Vibration and noise performance analysis and optimal design of V-rotor in permanent magnet synchronous motor: a new strategy for high efficiency and low noise

Interior Permanent magnet synchronous motors (IPMSMs) have become the preferred powertrain solution for electric vehicles due to their exceptional performance characteristics. However, the high-frequency electromagnetic noise generated during motor operation poses a significant challenge to occupant comfort within the vehicle. This study provides a comprehensive analysis of the electromagnetic forces, modal characteristics, and vibration noise for a 12-pole, 36-slot IPMSM, incorporating theoretical and simulation-based approaches as well as modal tests. By innovatively combining orthogonal experimental design with nonparametric regression techniques, a response surface model is developed to accurately characterize and optimize the radial electromagnetic force harmonics of the motor. The optimization results reveal a significant 37.7 % reduction in the motor’s surface vibration velocity and an 8.5 % decrease in peak noise levels, successfully meeting the engineering objectives for vibration and noise attenuation. This study not only contributes to the advancement of noise control technologies in electric vehicle power systems but also provides novel insights and methodologies for motor design, offering significant practical value and engineering relevance.