Optimal design of an high torque DC brushless in-wheel motor

Abstract

This paper deals with the design of an in-wheel DC brushless motor. As the design constraints are very hard (maximal torque of 6000 N.m during I minute, efficiency at rated point better than 90%, total mass as low as possible), the authors have developed an original approach. First, this method consists in developing a large analytical model of the machine. Then, the model is used to elaborate an optimal design program that is automatically generated by the software Pro@design. Finally the program is used to design the machine according to the specifications and minimizing the total mass. The model and the design are validated by comparison of theoretical results with measurements on a prototype which has been installed in an experimental armored car.