DESIGN AND ANALYSIS OF A HIGH-EFFICIENCY PERMANENT MAGNET SYNCHRONOUS MOTOR FOR ELECTRIC THREE-WHEELER APPLICATION

This study presents the design and analysis of a Permanent Magnet Synchronous Motor (PMSM) for an electric vehicle drivetrain, focusing on a rear-axle mounted motor with a two-speed variation. The motor was developed and optimized using Finite Element Method (FEM) 2D simulations, integrating theoretical and analytical calculations. The design process covered stator and rotor geometry, magnet sizing, and material selection to achieve optimal performance at rated voltage and peak torque conditions. A V-shaped neodymium magnet layout enhanced torque density minimized mechanical vibrations and reduced thermal losses. The proposed motor demonstrated high efficiency (95%) with minimal torque ripple, ensuring reliable operation without magnet saturation. Performance mapping confirmed that the motor achieves peak efficiency between 1000 and 1500 rpm and maintains above 90% efficiency under varying load conditions. The optimized magnet dimensions and material selection significantly reduced the cost, making the motor a cost-effective alternative to commercially available EV motors. These findings validate the suitability of the proposed PMSM design for high-efficiency electric vehicle applications, offering enhanced energy utilization, reduced losses, and improved reliability.