Design, Analysis, and Comparison of Electric Vehicle Drive Motor Rotors Using Injection-Molded Carbon-Fiber-Reinforced Plastics

Abstract

Due to their excellent mechanical strength, corrosion resistance, and ease of processing, carbon fiber and carbon-fiber-reinforced plastics are finding wide application in diverse fields, including aerospace, industry, and automobiles. This research explores the feasibility of integrating carbon fiber solutions into the rotors of 85-kilowatt electric vehicle interior permanent magnet synchronous motors. Two novel configurations are proposed: a carbon fiber wire-wound rotor and a carbon fiber injection-molded rotor. A finite element analysis compares the performance of these models against a basic designed rotor, considering factors like no-load back electromotive force, no-load voltage harmonics, cogging torque, load torque, torque ripple, efficiency, and manufacturing cost. Additionally, a comprehensive analysis of system efficiency and energy loss based on hypothetical electric vehicle parameters is presented. Finally, mechanical strength simulations assess the feasibility of the proposed carbon fiber composite rotor designs.

Keywords

• injection-molded carbon-fiber-reinforced plastics
• carbon-fiber sleeve
• electric vehicle traction motor
• rotor strength analysis
• finite element method