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Permanent magnet synchronous motors for electric vehicles should meet three criteria: high maximum torque, high efficiency at low torque, and constant output in a wide speed range. However, meeting these criteria has come with a trade-off in terms of the magnitude of the field magnetic flux. We propose a consequent-pole-PM-type axial-gap motor with ferrite PMs and field windings, which has structure variable field magnetic flux. In order to examine the operational characteristics of the proposed motor, we produced and tested a prototype. Experimental results show that the proposed structure meets all of the three criteria above.

This paper investigates a method to increase fuel economy of motors for an electric vehicle (EV) traction system. The low-torque region of an EV motor is frequently used in everyday urban driving and in fuel economy measurement. Pulsewidth modulation (PWM) carrier harmonic iron loss accounts for a high percentage of total loss for EV motors in this region. This paper reveals the relationship between phase current and carrier harmonic iron loss for a permanent-magnet synchronous motor (PMSM) in the low-torque region. Thus, a novel carrier harmonic loss reduction technique is proposed and applied to two sets of three-phase windings for a concentrated winding PMSM. The loss is successfully reduced in a 70-kW EV motor as well as a two-dimensional finite-element method (2-D-FEM) calculation. The efficiency of the developed motor is calculated and compared with that of a conventional motor in the JC08 mode driving cycle.

This paper discusses an accurate magnetic field analysis that addresses stress distribution in the magnetic core by using the finite-element method (FEM) to estimate motor characteristics. This analysis method consists of the following steps: 1) measurement of the magnetic characteristics of electrical steel sheets in a state where stress is added; 2) calculation of deformation and stress distribution using structural analysis; 3) preprocessing of the magnetic field analysis, which generates the FEM mesh taking account of the deformation by stress and the changes of the magnetic properties in each of the core elements corresponding to stress distribution; and 4) magnetic field analysis using the data measured in step 1) and the FEM mesh generated in step 3). As an example, a result of a permanent magnet motor's cogging torque calculation is shown, focusing on stress in the stator core resulting from shrink fitting into the frame. As a result, the cogging torque waveform was shown to differ depending on the shape and the materials of the frame.