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Optimal Design Considering AC Copper Loss of Traction Motor Applied HSFF Coil for Improving Electric Bus Fuel Economy

Author

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  • Kyoung-Soo Cha

    (Advanced Mobility System Group, Korea Institute of Industrial Technology, Daegu 42994, Republic of Korea
    These authors contributed equally to this work.)

  • Young-Hoon Jung

    (Department of Automotive Engineering, Yeungnam University, Gyeongsan 38541, Republic of Korea
    These authors contributed equally to this work.)

  • Soo-Hwan Park

    (Department of Mechanical, Robotics, and Energy Engineering, Dongguk University, Seoul 04620, Republic of Korea)

  • Min-Ro Park

    (Department of Electrical Engineering, Soonchunhyang University, Asan 31538, Republic of Korea)

Abstract

Improving the fuel economy of electric buses requires traction motors that provide not only high-power density but also high efficiency under diverse driving conditions. While high slot fill factor (HSFF) coils such as the maximum slot occupation (MSO) coil improve motor torque and power density, they inevitably increase AC copper losses due to elevated AC resistance, especially at high speeds. Unlike conventional motor optimization studies that mainly focus on efficiency at specific operating points, this paper proposes a drive-cycle-aware design optimization method that minimizes AC copper loss to enhance real-world fuel economy. By combining 2D finite element analysis (FEA) with vehicle-level simulations under three representative driving cycles (Manhattan, HWFET, HDUDDS), an optimal motor design was derived. The optimized motor achieved improvements in fuel economy by 0.20%, 0.86%, and 0.36%, respectively, compared to the initial design. Experimental validation through prototype fabrication confirmed the effectiveness of the proposed method. These results demonstrate that the proposed design approach can contribute to improving energy efficiency and reducing operational costs in electric bus applications.

Suggested Citation

  • Kyoung-Soo Cha & Young-Hoon Jung & Soo-Hwan Park & Min-Ro Park, 2025. "Optimal Design Considering AC Copper Loss of Traction Motor Applied HSFF Coil for Improving Electric Bus Fuel Economy," Mathematics, MDPI, vol. 13(9), pages 1-20, May.
    • Handle: RePEc:gam:jmathe:v:13:y:2025:i:9:p:1509-:d:1648814
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    References listed on IDEAS

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    1. Kwon, Kihan & Seo, Minsik & Min, Seungjae, 2020. "Efficient multi-objective optimization of gear ratios and motor torque distribution for electric vehicles with two-motor and two-speed powertrain system," Applied Energy, Elsevier, vol. 259(C).
    2. Klein, M. & Tong, S. & Park, J.W., 2016. "In-plane nonuniform temperature effects on the performance of a large-format lithium-ion pouch cell," Applied Energy, Elsevier, vol. 165(C), pages 639-647.
    3. Cha, Kyoung-Soo & Kim, Dong-Min & Jung, Young-Hoon & Lim, Myung-Seop, 2020. "Wound field synchronous motor with hybrid circuit for neighborhood electric vehicle traction improving fuel economy," Applied Energy, Elsevier, vol. 263(C).
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