Design and Optimization of a Multiphase PMSM with Integrated Charging for Light Electric Vehicles

This study presents a six-phase permanent magnet synchronous motor (PMSM) with integrated on-board charging for light electric vehicles (LEVs). Analytical pre-sizing across four slot-pole combinations is followed by finite-element analysis (FEA) to benchmark materials, phase counts, and rotor types. Three finalists - a double-V skewed interior permanent-magnet rotor, a surface-mounted permanent-magnet rotor, and a concentric-wound SPM rotor - are optimized via ANSYS optiSLang under Worldwide harmonized Light-duty Vehicles Test Cycle (WLTC) Class-1 operation to minimize losses, PM mass, and torque ripple while maximizing efficiency. The double-V skewed rotor yields the best compromise, reducing torque ripple by more than 80% relative to a reference design, achieving 94.9% nominal efficiency, and lowering total losses by 41.4%. Active material mass decreases by ~12%. Dual-mode traction and charging operation is demonstrated, confirming the motor's suitability for LEV platforms.