Development of a high-power-density motor for formula SAE electric race car

Abstract

Formula SAE is an international engineering design competition for university students to design, build and test a four-wheel race car in one year. Formula student electric series has been introduced into formula student duo to the increasing interest in electric mobility. This paper presents the development of a permanent magnet synchronous motor for a formula student electric race car. A 10 poles/12 slots with flux concentration configuration is employed. A high power to weight ratio is achieved by using high saturation magnetic flux iron-cobalt alloy and sintered NdFeB magnets as well as a fractional slot winding. Mechanical rotor strength and losses are analyzed due to the high rotation speed and high frequency. The electromagnetic and thermal behavior of the motor are simulated. A final design of 22Nm, 20kW is achieved with a total mass of 3.8 kg.