Design Analysis of a High Speed Copper Rotor Induction Motor for a Traction Application

Abstract

This paper deals with the design of a 200kW, 20krpm machine for an electric vehicle application. The aim of the research is to design a low cost, rare-earth free magnet electric motor while ensuring mass production feasibility and providing higher performance than currently available technologies. Electromagnetic, thermal and mechanical constraints are considered throughout the machine design process, from the specification to the optimization. Rotor die-casting, oil spray cooling and hairpin winding are among the solutions investigated to fulfill the project requirements. Analytical and numerical methods are adopted for electromagnetic and continuous performance calculations over the machine's full speed range, taking into account the mechanical limits from a stress and modal point of view.