Sequential Design Process of a 350-kW Class Dual Three-Phase IPMSM for a Wheeled Armored Vehicle

Optimal design of a traction motor is a complex process, as various requirements and constraints need to be satisfied. In addition, consideration of various physical aspects, such as stress and heat, is necessary to ensure the stability of the motor, including mechanical rigidity and insulation breakdown. In this article, to derive the optimal design of an interior permanent magnet synchronous motor (IPMSM), a novel sequential design process consisting of conceptual design, detailed design, and optimal design is proposed. The conceptual design enables the rapid execution of multiple case studies, as static electromagnetic analysis is used. The overall geometric parameters are determined through electromagnetic analysis in the detailed design stage and an initial model that satisfies the requirements is derived. Finally, in the optimal design stage, the optimal model is quickly derived using a machine learning method, and the stability of the model is examined through multiphysics analysis. To validate the applicability to the practical motor, design optimization for a 350-kW class dual three-phase IPMSM for a wheeled armored vehicle is conducted, and the feasibility of the proposed method is verified based on the experimental results of the manufactured prototype.