Design, Simulation and Performance Evaluation of Surface Permanent Magnet Brushless Motor for Heavy-Duty Electric Vehicles

The design, finite element analysis and performance evaluation of a surface Permanent Magnet Brushless (PMBL) motor intended for heavy-duty electric vehicles are presented in this paper. Surface PMBL motors are renowned for their strong performance, high efficiency, and power density, which makes them perfect for such applications. A 136 kW, 2000 rpm surface PMBL motor for heavy-duty electric vehicles is designed by assuming various design variables viz. specific magnetic loading, slot-loading, aspect ratio, split ratio, stacking factor, conductor packing factor, current density etc. The CAD program is written for the sizing and performance evaluation. In-depth simulations are carried out using finite element analysis (FEA) to validate the sizing. The results of FEA are compared with the CAD output. The results of FEA are fairly in line with the CAD results. The comparison proves the correctness of the CAD program and validates the design.