Research on a 60 kW High Speed Permanent Magnet Synchronous Integrated Motor Drive for Electric Vehicles

This paper focuses on the research of the integrated motor drive (IMD) and its controller for electric vehicles, starting from both the machine and the controller. The slot/pole combination of the machine in integrated motor drive is 20-slot 8-pole, and the magnet topology of the machine is determined U-type which overload capacity and wide-speed range capacity into consideration. Three main operating conditions: base speed operating condition, high speed operating condition and overload operating condition are determined. At the same time, main index and thermal analysis for each operating condition was evaluated and checked. For the controller part, the installation mode was determined the housing installation mode integration for high power density and low drive system volume. Controller using voltage source inverter with wide-bandgap SiC device, and matching the five phase sinusoidal phase width modulation to control the machine, the researched integrated motor driver prototype is manufactured.