Optimization Design of Flat Wire Permanent Magnet Synchronous Motor for Electric Vehicles

This study focuses on addressing the issues of insufficient rated torque, high torque ripple, and efficiency problems in a 150-kW flat wire motor. By optimizing the number of winding layers and the rotor topology of the original design, a comparative analysis using Motor-CAD simulation was conducted for the “U+1” rotor, “Double V” rotor, “V+1” rotor, as well as the performance of winding configurations with 6, 8, and 10 layers. Based on the simulation results, the “Double V” rotor and an 8-layer winding configuration were selected as the optimal solution.