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This paper aims to find the optimal winding topology for a 14‐pole permanent magnet synchronous motor (PMSM) to be used as an in‐wheel motor in automotive applications.

Comparison is first performed among lap windings with different combinations of slot numbers and pole numbers. A general method for calculating the winding factors using only these numbers is proposed, thus the preferable slot numbers resulting in relatively large winding factors for this 14‐pole PMSM are found. With these slot numbers, the Joule losses of armature windings are further investigated, where the impacts of different end‐winding lengths are considered. By this means, the optimal slot number that causes the least Joule loss is obtained. On the other hand, as a competitor to lap windings, toroidal windings are also discussed. The thermal performances of these two types of windings are compared by performing a finite element analysis (FEA) on their 2‐D thermal models.

For the 14‐pole in‐wheel PMSM discussed in this paper, the preferable slot numbers leading to relatively large winding factors are 12, 15 and 18. However, with the specified geometry constraints, the optimal choice of slot number is 15, which results in the least Joule loss and thus the highest efficiency. On the other hand, by implementing the toroidal winding topology, the armature windings of this machine can be effectively cooled and thus allow a larger electrical loading than the lap windings do.

This work can be continued with investigating the impacts of different combinations of slot number and pole number on harmonics and cogging torques.

This paper proposes a general method for calculating the winding factor of PMSMs using only the phase number, the slot number, and the pole number. With this method, the calculation procedure can be easily programmed and repeated.

Today's brushless permanent magnet (PM) drive systems usually adopt motors including the advancements in magnet technology, e.g. better thermal characteristics and higher magnetic strength. By this means, they become capable in the roughest applications yet maintain a high accuracy at competitive prices. These drive systems are not only appreciated for their high performance, but they are also advantageous for the applications requiring tough, dependable, and continuous‐duty operations, e.g. hybrid or complete electrical vehicles, extruders, wire drawers, winders, cranes, conveyors, and roll formers. The purpose of this paper is to provide an extended comparative study of the different motor configurations for the hybrid electric drive application, aiming at a compromise between high power density and extended speed capability.

To suit strict design requirements, such as the very limited volumetric envelope, high‐output power, wide constant power speed range, and pre‐selected in‐direct cooling system, the constraint variants of possible motor types are researched.

Considerably, high torque density and an extended speed range limit the options of PM rotor configurations for this motor design. The considered rotor configurations are the surface PM (SPM) and interior PM (IPM) types. The advantage of the (non‐salient) SPM configuration is its applicability with higher levels of magnetic flux densities without causing significant saturation in the rotor. On the other hand, an IPM rotor, which places the magnets in special rotor slots, open or closed (by saturation bridges), can operate on both the reluctance torque and the magnet alignment torque. This generally leads to a better performance in a wide speed range. However, this advantage can be eliminated by severe iron saturation resulting from the required high‐specific power.

The most appropriate rotor configuration will finally be selected between the two considered types, depending on detailed electromagnetic and thermal analysis. This paper usefully studies the correlation between the motor parameters required for high power density and field‐weakening performance.