Challenges in the Development of Ford Mustang Mach-E BEV Motor Calibration and Controls for NVH & Losses

The 300-mile range marquee 2021 Ford Mustang Mach-E all electric crossover vehicle (BEV) launched recently with variants like RWD and AWD in standard and extended range configuration is propelled by an interior permanent magnet (IPM) AC synchronous motor and a three phase two-level voltage source inverter system. This paper outlines the challenges encountered during the development of the electric drive system and how competing vehicle attributes like NVH, range and inverter system component thermal reliability are effectively managed by employing motor calibration and control strategies in delivering an uncompromising and superior vehicle performance.