Design and Analysis of High performance of a

BLDC Motor for Electric Vehicle

Rajnish Kumar Prabhakar Kumar Balmukund Kumar
Electrical Engineering Electrical Engineering Electrical Engineering
National Institute of Technology National Institute of Technology National Institute of Technology
Patna, India Patna, India Patna, India
2022 2nd International Conference on Emerging Frontiers in Electrical and Electronic Technologies (ICEFEET) | 978-1-6654-8875-4/22/$31.00 ©2022 IEEE | DOI: 10.1109/ICEFEET51821.2022.9848307

rajnishk.phd20.ee@nitp.ac.in prabhakark.pg20.ee@nitp.ac.in balmukundk.ph21.ee@nitp.ac.in

Parshuram Singh Rahul Kumar Amitesh Kumar

Electrical Engineering Electrical Engineering Electrical Engineering
National Institute of Technology National Institute of Technology National Institute of Technology,
Patna, India Patna, India Patna, India
parshurams.ph21.ee@nitp.ac.in rahulk.ph21.ee@nitp.ac.in amitesh.ee@nitp.ac.in

Abstract— Brushless DC motors are widely used in electric
vehicle due to its prominent features. It’s torque to weight ratio
is made high. The approach of developing a BLDC motor is
described in this work, along with comprehensive design
equations. Motor geometry is created using ANSYS by RMxprt
tool. For further investigation, the analytical design is
subsequently implemented in Maxwell 2D. The brushless DC
design motor has obtained an efficiency of 87.2% that is very
important for electric vehicle perspective.
Keywords—ANSYS, BLDC, EV.
I. INTRODUCTION
Brushless DC motor has some prominent features like
simple construction, light weight, high torque to weight ratio
and hence power density is more, these motor is more
preferred in electric vehicle application [1]. With the
increasing pollution and increasing demand of conventional
energy source, the battery electric vehicle(BEV) and hybrid
electric vehicle (HEV) is more convenient to use and can be
reduced the load on the environment and on conventional
energy source [2]. The efficiency of BLDC motor is also very
high which makes more attracting for the use of EVs. This
motor has simple in construction and it uses electronic
commutation rather than the mechanical commutation. So, it
delivers a constant high torque per ampere despite of their
operation. Which attracted the motor for a wide use like
industrial and domestic application [3]. Due to its high
demand in different area forces the motor is manufactured
with several design in the form of its geometry and
configuration. The two-configuration available for BLDC is
slotted and slot-less. Slot-less BLDC motor has come without
stator core[4]. According to the position of permanent
magnet, the rotor which is interior mounted is called axial flux
motor (AFM) and here the magnetic flux flow axially. The
rotor which is mounted on stator is called radial flux motor
(RFM) and here the magnetic flux flow in radial direction the
stator, to the rotor through airgap. AFMs provides higher
electromagnetic torque compared to RFMs [5][6]. Demand of
the electric bike in the market increasing and a high
performance having good efficiency motors is most suitable
for this application. In this paper the designed motor is suited
for the application of electric bike.
The inner structure of the motor simplifies the assembling
process and eliminates the difficulty of keeping the magnets
in place against to the centrifugal force. It has possibilities to
rectangular magnet is utilized despite of arc magnet Arc
magnet is utilized. AFMs with significant reluctance torque
has achieve wide range of speed variation at constant power
[7]. It is true that motor performance may be predicted even
before it is manufactured. With the software tool at very low
cost multiple design iterations are performed and new design
is obtained by optimization of original parameters [8]. In
faulty condition also the performance analysis can be done. In
terms of result analysis and field computation accurate
calculation of motor characteristics motor parameter is
speculated [9].
Different design configurations are described in the
literature, each with its own set of advantages and
disadvantages. In the literature [10] the back emf developed
by the motor is around 301Vp-p and maximum torque
developed by the motor is around 25 N-m. In the literature
[11] a high speed single phase permanent magnet BLDC is
described. But it suffers problem in torque ripple, starting of
motor and low torque per ampere. A three phase BLDC motor
design with same power output is found to be more efficient.
It is described in the literature [12] the three phase BLDC
motor is found to a maximum of 60.85% efficiency. In this
paper the dimension used for the simulation is getting 87.2%
of efficiency.
II. DESIGN PROCEDURE
In the design procedure we generally take two variables
such as dependent and independent variables. Input is
considered as a independent variable and output is consider
as a dependent variable. We choose winding turns, material
type and their dimension as a independent variables. And the
characteristics obtained like torque, efficiency, current are
considered as a dependent variable.
Fig. 1. Winding diagram of stator

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 Since, the dependent variables are required parameters of Where, Co is the co-efficient of output and it is equal to
the motor accordingly the independent variables are found
with the design equation available. After complete design of CO = 11Bav ack w ∗10 −3 (5)
the motor, the performance of the motor is verified using
ANSOFT RMxprt. After fulfilling the requirement, the
transient analysis is performed in 2-D in MAXWELL 13. At Where, Bav is the magnetic loading, kw is the winding factor
last, the design engineer verifies the performance of the motor and ‘ac’ is the electric loading.
and if it will not meet the demand then change is done D. Lossess
accordingly. From the design parameters of the machine the copper losses
for two phases is given by –
ρ LN 2 N c
Pcu = 2 I 2 (6)
k wb Ag
Where ρ is copper density, Kw,b is fill factor of bare wire, Ne
is per phase number of coil and Ag is the air gap area. The
mechanical losses are given by –

3
Pf = Pout (7)
100

Fig. 2. Cross-sectional view of stator and rotor Stator tooth weight is given by the formula

A rotor winding design is shown in the Fig. 1, where Wt = ρi At N s L (8)

the stator slot is 24 used in the motor. The stator has 4 pole
shown in Fig. 2.
Where ρi is iron density, At is cross-sectional area of teeth
III. DESIGN EQUATION and Ns is the number of total slots.
The design equation of the BLDC motor is given as [7] Weight of yoke of stator Wr,y and rotor Wr,y is given by Eqn
(9) and Eqn (10) respectively. –
A. Back EMF equation
The back emf equation of brushless DC motor is given by – Wsy = ρi Asy L (9)

Eb = 2 NN m Bg LRroWm = K e I (1)
Where, N m is number of stator poles, N is number of turns
present in the stator slot., Bg is flux density in the air gap, L
is the active length of motor. Rro is the outer diameter of rotor
and I is the conductor current. Wm is the angular speed of the
motor. A factor of 2N is used because of three phase inverters
operated in conduction mode with a conduction angle of 120
degree i.e at any time 2 phase is carrying current.
B. Electromagnetic Torque Equation
The electromagnetic torque produced by the BLDC motor is
T = 2 NN m Bg LRro I = kt I (2)
Comparing back emf and torque equations. Back emf and
electromagnetic torque equations are equal that can be easily
seen i.e,
Wry = ρ i Ary L (10)
Where Asy and Ary is the cross-sectional area of stator yoke
and rotor yoke respectively. Now, the total weight of iron is
the sum of stator tooth weight, stator yoke weight and rotor
yoke weight. i.e
Wtotal = Wry + Wsy + Wt (11)
The total fixed losses i.e iron losses is given by –
Piron = Lkg ∗ Wtotal (12)
Where Lkg is the loss (unit- watt per kg) of stator material.
The input power of the motor is the sum of output power,
fixed losses which includes iron loss, friction and windage
losses and variable loss which include stator and rotor copper
loss and it is given by Eqn (13).

ke = kt = 2 NN m Bg LRro (3) Piron = Pout + Pcu + Piron + Pf (13)

C. Output Equation
The output of the machine depends on the main dimensions, Hence, the overall efficiency of the machine is given by
magnetic loadings, speed and electric loading. The rating of
the motor expressed in KVA is given by- Pout
η (%) = (14)
Pin
Q = Co Rro 2 LWm (4)

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By using all the above equations, a BLDC motor is designed
analytically and the design is further analyzed by ANSYS
Maxwell.
BLDC motor design parameter is shown in the Table (1).

TABLE I. Design Parameter of motor

Parameter Values
Inner diameter (stator) 74 mm
Outer diameter (stator) 130 mm
Inner diameter (rotor) 26 mm Fig. 5. Flux linkage in the coil in transient condition
Stator length 60 mm It is clearly shown that the transient conditon is stable with
Rotor length 60 mm this model. The torque ripple waveform is also shown the Fig.
(6). The maximum ripple occur is around 2 N-m. The reason
Length of air gap 0.5 mm
for the torque ripple is the winding current. Winding current
Type of magnet XG196/96 is not smooth in the transient condition. The torque ripple can
Type of steel M19_24G also be minimized by selecting proper controller of BLDC
motor. For electric vehicle it gains much advantage due to the
less ripple in torque.
IV. SIMULATION USING ANSYS MAXWELL
The designed BLDC motor is simulated in RMxprt. It is a
design-based tool developed by ANSYS which provides fast
analytical calculation of performance of machine in 2D and
3D geometry for detail finite element calculation in the
software ANSYS Maxwell.

Fig. 6. Torque ripple

In the Fig (7) a torque-speed characteristics is shown. The

maximum torque at starting is very high and it equal to 37.5
N-m. In case of electric vehicle, the starting torque required
is high due to the initial load applied on the motor. So, this is
the great advantage of electric vehicle. The rated speed of the
motor is 1500 rpm. At rated condition the output torque is
around 6N-m.

Fig. 3. winding current in transient condition

With the above design parameter machine is

simulated and its transient and steady state behavior is
obtained. The transient current of the machine has not beyond
5A, as shown in Fig. (3). Voltage induced and flux linkage in
all phases are also shown in the Fig (4) and Fig (5)
respectively.
Fig. 7. Torque – speed characteristics of motor

In the Fig (8) and Fig (9) the output power and efficiency of
the motor is shown with respect to the speed of the motor.

Fig. 8. Output power – speed characteristics

Fig. 4. Induced voltage in phases

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The maximum output power is obtained at less than the rated
speed. At high load the requirement of power should be high,
this is required in case of electric vehicle. Due to high demand
of power the losses will be high. So, efficiency will be
reduced as obtained in the characteristics. At the rated speed
the output power is 560 W. The efficiency of the motor is
very high and it is equal to 87.2%. Due to the high efficiency
energy of the battery is saved and hence the run time of the
electric vehicle is increased.
a Start-up Research Grant under this project to carry out
research work at NIT Patna. Mr. Prabhakar Kumar (MTech
Student, NIT Patna) and Mr. Rajnish Kumar (PhD Student,
NIT Patna) acknowledge the Ministry of Education, Govt. of
India for the financial assistance. Authors are thankful to NIT
Patna for providing facility of simulation using Ansys
software.
REFERENCES

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V. CONCLUSION
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VI. ACKNOWLEDGEMENT
Motor for a Fan,” pp. 3–6, 2000.
[12] R. K. Gupta and N. Mohan, “A three-phase
The authors acknowledge the Department of Science and permanent magnet brushless DC motor for low-
Technology (DST), Govt. of India for the financial assistance power low-speed fan applications -optimizing cost
provided under DST SERB Project (File No. and efficiency,” Conf. Rec. - IAS Annu. Meet. (IEEE
SRG/2021/002110) to carry out the present work. Dr. Ind. Appl. Soc., pp. 846–852, 2007, doi:
Amitesh Kumar would like to thank DST SERB for providing 10.1109/IAS.2007.133.

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