque ripple that is difficult to control. This study addresses these challenges through innovative machine design optimization. The optimization process begins with sizing equations to establish an initial design. K-means clustering techniques are then employed to identify distinct loading points that accurately represent the full EV driving cycle, effectively minimizing computational power requirements. Following this, the Full Range Minimum Loss (FRML) strategy is applied to determine optimal current profiles across these loading points, significantly reducing copper losses. Finally, a multi-objective optimization approach is utilized to minimize torque ripple, enhance average torque, and optimize machine losses. The results demonstrate substantial improvements in torque and reduced ripple, validated through experiments conducted with a 2 kW lab-scale motor. This integrated approach not only ensures a robust and efficient motor design but also enhances fault tolerance, making it well-suited for advanced EV applications. • Optimized SPMSM design for EVs, enhancing torque and reducing torque ripples. • Enhanced performance in healthy and faulty conditions with reduced torque ripple. • Multi-objective optimization reduces radial forces and demagnetization risk. • Experimental validation shows 7.79 % torque boost and 7.2 % ripple reduction. • Fault-tolerant strategies ensure reliable and efficient motor design.