Electric Vehicle Design Optimization: Integration of a High-Fidelity Interior-Permanent-Magnet Motor Model

The simulation-based design optimization of an electric-vehicle (EV) propulsion system requires integration of a system model with detailed models of the components. In particular, a high-fidelity interior-permanent-magnet (IPM) motor model is necessary to capture important physical effects, such as magnetic saturation. The system optimization challenge is to maintain adequate model fidelity with acceptable computational cost. This paper proposes a design method that incorporates a high-fidelity motor, high-voltage power electronics, and vehicle propulsion simulation models in a system design optimization formulation that maximizes energy efficiency of a compact EV on a given drive cycle. The resulting optimal design and associated energy efficiency for a variety of drive cycles and performance requirements are presented and discussed.