Next generation xEV modular platforms powered by ProteanDrive In-Wheel Motor

Stephen Lambert (Protean Electric)

This presentation delves into the development of high-performance in-wheel motors tailored for premium automotive applications. As electric vehicles (EVs) continue to gain traction in the market, the demand for innovative propulsion systems that combine efficiency, power, and integration has grown. In-wheel motors, which integrate the motor (And potentially the power electronics) directly within the wheel, offer unique advantages to allow OEMs to deliver a new paradigm in Electric Vehicles with more space, improved energy efficiency, enhanced vehicle dynamics, and critically lower cost. However, this technology also presents challenges. This presentation explores these challenges and highlights the cutting-edge solutions and design strategies employed to overcome them, offering insights into the future of electric mobility.

Optimization of laminated stacks for electrified vehicle drives

Francis van der Sluis･Benny Seitzinger･Sander de Vet･Oleg Alexandrov･Emile Kruijswijk (Bosch Transmission Technology BV)･Andreas Herzberger (Robert Bosch)

Electric motors in xEV offer power loss, power density and cost optimization opportunities.
We present a minimization of hysteresis and eddy current losses in the laminated core by combining a dedicated heat treatment and glue as a joining method. Separate and combined effects are compared to the state-of-art.
Heat treatment reduces hysteresis by stress relief. Glue bonding maintains lamination flatness and prevents eddy currents to further reduce losses. Design dependent benefits up to 20% are reported.
Lower losses improve power density and reduce thermal loads to offer higher system power output or downsizing options that can reduce system cost.

Development of coil immersion oil cooling technology to improve continuous output

Takaki Itaya･Akihito Toya･Hideaki Goto･Akeshi Takahashi (Astemo)

The e-Axle for electric vehicles need to be compact and lightweight in order to be easily installed in the vehicle and to fit in the vehicle layout. The conventional indirect water-cooled structure has a problem that its cooling performance is insufficient for the increase in loss density due to the smaller size and lighter weight. In this report, we report the results of the evaluation of elemental tests and actual machine tests of motor with the coil-immersion oil-cooled structure applied.

Impact of Advanced Control Techniques on Electromagnetic Torque Generation Using a Multiphysics Simulation

Francisco Ramiro Ulloa-Herrera･Xavier Genaro-Munoz･Javier Arturo Corea-Araujo･Carlos Moya (IDIADA Automotive Technology)

This study presents a multiphysics simulation approach for permanent magnet synchronous motors (PMSMs) using Ansys and Simulink for co-simulation and control technic analysis. The methodology involves electromagnetic force analysis, accounting for voltage harmonics induced by current controllers under various control algorithms. A PMSM for traction applications is designed using Ansys and controlled via Simulink. The co-simulation evaluates magnetic and electrical interactions under different operating conditions. This approach allows the use of the same motor drive control across platforms, reducing development time and offers insights into extending the analysis to include vibroacoustic performance for enhanced motor design.

A Review on Inverter Testing Methodologies for Electric Vehicle Industry

Xavier Genaro-Munoz･Francisco Ulloa-Herrera･Javier Arturo Corea-Araujo (IDIADA Automotive Technology)

The electric vehicle (EV) industry faces the challenge of balancing rapid technological innovation with competitive pricing. Consumer trust hinges on vehicle reliability and low maintenance. This study identifies the inverter as a critical but vulnerable part of the EV powertrain, particularly as higher voltage systems are increasingly adopted for efficiency. To accelerate development and reduce costs, testing the inverter may sometimes begin before a fully developed motor is available. This review explores practical methodologies for inverter testing, evaluating their strengths and limitations to guide engineers in creating robust setups that drive innovation and ensure reliability in EV inverter technologies.