Fractional slot, PMSM motors with a properly designed electromagnetic circuit allow for obtaining high power density factors (more than 4 kW per 1 kg of total motor weight). The selection of the number of magnetic poles to the specific dimensions and operating conditions of the motor, as well as the number of slots for the selected number of magnetic poles is the subject of the analysis in this article. This issue is extremely important because it affects the mass of the motor, the value of shaft torque, shaft power and the value of rotor losses. The aim of the work is to select solutions with the highest values of power density factor and, at the same time, the lowest values of rotor losses. The object of the study is a fractional slot PMSM motor with an external solid rotor core with surface permanent magnets (SPM). Motor weight is approximately 10 kg, outer diameter is 200 mm and a maximum power is 50 kW at 4800 r/min. The article analyzes the selection of magnetic poles in the range from 2p = 12 to 2p = 24 and various slot-pole combinations for individual magnetic poles. The target function of the objective was achieved and the calculations results were verified on the physical model. The best solutions were 20-pole, 30-slots (highest efficiency and lowest rotor loss) and 24-pole, 27 slots (highest power density).

Fractional-slot PMSM motors allow for obtaining high values of power density factors, but at the same time, they are characterized by high values of rotor losses—in the rotor core and permanent magnets. The main causes of rotor losses in this type of motor are subharmonics and a high content of higher harmonics in the distribution of the magnetomotive force MMF. The use of a solid rotor core simplifies the construction and technology of the rotor but eddy current losses in the core account for a significant percentage of the total rotor losses. It is well known that a laminated core reduces eddy currents, while for motors with an outer rotor, it complicates the construction and increases weight. Thus, the question arises about the necessity to use a laminated core in a high power density motor and the real benefits of this. The article presents a comparison of the motors with a solid rotor core and a laminated rotor core, considering the value of rotor losses, power density factor, efficiency and the range of rotational speed and range of current load. The analysis was carried out for various types of sheets for laminated core and solid steel and SMC (Soft Magnetic Composite) material for solid rotor core. FEM models were used in the analysis, and the results were partially verified with the results of laboratory tests of motor models. The object of the analysis is a fractional-slot PMSM motor with an external rotor with surface permanent magnets (SPM). Motor weight is about 10 kg, and the maximum power is 50 kW at 4800 rpm.

The analysis of the performance of various structural solutions of the cooling system for the in wheel car motor is presented in the work. The analysis was conducted on the prepared spatial calculation models using the CFD software. The maximum motor temperature for various solutions of the stator support structure and for different shapes of the water jacket channel was determined as a result of simulation. The analysis for a steady state with constant losses corresponding to the S1 motor operation point and the constant flow of the cooling medium was carried out. The calculations were made by building separate discrete models for each analyzed case. The information how the structural changes affect the efficiency of the cooling system and how to improve the prototype of the in wheel car motor was given as a result of conducted thermal simulations.

The dynamic development of electromobility has resulted in new directions of research, one of which is the analysis of the noise of traction motors. The designs of the motors used in electric vehicles are relatively new and often modified. In addition, strong competition also forces an increase in the power generated per unit mass of the motor, often at the expense of weakening the mechanical structure. This may result in an increase in the noise level generated by the electric drive, so this issue should be analyzed at the motor design stage. Different construction and operating conditions in relation to industrial or railway traction motors make it necessary to constantly develop methods for the noise analysis of the motors for electric vehicles. The aim of this article is to review the methods used so far in an analysis of the noise generated by the motors for electric vehicles. Three main methods are used by the authors of this paper: the analytical method, the hybrid method using two-dimensional models, and the hybrid method using three-dimensional models. In addition to the review of these methods, the paper also focuses on a synthetic summary of the most important factors determining the level and nature of the noise generated by electric vehicle motors.

Fractional slot PMSM motors enable high power density factors to be obtained provided that their electromagnetic circuit, appropriate mechanical structure and cooling system are properly designed, as well as when operating at a high frequency of power supply voltage (400–800 Hz) with high magnetic saturation and high current loads (approx. 12–15 A/mm2). Such operating conditions, especially in the case of fractional slot motors, may be the reason for excessive rotor losses, mainly in the rotor yoke and permanent magnets. One of the conditions for obtaining high values of continuous power of the motor is the reduction of these losses. This paper presents selected design methods for limiting the value of rotor losses with simultaneous consideration of their influence on other motor parameters. The analysiswas carried out for aPMSMmotor with an external rotorweighting approx. 10 kg and a maximum power of 50 kW at a rotational speed of 4 800 rpm.

Disk motors are characterized by the axial direction of main magnetic flux and the variable length of the magnetic flux path along varying stator/rotor radii. This is why it is generally accepted that reliable electromagnetic calculations for such machines should be carried out using the FEM for 3D models. The 3D approach makes it possible to take into account an entire spectrum of different effects. Such computational analysis is very time-consuming, this is in particular true for machines with one magnetic axis only. An alternate computational method based on a 2D FEM model of a cylindrical motor is proposed in the paper. The obtained calculation results have been verified by means of lab test results for a physical model. The proposed method leads to a significant decrease of computational time, i.e. the decrease of iterative search for the most advantageous design.