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<p>This study presents the design and optimisation of an axial flux wound rotor synchronous motor (AFWRSM) for electric vehicles. Permanent magnet synchronous motors, which are widely used in the electric vehicle industry today, have motivated the research for alternatives due to the high cost and environmental impact of rare earth elements. In this context, radial flux wound rotor synchronous motors (WRSM) represent a viable alternative, while axial flux topologies offer advantages in terms of torque density and compactness. The proposed AFWRSM is analysed using three-dimensional finite element simulations, and rotor pole geometric parameters are optimised through a multi-objective optimisation approach. The performance of the designed motor is evaluated under traction-relevant operating conditions defined by liquid-cooled current density limits of up to 30&#xa0;A/mm². The efficiency characteristics of the proposed AFWRSM are discussed in comparison with reported performance data of radial flux wound rotor synchronous motors available in the literature. At the base speed, a nominal power of 35&#xa0;kW is achieved with a torque ripple of 2.63% and an efficiency of 93.57%. Efficiency values above 93% are not only obtained at the nominal operating point but are also maintained over a wider speed range between 3000 and 7000&#xa0;rpm. When compared with literature-reported efficiency maps of radial flux WRSMs, which typically indicate nominal efficiencies around 92% and peak efficiencies of approximately 93% over more limited speed ranges, the proposed AFWRSM demonstrates favourable efficiency characteristics under traction-relevant operating conditions.</p>

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Design of a Novel Axial Flux Wound-Rotor Synchronous Motor for Electric Vehicles

  • 期刊论文

  • 发表日期：

    2026年3月25日

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  • Mustafa Özsoy

摘要

This study presents the design and optimisation of an axial flux wound rotor synchronous motor (AFWRSM) for electric vehicles. Permanent magnet synchronous motors, which are widely used in the electric vehicle industry today, have motivated the research for alternatives due to the high cost and environmental impact of rare earth elements. In this context, radial flux wound rotor synchronous motors (WRSM) represent a viable alternative, while axial flux topologies offer advantages in terms of torque density and compactness. The proposed AFWRSM is analysed using three-dimensional finite element simulations, and rotor pole geometric parameters are optimised through a multi-objective optimisation approach. The performance of the designed motor is evaluated under traction-relevant operating conditions defined by liquid-cooled current density limits of up to 30 A/mm². The efficiency characteristics of the proposed AFWRSM are discussed in comparison with reported performance data of radial flux wound rotor synchronous motors available in the literature. At the base speed, a nominal power of 35 kW is achieved with a torque ripple of 2.63% and an efficiency of 93.57%. Efficiency values above 93% are not only obtained at the nominal operating point but are also maintained over a wider speed range between 3000 and 7000 rpm. When compared with literature-reported efficiency maps of radial flux WRSMs, which typically indicate nominal efficiencies around 92% and peak efficiencies of approximately 93% over more limited speed ranges, the proposed AFWRSM demonstrates favourable efficiency characteristics under traction-relevant operating conditions.