Thesis Work - Electric Machine 3D FEM modeling and design impact on torque ripple

About this opportunity - Background

For Volvo cars, the future is electric, meaning that all future drivelines contain at least one electric machine. Compared to internal combustion engines, electric machines deliver much more consistent torque. Still, the produced torque from an electrical machine does include some harmonics, which result in torque ripple that can impact the driving experience in the form of sounds and vibrations. Some machine design actions can be implemented to minimize the torque, such as a distributed winding configuration, slot and pole combination, or skewing either the rotor or the stator. During the design phase of an electrical machine, a 2D finite element method (FEM) model is typically used to evaluate its performance as an efficient compromise between accuracy and computational time. However, the real machine is a 3D object, and some of the design elements (such as skewing) are implemented in 3D, meaning that a 2D model cannot accurately represent the final performance of the machine. 

Scope of the thesis work

The main objective is to investigate the discrepancy between 2D and 3D FEM models of permanent magnet synchronous machines for an automotive application. From the results, a recommendation should be given about when to use 2D models and when 3D models are needed. Different machine designs should be simulated to identify if/which design actions need to be verified using 3D models. If time allows, additional aspects such as thermal aspects or loss modelling can also be considered.

The work will mainly be done using open-source FEM software on site at Volvo Cars in Torslanda, Gothenburg.

What you'll bring

We expect that the applying students have experience/studied electrical power engineering or engineering physics, or similar, and are comfortable with (Python) scripting. The student(s) are also expected to be present on site at Volvo Cars in Gothenburg during most of the thesis work, and any living arrangements need to be organized by the student(s).

Duration

•    The work will start in January 2026, the exact date is to be discussed/agreed
•    The duration for this thesis work is 20 weeks.
•    30 ECTS (academic credits) if in agreement with your Thesis Advisor at the University
•    This thesis is to be conducted by 1 or 2 students working in pair.