Design of a Novel Embedded Magnet Rotor Geometry to Reduce Rotor Stress Concentration Effects in IPM Machines for EVs

초록

This paper presents a novel rotor flux barrier design method for electric vehicle (EV) traction motor, focusing on mitigating mechanical stress concentrations in rotor rib regions. Three stress-relief techniques, such as fillet, dumbbell, and hole techniques, were systematically evaluated through finite element analysis (FEA) to assess their effectiveness in reducing maximum mechanical stress (MMS). Based on these findings, a ribbon-shaped flux barrier design incorporating rib angle optimization was introduced. The final geometry was obtained via surrogate-based optimization using genetic algorithm, with key design parameters identified and tuned accordingly. FEA simulations confirm that the proposed design achieves a 20% reduction in MMS without compromising output torque performance.

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