Response Surface Methodology Based Optimization of Surface PM Machine Incorporating Stator Slotting and PM Sizing Effects to Extend the Operating Limits for Direct-Drive EV Application

Direct-drive electric vehicle motors have requirements such as high-torque, low-speed and a constant power speed range (CPSR) between 3 and 5 depending on the tire size. Furthermore, these motors must deliver lower cogging torque and torque ripple when compared to conventional electric vehicle high-speed motors due to absence of any damping mechanism. Surface permanent magnet synchronous machines (SPMSMs) with distributed winding configuration are found to favor the aforementioned characteristics for the above application. However, in spite of the lower CPSR requirements for direct-drive application, SPMSMs suffer from poor flux weakening operation. Various rotor structural modifications as well as optimal PM sizing solutions are proposed in literature. However, they fail to take into account the stator slotting effect which significantly affects the flux weakening operation of the machine. Thus, in order to alleviate the challenges involved in realizing a SPMSM as a direct-drive motor, Response Surface Methodology (RSM) is implemented with magnet size and stator slot dimensions as design variables in an effort to optimize the characteristic current and further enhance the CPSR of the machine. Finite element models of the optimal machine are used to verify the output power- and torque-speed characteristics over entire operating range calculated from analytical equations.