Design Approach Incorporating MTPA and Winding Function Theories for On-Board Direct-Drive Surface PM Machines with Concentrated Windings in EVs

Removal of the gear-box from a conventional all-electric vehicle (EV) power-train and incorporating direct-drive topology is expected to improve motor-to-wheel efficiency. Firstly, this paper discusses the merits and challenges of a novel direct-drive scheme employing a single on-board motor in an EV. Thereafter, motor design targets established for such an application in a typical super-mini EV are discussed. A novel bottom-up approach based on maximum-torque-per-ampere (MTPA) control and winding function theories of PM machines is proposed to design an on-board direct-drive surface permanent magnet (PM) machine with fractional-slot concentrated-windings in the stator. A typical direct-drive motor is designed employing the proposed approach and its performance is analyzed using its electromagnetic model in conjunction with finite element analysis and MTPA control scheme over the entire speed range of the motor. Comparative analysis of results obtained from analytical calculations and finite element analysis is performed. It is also shown that the proposed direct-drive scheme in EV is worth considering for advancement of state-of-the-art EV drive-train systems technology.