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Volume 14
Issue 5
10.3390/machines14050530
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications

by
Wasiq Ullah
1,*,
Mehroz Fatima
2,
Mohammad A. Abido
3,
Udochukwu B. Akuru
4,
Husam S. Samkari
5,6,
Mohammed F. Allehyani
5 and
Abdul Khalique Junejo
3
1
Department of Electrical Engineering, Kabul Polytechnic University, Kabul 1001, Afghanistan
2
Department of Electrical Power Engineering & Mechatronics, Tallinn University of Technology, 19086 Tallinn, Estonia
3
Interdisciplinary Research Center for Sustainable Energy Systems, King Fahd University of Petroleum & Minerals, Dhahran 31261, Saudi Arabia
4
Department of Electrical Engineering, Tshwane University of Technology, Pretoria 0183, South Africa
5
Department of Electrical Engineering, University of Tabuk, Tabuk 47713, Saudi Arabia
6
Artificial Intelligence and Sensing Technologies Research Center, University of Tabuk, Tabuk 47713, Saudi Arabia
*
Author to whom correspondence should be addressed.
Machines 2026, 14(5), 530; https://doi.org/10.3390/machines14050530 (registering DOI)
Submission received: 30 March 2026 / Revised: 1 May 2026 / Accepted: 8 May 2026 / Published: 9 May 2026
(This article belongs to the Section Electrical Machines and Drives)
Versions Notes

Abstract

Due to the widespread adoption of high-performance electric vehicles (EVs), Interior Permanent Magnet (IPM) machines have achieved significant advancement in the field of electric motors due to their high torque density and efficiency. However, research has been ongoing for many decades to suppress the rare-earth permanent magnet (PM) usage without sacrificing electromagnetic performance while still achieving the required torque, power, and efficiency. In this regard, various EV manufacturers, such as Honda, Toyota, Chevrolet, BMW, and Nissan, have developed different types of IPM topologies; however, the rare-earth PM usage is extensively high, and the torque density is lower. Thus, to reduce the PM consumption and improve the electromagnetic performance, especially torque density, this paper proposes a novel segmented delta-shaped IPM (SΔ-IPM) with a three-notched rotor pole shape having two different specifications and featuring embedded circular flux barriers and an intermediate flux bridge. Secondly, torque performance is analytically discussed, and electromagnetic performance has been evaluated using 2D finite element analysis (FEA). Due to its unique design featuring improved magnetic field shifting, an average torque of 393.7 Nm with torque ripples of 5.1% and a cogging torque of 0.57 Nm has been achieved. Finally, an extensive comparative analysis of the aforementioned ten state-of-the-art industry models has been conducted, which confirms the effectiveness of the proposed design for high torque density with minimum PM usage.
Keywords: Interior Permanent Magnet; IPM motor; magnetic field shifting; synchronous machine; Electric Vehicles Interior Permanent Magnet; IPM motor; magnetic field shifting; synchronous machine; Electric Vehicles

Share and Cite

MDPI and ACS Style

Ullah, W.; Fatima, M.; Abido, M.A.; Akuru, U.B.; Samkari, H.S.; Allehyani, M.F.; Junejo, A.K. Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications. Machines 2026, 14, 530. https://doi.org/10.3390/machines14050530

AMA Style

Ullah W, Fatima M, Abido MA, Akuru UB, Samkari HS, Allehyani MF, Junejo AK. Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications. Machines. 2026; 14(5):530. https://doi.org/10.3390/machines14050530

Chicago/Turabian Style

Ullah, Wasiq, Mehroz Fatima, Mohammad A. Abido, Udochukwu B. Akuru, Husam S. Samkari, Mohammed F. Allehyani, and Abdul Khalique Junejo. 2026. "Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications" Machines 14, no. 5: 530. https://doi.org/10.3390/machines14050530

APA Style

Ullah, W., Fatima, M., Abido, M. A., Akuru, U. B., Samkari, H. S., Allehyani, M. F., & Junejo, A. K. (2026). Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications. Machines, 14(5), 530. https://doi.org/10.3390/machines14050530

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