Work

Design of a High-Specific-Power Traction Motor: Innovations and Strategies for Superior Performance

Year: 2025

Type: article

Abstract: In electric vehicle (EV) and non-road mobile machine (NRMM) traction, energy conversion by electric motors has to be material and energy efficient to reduce environmental burden caused by the manufacture and operation of the systems and to help in efficient transition towards net zero future. The scarcity of key materials like rare earths and copper must be addressed in the design. Novel traction motors need a different approach compared to traditional industrial motor designs. Here, we focus on innovative design and optimization strategies to enhance material and energy efficiency and meet the escalating demand for sustainable transportation solutions. We are developing a prototype motor that achieves a specific power of 7 kW/kg, significantly exceeding current automotive standards. This will be achieved by elevated operational speed of the traction motor, integrating advanced materials, and innovative cooling techniques such as direct liquid cooling (DLC) through the use of hollow hairpin conductors, and insulating them with polyetheretherketone (PEEK) extrusion and Vacuum Pressure Impregnation (VPI) or expandable mainwall insulation material. The approach reduces reliance on rare earth permanent magnet (PM) materials by 60%, aligning with global sustainability objectives. Through simulation, modelling, and practical case studies, the research demonstrates the feasibility of these innovations in real-world applications, highlighting potential advancements in EV propulsion systems. This study sets the foundation for the next generation of electric traction motors, contributing to a more sustainable future by optimizing electric motor design for improved performance and reduced environmental impact.

Source: IEEE Access

DOI: 10.1109/access.2025.3589939