Design to Reduce Cost and Improve the Mechanical Durability of IPMSM in Traction Motors

Abstract

The interior permanent-magnet synchronous motor (IPMSM) is often used for the traction motor of hybrid electric vehicles (HEVs) and electric vehicles (EVs) due to its high power density and wide speed range. This paper introduces the 120kW class IPMSM for traction motors in military trucks. This system, as a SHEV (series hybrid electric vehicle), requires a traction motor that can generate high torque. This study introduces a way to reduce costs by proposing a design approach that creates reluctance torque that can be maximized by varying the dq-axis inductance. If a model designed by a design approach meets the desired torque, the magnetic torque can be reduced by an amount equal to the increase in reluctance torque and consequently the amount of permanent magnets can be reduced. A reduction gear and high speed operation of motors are necessary for the miniaturization of the motor. Thus, a fairly large centrifugal force is generated due to the high speed rotation. This force causes mechanical interference between the rotor and the stator, and a design approach for adding an iron bridge is explained to solve the interference. In this study, the initial model and the improved model that reduces cost and improves mechanical durability are compared by FEA, and the models are produced. Finally, the FEM results were verified experimentally.