Design of a High-Specific-Power Traction Motor: Innovations and Strategies for Superior Performance
In electric vehicle (EV) traction, energy conversion by electric motors must 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 ear...
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IEEE
2025-01-01
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| Online Access: | https://ieeexplore.ieee.org/document/11082312/ |
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| author | Juha J. Pyrhonen Ilya Petrov Daniil Zadorozhniuk Lasse Laurila Miika Parviainen Giota Goswami Charles Nutakor Jussi Sopanen Iikka Martikainen Dieter Zeppei Jonas Bickel Jenni Pippuri-Makelainen Janne Keranen Kalle Kinnunen Juho Montonen |
| author_facet | Juha J. Pyrhonen Ilya Petrov Daniil Zadorozhniuk Lasse Laurila Miika Parviainen Giota Goswami Charles Nutakor Jussi Sopanen Iikka Martikainen Dieter Zeppei Jonas Bickel Jenni Pippuri-Makelainen Janne Keranen Kalle Kinnunen Juho Montonen |
| author_sort | Juha J. Pyrhonen |
| collection | DOAJ |
| description | In electric vehicle (EV) traction, energy conversion by electric motors must 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 to some extent 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 continuous 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) using hollow hairpin conductors, and insulating them with polyether-ether-ketone (PEEK) extrusion and expandable mainwall insulation material. The approach reduces reliance on rare earth permanent magnet (PM) materials by 60% compared to existing motors, aligning with global sustainability objectives. Through simulation, modeling, and practical case studies, the research demonstrates the feasibility of these innovations in real-world applications, highlighting potential advancements in EV propulsion systems. The article not only represents the insights into the latest developments in the design of electric motors for EV but also delineates the journey towards the creation of such a motor with considering accompanying electromagnetic and mechanical challenges. |
| format | Article |
| id | doaj-art-0fa6eb443ccb4e94a59fa10eeff4ebf9 |
| institution | DOAJ |
| issn | 2169-3536 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | IEEE |
| record_format | Article |
| series | IEEE Access |
| spelling | doaj-art-0fa6eb443ccb4e94a59fa10eeff4ebf92025-08-20T02:48:16ZengIEEEIEEE Access2169-35362025-01-011312565912567510.1109/ACCESS.2025.358993911082312Design of a High-Specific-Power Traction Motor: Innovations and Strategies for Superior PerformanceJuha J. Pyrhonen0https://orcid.org/0000-0001-6704-1315Ilya Petrov1https://orcid.org/0000-0002-7419-0017Daniil Zadorozhniuk2https://orcid.org/0009-0009-1582-4102Lasse Laurila3https://orcid.org/0000-0002-6365-2861Miika Parviainen4https://orcid.org/0009-0005-7220-6432Giota Goswami5https://orcid.org/0000-0002-3786-8140Charles Nutakor6https://orcid.org/0000-0002-5884-1529Jussi Sopanen7https://orcid.org/0000-0003-4371-1606Iikka Martikainen8Dieter Zeppei9Jonas Bickel10https://orcid.org/0009-0006-6318-876XJenni Pippuri-Makelainen11https://orcid.org/0000-0002-9698-1549Janne Keranen12https://orcid.org/0000-0003-1195-0856Kalle Kinnunen13https://orcid.org/0009-0000-8178-2363Juho Montonen14https://orcid.org/0000-0001-5836-9474Laboratory of Electrical Drives, Lappeenranta-Lahti University of Technology (LUT University), Lappeenranta, FinlandLaboratory of Electrical Drives, Lappeenranta-Lahti University of Technology (LUT University), Lappeenranta, FinlandLaboratory of Electrical Drives, Lappeenranta-Lahti University of Technology (LUT University), Lappeenranta, FinlandLaboratory of Electrical Drives, Lappeenranta-Lahti University of Technology (LUT University), Lappeenranta, FinlandDepartment of Mechanical Engineering, Lappeenranta-Lahti University of Technology (LUT University), Lappeenranta, FinlandDepartment of Mechanical Engineering, Lappeenranta-Lahti University of Technology (LUT University), Lappeenranta, FinlandDepartment of Mechanical Engineering, Lappeenranta-Lahti University of Technology (LUT University), Lappeenranta, FinlandDepartment of Mechanical Engineering, Lappeenranta-Lahti University of Technology (LUT University), Lappeenranta, FinlandDepartment of Mechanical Engineering, Lappeenranta-Lahti University of Technology (LUT University), Lappeenranta, FinlandKibo Tech Center–Global Engineering, BorgWarner Systems Engineering GmbH, Kirchheimbolanden, GermanyKibo Tech Center–Global Engineering, BorgWarner Systems Engineering GmbH, Kirchheimbolanden, GermanyVTT Technical Research Centre of Finland Ltd., Espoo, FinlandVTT Technical Research Centre of Finland Ltd., Espoo, FinlandVTT Technical Research Centre of Finland Ltd., Espoo, FinlandDanfoss Editron, Lappeenranta, FinlandIn electric vehicle (EV) traction, energy conversion by electric motors must 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 to some extent 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 continuous 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) using hollow hairpin conductors, and insulating them with polyether-ether-ketone (PEEK) extrusion and expandable mainwall insulation material. The approach reduces reliance on rare earth permanent magnet (PM) materials by 60% compared to existing motors, aligning with global sustainability objectives. Through simulation, modeling, and practical case studies, the research demonstrates the feasibility of these innovations in real-world applications, highlighting potential advancements in EV propulsion systems. The article not only represents the insights into the latest developments in the design of electric motors for EV but also delineates the journey towards the creation of such a motor with considering accompanying electromagnetic and mechanical challenges.https://ieeexplore.ieee.org/document/11082312/Energy conversionenergy systemelectric motortraction motorelectric vehiclenon-road electric vehicle |
| spellingShingle | Juha J. Pyrhonen Ilya Petrov Daniil Zadorozhniuk Lasse Laurila Miika Parviainen Giota Goswami Charles Nutakor Jussi Sopanen Iikka Martikainen Dieter Zeppei Jonas Bickel Jenni Pippuri-Makelainen Janne Keranen Kalle Kinnunen Juho Montonen Design of a High-Specific-Power Traction Motor: Innovations and Strategies for Superior Performance IEEE Access Energy conversion energy system electric motor traction motor electric vehicle non-road electric vehicle |
| title | Design of a High-Specific-Power Traction Motor: Innovations and Strategies for Superior Performance |
| title_full | Design of a High-Specific-Power Traction Motor: Innovations and Strategies for Superior Performance |
| title_fullStr | Design of a High-Specific-Power Traction Motor: Innovations and Strategies for Superior Performance |
| title_full_unstemmed | Design of a High-Specific-Power Traction Motor: Innovations and Strategies for Superior Performance |
| title_short | Design of a High-Specific-Power Traction Motor: Innovations and Strategies for Superior Performance |
| title_sort | design of a high specific power traction motor innovations and strategies for superior performance |
| topic | Energy conversion energy system electric motor traction motor electric vehicle non-road electric vehicle |
| url | https://ieeexplore.ieee.org/document/11082312/ |
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