Optimization of Electric Powertrains Based on Scalable Cost and Performance Models

This work presents a methodology for modeling, designing, and scaling the electromagnetic, mechanical, and thermal characteristics of the main components in an electric powertrain (excluding the battery), i.e., a power electronics converter, an electrical machine, and mechanical transmission. Additionally, a framework for estimating the cost of these components is described. This framework takes into consideration not only the material cost, but also all major manufacturing steps required for the production of a component and their dependence on expected production volumes. Moreover, a procedure to optimize the design of an electric powertrain, taking advantage of the aforementioned models, is proposed. Finally, the powertrain for a passenger electric vehicle is optimized using the proposed methodology, and the results are compared in terms of the electrical machine topology, powertrain concepts, cost, weight, gear ratio(s) in the transmission, and overloading capabilities.