© 2020 JETIR October 2020, Volume 7, Issue 10 www.jetir.

org (ISSN-2349-5162)

DESIGN OF BRUSHLESS DC MOTOR

FOR ELECTRIC VEHICLE
Vijay T[1],Naveen Gowda BR [2],Farman Hafeez [3],Praveen S[4]
Students, Department of EEE, Acharya Institute of technology, Bangalore
Sunitha N.S[5]
Assistant professor, Department of EEE, Acharya Institute of technology, Bangalore

ABSTRACT desire to reduce greenhouse gas emissions and improve

urban air quality.[1] Electric Vehicles have several
In this project, an analytical method to design a benefits over conventional internal combustion engine
brushless DC (BLDC) motor is developed. The main
automobiles, including a significant reduction of local
dimension, stator, and rotor parameters were
air pollution, as they do not directly emit pollutants
calculated by using the existing magnet to achieve
the required torque and speed. The magnet such as particulates, volatile organic compounds,
assembly, gap, and rotor saturation webs are hydrocarbons, carbon monoxide, ozone, lead, and
considered for the design, and also flux leakage various oxides of nitrogen.[2]
coefficient and selected working point of a
permanent magnet were used. An advanced
equivalent magnetic circuit was developed to verify
the total flux leakage and the quiescent operating
point based on design parameters. Key design
method points are considered and analyzed. An
electromagnetic field analysis based on Ansys
maxwell and the finite element method (FEMM)
were used in the design to verify the equivalent
magnetic circuit and to optimize the BLDC motor
parameters. Then by using these calculated values, Fig 1: Schematic diagram of an EV motor arrangement
the 3D model of the motor is constructed in the
SOLIDWORKS software. Then the electrical and Electric vehicles are not something new to this world,
mechanical designs are combined, and the BLDC but with the technological advancement and increased
motor is developed and simulation is carried out concern on controlling pollution has given it a tag of
using Ansys Maxwell. In this paper, the simulation future mobility. The core element of the EV apart
results show that an analytical method carried out to from Electric Vehicle Batteries, which replaces the
design a brushless DC (BLDC) motor can be used to Internal Combustion engines, is an Electric motor.[3]
optimize the design of motor parameters which are The rapid development in the field of power
in good agreement with calculated values. electronics and control techniques has created a space
Keywords: Brushless DC (BLDC) motor, Electric for various types of electric motors used in Electric
Vehicles, FEM, Ansys Maxwell. Vehicles. The electric motors used for automotive
applications should have characteristics like high
ABBREVIATION starting torque, high power density, excellent efficiency,
BLDC Brushless DC etc.[4]
EV Electric Vehicle
OD Outer Diameter
ID Inner Diameter

I. INTRODUCTION

An electric vehicle is an automobile that is propelled by

one or more electric motors, using energy stored
in rechargeable batteries—the first practical electric a: Out run b: In run
vehicles produced in the 1880s. From 2008, a
Fig 2. BLDC Motor
renaissance in electric vehicle manufacturing occurred
due to advances in electric motors, batteries, and the

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© 2020 JETIR October 2020, Volume 7, Issue 10 www.jetir.org (ISSN-2349-5162)

The permanent magnet brushless dc motors where S= number of slots and Ͳ=tau(slot pitch)
(PMBLDCM) are either of outer rotor motor or inner  Width of the slot ts,
rotor motor as shown in fig 2. The outer rotor motor 0.4 Ͳs ≤ ts ≤ 0.6 Ͳs
consists of magnets on the outer body of the motor, and  bs = Ͳs - ts
the inner body includes windings that are excited from
the external supply. In the case of the inner rotor motor,  The height of the slot had been calculated
the windings are placed on the outer body, and magnets using dso, ds1, and ds.
are provided on the inner body of the motor.[5] So  To find ds, we have 3 ts ≤ ds ≤ 7 ts
while designing the BLDC motors, the type of rotor  ds0=(0.005 to 0.05) * bs
plays an important role. As the name indicates that
 ds1=(0.002 to 0.005) * bs
‘brushless DC motors, no brushes are used for
 Therefore, Total height= ds + ds0 + ds1
construction. Therefore, for reduced size, the required
parameters can be achieved, such as high torque, high
 The minimum distance from OD to the
speed, increased reliability, reduced noise, and longer
slot is 20mm to 25mm.
lifespan. Hence from the above parameters, these
Therefore,ID of stator is= OD - (2* height of slot)
motors are employed to the electric vehicles, which act
as a prime mover for the car. Before manufacturing the - (2*minimum distance from OD to slot)
motor, the various characteristics are analyzed using
FEMM and Ansys maxwell software for the better
performance of the motor, and it is designed using 2.3 Rotor Calculations
different drawing software such as auto cad for 2D
drawing and solid works for 3D drawing.[6][7][8]

DESIGN OF BLDC
II.
2.1 Main Dimension Calculation

 The main dimensions are calculated by considering

the number of poles, required torque, and existing
magnet dimension.
 The length of the stack is taken the same as that of Fig 4: Rotor parameters
magnet length. The air gap is selected as per requirement which
 The bore diameter is calculated by using equation 1 should not vary above 1mm

wo=(D2Li ) / Tm ................................(1) Therefore, OD of rotor = ID of stator – (2*airgap)

Where, D=bore diameter, Li=stack length, Tm=torque, The dimension of the shaft is selected as per the
wo=coefficient (20µ m2/kg to 25 µ m2/kg) requirement.

2.2 Stator Calculations

Fig 3: Stator parameters Fig 5: Two magnet embedded

type
Typically, the experienced equations are used to
 As shown in fig 5 the pole is two magnets
determine the stator slots’ size. Fig 3 shows the
embedded type; thus the angle between
schematic structural view of the stator slots considered
them is 145°
for the design. [5]
 The maximum distance from the OD of
 Ͳs = ( π * D) / S .......................... (2) the rotor to a magnet (Rib) should not
vary from 2mm to2.5mm.

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 Due to 145° displacement, the bridge can be AA|bb|CC|aa|BB|cc|AA|bb|CC|aa|BB|cc|

calculated from designing in the AutoCAD
ABC: Incoming wires (+)
software or any relevant software.
abc: Outgoing wires (-)
 The bridge is varied depending on the number
of poles.
2.4 Magnetic Calculation

 Area of the magnet, Am=2wl+2lh+2hw

 Standard values of the NdFeb magnet
o Remanent flux density, Br = 1.28 T
o Coercive factor, Hc = 923 kA/m
 Maximum flux density Bm,
Bm = (0.7 to 0.95) * Br
 Maximum magnetic field intensity Hm,
Hm=Bm/ µo
 Remanent flux Φr, Φr = Br * Am
 Coercive magnetic force, Fc= Hc Lm
 Main flux Φm, Φm= Bm Am
 Mmf drop Fm, Fm = Hm Lm
 Airgap flux Φg, Φg= Φm – ΦL
 Leakage coefficient, Flkg = Φg / Φm

Where, Lm=length of the magnet, Φm=main flux

ΦL=leakage flux, and Φg=gap flux

2.5 Winding Calculation

Fig 7: Winding Diagram
The required winding for the motor has been calculated
coil span= no of slots / 2p III. SOFTWARE USED AND DESIGN
Offset= (2/3) * (Ns/2p) CONSIDERATION

Total no of conductors in a slot, Z= 4aNPh 3.1 FEMM

Where, p = pair of poles, Ns = No of slots, a = No of The finite element method (FEM) is a numerical
parallel paths, and NPh = No of phases procedure that can be applied to obtain solutions to
a variety of problems in engineering and science.
LAP winding is preferred as it has to withstand high Steady, transient, linear, and nonlinear problems in
current. electromagnetics, structural analysis, and fluid
dynamics may be analyzed and solved with it. Its
Considering double-layer LAP winding, 12 slots, and 2 main advantage is its capability to treat any type of
pairs of poles, coil span=3, offset=2, and Z=24. The geometry and material inhomogeneity without a
winding scheme and winding diagram are obtained as need to alter the formulation of the computer code
shown in fig 6 and fig 7 respectively. that implements it providing geometrical fidelity
and unrestricted material treatment.

3.2 ANSYS MAXWELL

Designers of electrical machines and generators
can enhance Ansys Maxwell with Ansys RMxprt,
a template-based design tool. Together Maxwell
and RMxprt create a truly customized machine
design flow to meet market demand for higher
efficiency, lower- cost machines. Using classical
analytical motor theory and equivalent magnetic
circuit methods, RMxprt can calculate machine
Fig 6: winding scheme performance, make initial sizing decisions, and
perform hundreds of "what if" analyses in a matter
of seconds.

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3.3 FLOWCHART IV. SIMULATION AND RESULT

DISCUSSION
The design process of the BLDC motor is more
complicated compared to the surface permanent magnet
4.1 FEMM
motor. The leakage path of a BLDC motor usually FEMM simulation is carried out to know the magnetic
includes saturable magnetic bridges and webs. These flux density and magnetic field intensity.
bridges and webs are designed to provide integrity to
the rotor. These bridges and webs introduce magnetic
short circuits and complicate the design and analysis of
the BLDC motor. The coefficient of flux leakage
Flkgvaries because of saturable magnetic bridges and
webs. Figure 8 shows the whole design process. A
coefficient of the flux leakage Flkg and a selected
working point of the permanent magnet is used for the
initial design of BLDC motor. The value of the
coefficient of flux leakage Flkg and the working point of
permanent magnet will be calculated after the rough
parameters are determined based on our equivalent
magnetic circuits model. Structural parameters will be Fig 9: Flux density plot
adjusted using a computer-aided tool. We provide the
initial BLDC motor parameters design size
mathematical model, and a much smaller torque angle
than that in traditional designs at rated load and thus has
higher overloading handing capability and improved
efficiency. After that, electromagnetic analysis and
FEM simulation can be performed to optimize the
design parameters.

Fig 10: The result of the flux density plot

Fig 11: Field intensity plot

Fig 8: Flow chart for design Fig 12: The result of the field intensity plot

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© 2020 JETIR October 2020, Volume 7, Issue 10 www.jetir.org (ISSN-2349-5162)

For example, the value of B m and Hm should be

equal or lesser than the calculated value, hence as
shown in the above result from fig 9 to 12, field
intensity and flux density are compared with the
calculated values as listed in table 1.

Power in(W)
Table 1: Comparative result

Parameters Theoretical Analyzed

value value
Flux density (Bm) 0.896 T 0.427 T
Field intensity 713.014 kA/m 703.502 k A/m
(Hm)
 These values are lesser than the calculated value;
hence the performance of the machine is good. Speed in rpm
 Otherwise, while running, the motor becomes Fig 15: Output power vs. Speed
unbalance, and a large current flows to the motor
than the rated current which leads to the burning or
damage of the windings.

4.2 Ansys Maxwell

Torque in(Nm)

The simulation is done in Ansys maxwell to study the

different characteristics of the calculated values of the
motor.
Input current in (A)

Speed in rpm
Fig 16: Torque vs. Speed

The following results are achieved by simulating in the

Ansys maxwell which is shown in table 2 and table 3.

Table 2: No load operation

Speed in rpm
Fig 13: Input current vs. Speed
Efficiency in(%)

Speed in rpm
Fig 14: Efficiency vs. Speed

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Table 3: Full load operation CONCLUSION

In this project, an analytical method is introduced to

design the BLDC motor. The dimensions of the stator,
rotor are calculated with the equations. The magnetic
properties are calculated with the existing magnet. Then
the theoretically obtained values are compared with the
simulation result. The magnetic properties are obtained
by simulating in the FEMM software so that maximum
flux density and maximum field intensity does not
exceed the theoretical value. Other properties such as
no-load performance, full load performance, torque,
speed, output power, and their characteristics have been
analyzed using Ansys maxwell software, and the result
is obtained. After analyzing, the 3D model of the motor
is designed in the SOLIDWORKS software. The
simulation results show that an analytical method
carried out to design a brushless DC (BLDC) motor
can be used to optimize the design of motor parameters
which are in good agreement with calculated values.
Further BLDC motor can be developed for the designed
4.3 SOLIDWORKS values and the performance of the motor can be verified
experimentally.
The SOLIDWORKS CAD software is a mechanical
design automation application that lets designers
quickly sketch out ideas, experiment with features and REFERENCE
dimensions, and produce models and detailed drawings.
[1] J.R. Hendershot and The Miller - Design of
3D model in SolidWorks
brushless permanent magnet motors-text book 2000.
As per the design the 3D model is constructed in the
[2] Dr. Duane Hanselman- Brushless permanent magnet
SolidWorks as shown in fig 17
motor design.-text book second edition 2003.
[3] Roman Nadolski - Utilization of BLDC motor in
electric vehicles - KONMOT2018
[4] Szymon Racewicz - Use of 3 kW BLDC motor for
light two-wheeled electric vehicle construction –
research gate 2012
[5] Chengyuan He - Permanent Magnet Brushless DC
Motor and Mechanical Structure Design for the Electric
Impact Wrench System.- energies 2019.
[6] Carunai selvane.C - Generalized Procedure for
BLDC Motor Design and Substantiation in MagNet
7.1.1 Software – ICCEET 2012
[7] G.Prasad - Modelling and Simulation Analysis of
the Brushless DC Motor by using MATLAB – IJITEE
2012
[8] Tushar Waghmare - Design of internal permanent
magnet brushless dc motor using Ansys – IJRPET 2016

Fig 17: 3D model of assembling the motor

Fig 17: 3D model in SolidWorks

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