Design Optimization and Thermal Analysis of a Dual Three-Phase PM Motor for Electric Vehicles

This paper presents a comprehensive investigation into the design principles and operational characteristics of dual three-phase permanent magnet (PM) machines. The study focuses on optimizing the winding arrangement and slot-pole combinations for enhanced performance and reliability. Through detailed analysis, an optimal configuration is proposed, and a dual three-phase machine based on this design is developed. The operational behavior of the machine is thoroughly examined under healthy conditions, with particular attention given to its thermal performance to ensure it can sustain high power density and output power without compromising reliability. The effectiveness of the proposed design and thermal analysis is validated through advanced simulation results, which demonstrate the motor's robust performance, efficiency, and ability to maintain stable operation under demanding conditions. Under natural cooling, the dual three-phase motor operates safely within its thermal limits, with a maximum winding temperature of 139.99℃, below the 180℃ insulation limit, and a maximum magnet temperature of 105.62℃, below the 150℃ limit. This research highlights the potential of dual three-phase PM machines for applications requiring high reliability and performance.