Performance optimisation of the brushless motor with IPM rotor for automotive applications

The paper deals with an analysis of permanent magnet brushless motors with interior pocket magnets (IPM) designed for automotive applications. The presented motors are used in automated manual transmission (AMT) and twin-clutch systems. The AMT systems allow fuel consumption and CO₂ emission to be reduced in the vehicle. In the paper are described two versions of the motor design-with 8 pole rotor and with 10 pole rotor. Optimization of both IPM rotor shapes in case of sinusoidal or block current supply is delivered. The stators of both versions are wounded with needle winding technique which is very robust but ensures relatively low copper fill factors in slots. The described motors are designed for mass production and tolerance analysis hat influence of their output performance. The results of the robust analysis are also included in the paper.