Synergizing Efficiency and Silence: A Novel Approach to E-Machine Development

Abstract

In recent years, the automotive industry has dedicated significant attention to the evolution of electric vehicles (EVs). The Electric-machine (as motor and generator, here and onward called E-machine as more general term) as the heart of the EDU (Electric Drive Unit) is very important component of powertrain and is the one of the main focuses of development. Traditionally, E-machine design has primarily focused on factors like efficiency, packaging, and cost, often neglecting the critical aspects of Noise, Vibration, and Harshness (NVH) specially at the early decision-making stages. This disconnect between E-machine design teams and NVH teams has consistently posed a challenge, which is the experience seen in many OEMs. This paper introduces an innovative workflow that unifies these previously separate domains, facilitating comprehensive optimization by integrating NVH considerations with other E-machine objectives, efficiency, weight, packaging and cost. This paper highlights AVL's approach in achieving this transformation and demonstrates how this integrated approach sets a new standard for E-machine design.The presented novel approach, which is also patented, relies on AI-driven algorithms and computational tools. The important aspect of this methodology is that from the first step of E-machine design, NVH is included. This advanced methodology makes sure that with predictive modeling and advanced optimization, an optimal electric machine is developed for NVH without compromising on efficiency or costs.