Design Optimization and Experimental Verification of Permanent Magnet Synchronous Motor Used in Electric Compressors in Electric Vehicles

Featured Application Optimal design of permanent magnet synchronous motors (PMSMs) used in electric compressors in electric vehicles. Based on the proposed optimization method, the efficiency and cogging torque characteristics of the PMSM can be improved. Abstract In this study, a shape design optimization method is proposed to improve the efficiency of a 3 kW permanent magnet synchronous motor (PMSM) used in an electric compressor intended for use in an electric vehicle. The proposed method improves the efficiency performance of the electric compressor by improving the torque characteristics of the initial PMSM model. The dimensions of the rotor were set as the design variables and were chosen to maximize efficiency and reduce cogging torque. During the determination of the design points with conventional Latin hypercube design, the experimental points may be closely related to each other. Therefore, the optimal Latin hypercube design was used to optimally distribute the experimental points evenly and improve the space filling characteristics. The Kriging model was used as an interpolation model to predict the optimal values of the design variables. This allowed the formulation of more accurate prediction models with multiple design variables, complex reactions, or nonlinearities. A genetic algorithm was used to identify the optimal solution for the design variables. It was used to satisfy the objective function and to determine the optimal design variables based on established constraints. The optimal design results obtained based on the proposed shape optimization method were confirmed by finite element analyses. For practical verification, the optimal model of the prototype PMSM of an electric compressor was manufactured, and a 1.5% improvement in its efficiency performance was confirmed based on an experimental dynamometer test.