Optimization of squirrel-cage induction motor design for EV applications through FEM simulations with ANSYS

Electric Vehicles (EVs) are gaining significant traction as environmentally friendly alternatives to traditional combustion engine-powered vehicles. The adoption of Squirrel-Cage Induction Motors (SCIM) in EV propulsion systems is highly regarded for their durability, low cost, and robust operational characteristics. However, for SCIMs to meet the demanding performance requirements of EVs, including high torque density, reliability, and minimal energy losses, careful design and material optimization are essential. This study explores the optimization of SCIMs specifically for EV applications by leveraging the power of Finite Element Method (FEM) simulations through ANSYS Maxwell. The research focuses on the selection of core and winding materials that contribute to improved efficiency, higher torque production, and overall motor performance. By utilizing FEM-based simulations, the study analyzes the motor’s behavior under various loading conditions, enabling the precise tuning of design parameters. The results of the simulations indicate that the optimized motor design achieves an efficiency of 91.48%, with stator and rotor losses being reduced to 3.78 W and 3.16 W, respectively. Additionally, iron-core losses are minimal, contributing only 0.16 W to the overall motor loss. The motor’s rated torque of 302.65 Nm at 1500 r/min and a slip of 0.133% demonstrate its suitability for EV propulsion. The findings of this study underline the effectiveness of FEM simulations in designing energy-efficient SCIMs, thereby contributing to the development of advanced EV motors that are both energy-efficient and cost-effective. This research also highlights the importance of optimized material selection in achieving the best performance outcomes for EV applications.