Geometric and Magnetic Enhancements in IPMSM Design for Electric Vehicles and Industrial Applications

Abstract

With the development of technology, the use of electric vehicles (EV) has been increasing rapidly in recent years. The drive motors used in EV systems have to meet stringent requirements such as high efficiency, compact design, high performance, reliability and cost effectiveness. The main types of motors commonly preferred in EV applications include high-efficiency machines such as synchronous reluctance motors, induction motors and permanent magnet synchronous motors (PMSMs). However, conventional PMSMs have some disadvantages such as high material costs and the risk of demagnetization in harsh operating conditions. In this context, interior permanent magnet synchronous motors (IPMSMs) have attracted great interest in recent years due to their high torque density, superior efficiency and dynamic response. This study aims to address key design challenges and improve electromagnetic performance by developing an IPMSM design specifically optimized for EV drive systems. In the proposed design, geometrical and magnetic improvements have been realized in the rotor structure. Key parameters such as air gap length, magnet placement and shape, rotor geometry are systematically modified and optimized, and the analysis is performed using the finite element method (FEM). Simulation results show that the torque ripple is significantly reduced, torque density is increased, and demagnetization risk is reduced. The proposed motor design represents a promising and efficient solution specifically designed for next-generation EV applications and shows potential for adaptation in industrial applications.