An Interior Permanent Magnet Synchronous Motor with High Strength Soft Magnetic Cobalt-Iron Alloy as Stator-Rotor Material for Electric Vehicle Application

• Main Authors: Sabnis, Avdhut, Shroff, Roopesh
• Format: Report
• Language: English
• ISSN: 0148-7191; 2688-3627
• DOI: 10.4271/2022-28-0057

Interior Permanent Magnet Synchronous Motor (IPMSM) is widely used in Electric Vehicle (EV) applications. In EV, the electric motor is characterized by high power density, high speed, and light weight. The high-speed, high-power density, fault tolerance capability of the IPMSM make it a suitable candidate for such an EV system. The performance improvement of IPMSM during design is highly desirable. With the application of soft magnetic alloy material Hiperco 50A in place of traditional steel material, the performance of the IPMSM can be greatly improved. Compared to the steel material, the Hiperco 50A provides high power density, low core loss and improved efficiency. With this focus, this paper investigates the application of soft magnetic alloy material (Hiperco 50A) in 150 kW power IPMSM. The impacts of Hiperco 50A material in IPMSM have been investigated through Electromagnetic Finite Element Analysis (FEA) static and dynamic characterization with purpose of reducing the core loss and increasing the power density of the motor. Efficiency contour map on torque-Speed axis have been plotted to check the maximum efficiency over any torque speed combinations. From the efficiency map, drive cycle for the vehicle has been selected and drive cycle analysis has been performed to check the motor performance. Coupled electromagnetic - thermal analysis has been carried out to predict the temperature rise in the motor components. Stress analysis has been carried out to check all the stress occurred in the motor are within the safer limit with the speed. All the above study is carried out to characterize and compare key advantages of Hiperco 50 material with the conventional silicon steel material.