Optimal Design Considering AC Copper Loss of Traction Motor Applied HSFF Coil for Improving Electric Bus Fuel Economy

Improving the fuel economy of electric buses requires traction motors that provide not only high-power density but also high efficiency under diverse driving conditions. While high slot fill factor (HSFF) coils such as the maximum slot occupation (MSO) coil improve motor torque and power density, they inevitably increase AC copper losses due to elevated AC resistance, especially at high speeds. Unlike conventional motor optimization studies that mainly focus on efficiency at specific operating points, this paper proposes a drive-cycle-aware design optimization method that minimizes AC copper loss to enhance real-world fuel economy. By combining 2D finite element analysis (FEA) with vehicle-level simulations under three representative driving cycles (Manhattan, HWFET, HDUDDS), an optimal motor design was derived. The optimized motor achieved improvements in fuel economy by 0.20%, 0.86%, and 0.36%, respectively, compared to the initial design. Experimental validation through prototype fabrication confirmed the effectiveness of the proposed method. These results demonstrate that the proposed design approach can contribute to improving energy efficiency and reducing operational costs in electric bus applications.