Optimized Design and Improved Performance of IPM-BLDC Motor for Light Electric Vehicles

The electric motor, functioning as a significant part of the drivetrain, is a key component in an Electric Vehicle (EV) system. The Brushless DC (BLDC) motor, in particular, presents beneficial traction characteristics with minimal maintenance, primarily due to its brushless design. This paper discusses the design of an Interior Permanent Magnet Brushless DC (IPM-BLDC) motor, specifically tailored for light EV drivetrains. Our analysis and design parameters, including 3 KW, 4400 rpm, 8 poles, and 24 slots, have been completed using the JMAG-Express Classic 15.0 software platform. Notably, we achieved improvements in key parameters such as breakdown torque, efficiency, and power factor, affirming the motor's suitability for EV applications. Furthermore, we employed a PID controller-based closed loop speed control technique in MATLAB/Simulink to assess the speed control performance of the designed BLDC motor. Through simulation, we validated that our designed BLDC motor drive performs satisfactorily even when it exceeds its rated speed by 25 %.