Comprehensive Design of a Permanent-Magnet-Assisted Reluctance Machine for an Electric Vehicle Application

Recently, permanent magnet (PM)-assisted reluctance (PMAREL) machines are gaining increasing attention for traction applications to reduce magnet consumption. In this article, a comprehensive design methodology is applied to design a PMAREL machine for an electric vehicle (EV) propulsion application. The design method includes both electromagnetic and mechanical analyses. A finite element analysis (FEA)-based differential evolution (DE) algorithm is adopted to find the best reluctance (REL) rotor geometry. The PM dimensions are calculated analytically, which allows a fast identification for the initial design. An FEA model for mechanical analysis is developed, and some remedial techniques are adopted to improve the mechanical stress. The design procedure starts with the selection of the stator split ratio. Then it continues with REL optimization and PM dimension determination. Finally, the rotor structure is modified iteratively based on electromagnetic and mechanical performance. FEA validations show that the designed PMAREL motor satisfies the requirements of the targeted propulsion application.