The design of a traction motor is a balance between its electrical performance and the cooling, structural and vibro-acoustic performance. The motor cooling and its structure should ensure the electrical structure performs optimally to ensure the drive train service life (300,000 km or 15 years), independent of the ambient and drive-cycling conditions. That is, it should withstand electromagnetic, thermal, vibration and structural stress, as well as be acoustic complaint without significant deterioration in performance for the specified power train warranty. Compact designs lower the ePowertrain mass at the expense of electromagnetic, thermal and structural masses. This limits the electrical performance while overheating and vibration accelerates aging, as well as acoustic non-compliance. Hence, the need for an iterative multiphysics (EM-CFD-Structural-NVH) development process will be illustrated during this talk, using an in-wheel traction motor. The initial electrically optimized structure will be shown to undergo changes to accommodate the cooling and structural changes to ensure the motor's availability at peak demand at the highest foreseeable temperature, ensuring reliability and compliance.

Takeaway

A practical iterative multiphysics traction motor design process (EM-CFD-Structural-NVH):
• EM analysis at its rated, peak and maximum speed test points, demagnetization and fault analysis.
• Optimizing its cooling structure using CFD analysis
• Structural integrity tests on the rotor for max speed centrifugal test, and the stator ability to withstand faulty EM loads
• Vibro-acoustics (NVH) compliance

Intended Audience

• Electric Powertrain Designers/Engineers/Leads/Managers
• Vehicle Thermal Management Engineers/Leads/Managers
• Automotive Engineers/Leads/Managers
• Traction Motor Engineers/Designers/Leads
• Simulation-Driven Development Leads/Heads/Managers