Today’s automotive industry has focused its studies on electric vehicles (EVs) or hybrid electric vehicles (HEVs) rather than gasoline-powered vehicles. For this reason, more investment has been made in electric motors with high efficiency, high torque density, and high-power factor to be used in both EVs and HEVs. In this study, an outer-rotor permanent-magnet-assisted synchronous reluctance motor (PMaSynRM) with a new rotor topology was designed for use in an EV. The design has a transversally laminated anisotropic (TLA) rotor structure. In addition, neodymium-iron-boron (NdFeB) magnets were used in rotor topology. The stator slots were designed as distributed windings, so torque ripples are minimized. At the same time, the maximum electromagnetic torque was achieved. The analysis of the designed motor was carried out using the finite element method (FEM). Optimal values of motor parameters were obtained by improving the rotor geometry of the three-phase PMaSynRM in order to obtain maximum torque and minimum torque ripple in the design. The motor is in a 48/8 slot/pole combination, a speed of 750 rpm and a power of 1 kW. The simulation results showed that the design achieved maximum torque and minimum torque ripple.

This study presents the prototype manufacturing and experimental validation of a 1 kW, 750 rpm three-phase outer-rotor permanent magnet-assisted synchronous reluctance motor (PMASynRM) designed for in-wheel electric vehicle applications. The work is based on a previously reported electromagnetic design and finite element method (FEM)-based optimization framework and focuses on the physical implementation and experimental evaluation of the proposed motor. The prototype was manufactured using M470-50A grade electrical steel laminations and arc-shaped N35H NdFeB permanent magnets embedded within a three-barrier transversally laminated anisotropic rotor structure. A custom-built experimental test bench consisting of the PMASynRM prototype, a PMSM generator with a controllable resistive load bank, a torque transducer, and a precision power analyzer was developed to evaluate motor performance under controlled operating conditions. Experimental investigations were carried out under four steady-state load conditions—no-load, 13 Nm, 20 Nm, and 26 Nm—as well as during dynamic stepwise load transitions representative of in-wheel drive operation. The measured results show good agreement with FEM predictions, with a maximum efficiency of 90.55% at nominal load and efficiency values remaining above 87% under overload conditions up to 26 Nm. Minor differences between simulation and experimental results are mainly associated with mechanical friction, bearing losses, and manufacturing tolerances that are not fully captured in the numerical model. The study provides experimental validation of an outer-rotor PMASynRM prototype under multi-load steady-state and dynamic operating conditions for in-wheel electric vehicle applications.