Abstract
Optimal design and validation combined with finite-element method (F.E.M) and mesh adaptive direct search (MADS) have been performed to realize the maximum efficiency distribution of interior permanent magnet synchronous motor (IPMSM) compatible to the maximum energy consumption areas of heavy-duty electric vehicle (HD-EV). Particularly, the target energy consumption areas are specified with vehicle simulation in accordance with the real-road driving test cycles of HD-EV. The dominant electromagnetic losses and efficiency of IPMSM are numerically identified in association with F.E.M and MADS. In addition, the proposed IPMSM is optimally modeled taking the maximum torque per ampere control strategy into consideration. Furthermore, the optimally designed prototype is validated via the resultant efficiency map built-up by the dynamometer tests.
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