A Copper Rotor Induction Motor Solution for Electrical Vehicles Traction System

This paper deals with the design of a scalable 200kW/ 370Nm or 75kW/ 200Nm, induction machines for electrical vehicles traction system. Two configurations are considered as low cost rare-earth free magnet electric motor alternatives: inner rotor and outer rotor. Both designs allow mass production while providing higher performance compared to current technologies. The electromagnetic, thermal and mechanical constraints are considered throughout the machine design, from the specifications to the optimization. Rotor die-casting, oil spray cooling and hairpin stator winding are used in the analyzed solutions. Analytical and numerical methods are used for electromagnetic and continuous thermal performance calculation over the full speed range of the machine, along with the mechanical limits from a stress and modal point of view.