Thermal and mechanical reliability study of electric vehicle drive motor based on CFD and finite element simulation

The rising demand for electric vehicle highlights the importance of developing high performance, reliable and durable drive motors capable of withstanding thermal and mechanical stresses. This study uses CFD and FEM simulations to assess the thermal and mechanical reliability of electric motor drive motors. CFD simulations separately analyzed the stator and rotor oil passages to evaluate cooling performance under varying condition, FEM simulations assessed the strength of the gear, shell and bearings to ensure mechanical reliability. Bench tests validated these findings, confirming the motors ability to achieve maximum speed while maintaining acceptable winding temperatures and operating durations.