Fast Driving Cycle Efficiency optimization of an IPMSM with Hairpin Windings Considering PWM-Induced Losses

This paper proposes a method for the fast driving cycle efficiency optimization of interior permanent magnet synchronous machines (IPMSMs) with hairpin windings, considering pulse-width modulation (PWM) induced harmonic losses. The previously established rapid calculation method of PWM-induced harmonic losses based on the small-signal time-harmonic finite element method is incorporated in the multi-objective optimization process. The paper starts by extracting representative operating points within the cycle period. Subsequently, simplified fast calculation methods for PM losses, iron losses and copper losses under both sinusoidal current source (SCS) supply and PWM voltage source inverter supply are summarized. By doing so, the multi-optimization of the efficiency and cost of IPMSMs considering the automotive driving cycle is achieved. The results indicate that the method considering PWM-induced harmonic losses in multi-objective optimization procedure yields better performance compared to the method considering only losses under SCS supply. Specifically, the total loss is reduced by 3.57% at the same cost, with only 16.5% increase of computational time.