Simulation Applications Streamline The Development Of Electric Vehicle Motors

Volkswagen Kassel accelerates the design process for electric motors by building and distributing simulation applications that evaluate the strength of rotor laminations, writes Thomas Forrister.

- Thomas Forrister

As more consumers express concern for the environment, electric vehicles are on track to outpace conventional internal combustion engine vehicles as the transportation mode of choice. In response to this growing demand, leading auto makers are doing their part to pave the way for EVs, revving up the development of electric and hybrid motors alongside the manufacturers of combustion engines. One such auto maker is Volkswagen, whose Kassel plant in Germany specialises in the development, planning, and production of electric drives. It has a production output of 150 electric and 300 hybrid drives daily.

As essential components in electric drives, rotors need to be tested for durability, since they must endure a very large number of revolutions at varying speeds and torque during drive operation. However, evaluating the strength of rotor laminations is time-consuming. VW Kassel is automating this test process for rotors, as well as reducing development costs and increasing product quality, by building simulation applications with the COMSOL Multiphysics® software.

Balancing electromagnetic and mechanical requirements

In 2015, Volkswagen began developing a modular system to optimise EV design and make the manufacturing process more efficient, called the Modular Electrification Toolkit (MEB). The MEB accounts for the torque, power, and speed for the main rear-wheel drive and for the optional front-wheel drive that is used in all-wheel-drive versions