Structural Optimization Design and Analysis of Interior Permanent Magnet Synchronous Motor with Low Iron Loss Based on the Adhesive Lamination Process
The interior permanent magnet synchronous motors (IPMSMs) are extensively applied in the field of new energy vehicles due to their high-power density and excellent performance control. However, the iron loss has a significant impact on their performance. This study conducts an optimization analysis...
Saved in:
| Main Authors: | , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-06-01
|
| Series: | World Electric Vehicle Journal |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2032-6653/16/6/321 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849418239378980864 |
|---|---|
| author | Liyan Guo Huatuo Zhang Xinmai Gao Ying Zhou Yan Cheng Huimin Wang |
| author_facet | Liyan Guo Huatuo Zhang Xinmai Gao Ying Zhou Yan Cheng Huimin Wang |
| author_sort | Liyan Guo |
| collection | DOAJ |
| description | The interior permanent magnet synchronous motors (IPMSMs) are extensively applied in the field of new energy vehicles due to their high-power density and excellent performance control. However, the iron loss has a significant impact on their performance. This study conducts an optimization analysis on the processing technology of silicon steel sheets and motor structure, targeting the reduction of iron loss and the improvement of the motor’s integrated efficiency. Firstly, the influences of two iron core processing technologies on iron loss, namely gluing and welding, are compared. Through experimental tests, it is found that the iron loss density of the gluing process is lower than that of the welding process, and as the magnetic flux density increases, the difference between the two is expanding. Therefore, the iron loss test data from the adhesive process are employed to develop a variable-coefficient iron loss model, enabling precise calculation of the motor’s iron loss. On this basis, aiming at the problem of excessive iron loss of the motor, a novel topological structure of the stator and rotor is proposed. With the optimization goal of reducing the motor iron loss and taking the connection port of the air magnetic isolation slot and the gap of the stator module as the optimization variables, the optimized design of the IPMSM with low iron loss is achieved based on the Taguchi method. After optimization, the stator iron loss decreases by 13.60%, the rotor iron loss decreases by 20.14%, and the total iron loss is reduced by 15.34%. The optimization scheme takes into account both the electromagnetic performance and the process feasibility, it offers technical backing for the high-efficiency operation of new energy vehicle drive motors. |
| format | Article |
| id | doaj-art-e953586ceea04e19926781d8010fb84e |
| institution | Kabale University |
| issn | 2032-6653 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | World Electric Vehicle Journal |
| spelling | doaj-art-e953586ceea04e19926781d8010fb84e2025-08-20T03:32:28ZengMDPI AGWorld Electric Vehicle Journal2032-66532025-06-0116632110.3390/wevj16060321Structural Optimization Design and Analysis of Interior Permanent Magnet Synchronous Motor with Low Iron Loss Based on the Adhesive Lamination ProcessLiyan Guo0Huatuo Zhang1Xinmai Gao2Ying Zhou3Yan Cheng4Huimin Wang5School of Electrical Engineering, Tiangong University, Tianjin 300387, ChinaSchool of Electrical Engineering, Tiangong University, Tianjin 300387, ChinaState Key Laboratory of High-speed Maglev Transportation Technology, CRRC Qingdao Sifang Company LTD, Qingdao 266031, ChinaState Key Laboratory of High-speed Maglev Transportation Technology, CRRC Qingdao Sifang Company LTD, Qingdao 266031, ChinaSchool of Electrical Engineering, Tiangong University, Tianjin 300387, ChinaZhejiang University Advanced Electrical Equipment Innovation Center, Hangzhou 311107, ChinaThe interior permanent magnet synchronous motors (IPMSMs) are extensively applied in the field of new energy vehicles due to their high-power density and excellent performance control. However, the iron loss has a significant impact on their performance. This study conducts an optimization analysis on the processing technology of silicon steel sheets and motor structure, targeting the reduction of iron loss and the improvement of the motor’s integrated efficiency. Firstly, the influences of two iron core processing technologies on iron loss, namely gluing and welding, are compared. Through experimental tests, it is found that the iron loss density of the gluing process is lower than that of the welding process, and as the magnetic flux density increases, the difference between the two is expanding. Therefore, the iron loss test data from the adhesive process are employed to develop a variable-coefficient iron loss model, enabling precise calculation of the motor’s iron loss. On this basis, aiming at the problem of excessive iron loss of the motor, a novel topological structure of the stator and rotor is proposed. With the optimization goal of reducing the motor iron loss and taking the connection port of the air magnetic isolation slot and the gap of the stator module as the optimization variables, the optimized design of the IPMSM with low iron loss is achieved based on the Taguchi method. After optimization, the stator iron loss decreases by 13.60%, the rotor iron loss decreases by 20.14%, and the total iron loss is reduced by 15.34%. The optimization scheme takes into account both the electromagnetic performance and the process feasibility, it offers technical backing for the high-efficiency operation of new energy vehicle drive motors.https://www.mdpi.com/2032-6653/16/6/321interior permanent magnet synchronous motorvariable coefficient iron loss modeliron loss calculationTaguchi method |
| spellingShingle | Liyan Guo Huatuo Zhang Xinmai Gao Ying Zhou Yan Cheng Huimin Wang Structural Optimization Design and Analysis of Interior Permanent Magnet Synchronous Motor with Low Iron Loss Based on the Adhesive Lamination Process World Electric Vehicle Journal interior permanent magnet synchronous motor variable coefficient iron loss model iron loss calculation Taguchi method |
| title | Structural Optimization Design and Analysis of Interior Permanent Magnet Synchronous Motor with Low Iron Loss Based on the Adhesive Lamination Process |
| title_full | Structural Optimization Design and Analysis of Interior Permanent Magnet Synchronous Motor with Low Iron Loss Based on the Adhesive Lamination Process |
| title_fullStr | Structural Optimization Design and Analysis of Interior Permanent Magnet Synchronous Motor with Low Iron Loss Based on the Adhesive Lamination Process |
| title_full_unstemmed | Structural Optimization Design and Analysis of Interior Permanent Magnet Synchronous Motor with Low Iron Loss Based on the Adhesive Lamination Process |
| title_short | Structural Optimization Design and Analysis of Interior Permanent Magnet Synchronous Motor with Low Iron Loss Based on the Adhesive Lamination Process |
| title_sort | structural optimization design and analysis of interior permanent magnet synchronous motor with low iron loss based on the adhesive lamination process |
| topic | interior permanent magnet synchronous motor variable coefficient iron loss model iron loss calculation Taguchi method |
| url | https://www.mdpi.com/2032-6653/16/6/321 |
| work_keys_str_mv | AT liyanguo structuraloptimizationdesignandanalysisofinteriorpermanentmagnetsynchronousmotorwithlowironlossbasedontheadhesivelaminationprocess AT huatuozhang structuraloptimizationdesignandanalysisofinteriorpermanentmagnetsynchronousmotorwithlowironlossbasedontheadhesivelaminationprocess AT xinmaigao structuraloptimizationdesignandanalysisofinteriorpermanentmagnetsynchronousmotorwithlowironlossbasedontheadhesivelaminationprocess AT yingzhou structuraloptimizationdesignandanalysisofinteriorpermanentmagnetsynchronousmotorwithlowironlossbasedontheadhesivelaminationprocess AT yancheng structuraloptimizationdesignandanalysisofinteriorpermanentmagnetsynchronousmotorwithlowironlossbasedontheadhesivelaminationprocess AT huiminwang structuraloptimizationdesignandanalysisofinteriorpermanentmagnetsynchronousmotorwithlowironlossbasedontheadhesivelaminationprocess |