Design of a Traction Motor with Two-Step

Gearbox for High-Torque Applications

Juho Montonen, Simo Sinkko, Pia Lindh, and Juha Pyrhnen
Abstract New combination of an electrical machine and a
two-step planetary gear for high torque traction applications
is introduced. This kind of a machine can act as a propulsion
motor for working machines such as e. q. agricultural tractor
that needs to generate very high traction forces and also
higher travelling speeds. The technology also suits in some
road vehicle use e.g. for buses or trucks. Detailed information
about the electrical machine design is provided. The machine
has tooth-coils in the stator, embedded permanent magnets in
the rotor and its cooling is arranged via the gear lubrication as
the chamber is semi-filled with oil.

configuration can be used as a hub motor or just normally

with a driveshaft.

Index TermsPermanent Magnet Machines, Traction

Motors, Torque, Planetary Gear

I.

Fig. 1 Integrating an electrical machine and a two-step planetary gearbox.

INTRODUCTION

N the working machine field there is a need to produce

high torques for low-speed operation and also a need to
drive in highway at higher speeds. Usually, electrical
machines alone are not capable to produce the whole
operating range of a propulsion system in heavy traction
applications but a gearbox is needed. The size of the
package is often large if a separate electrical machine and a
gearbox are mounted on the same axle. By combining the
gearbox and the electric motor the size of the system can be
limited significantly.
There are several machine types that are used in traction
applications [1], [2]. Permanent magnet synchronous
machine (PMSM) seems a viable option nowadays as it can
fulfill the demands of typical working machine load cycles
or road vehicle cycles in an efficient way at all loads. We
have e.g. designed and tested direct drive PMSMs with
distributed windings for a 44 electric sports car [3], [4]. In
recent years, especially, fractional slot concentrated nonoverlapping (tooth-coil) wound permanent magnet
synchronous machines have gained lots of interest mainly
due to their high-torque density, high efficiency, compact
structure and easy winding manufacturing [5]. Especially,
the possibility of shortening the end-windings of the
machine makes tooth-coil PMSMs an attractive choice for
traction applications where a small and robust structure is
beneficial. Another benefit is the low mutual coupling
between the phases which makes some tooth-coil PMSMs
fault tolerant. Also the high leakage inductance helps in
creating a wide field weakening area for the machine.
The machine presented in this paper is studied because in
the vehicle and working machine field there is a great need
for such a two-step planetary gearbox to be able to multiply
the traction motor output typically by a factor of 1 with the
direct gear or by 35. If the motor itself can provide 34
times its rated torque at start with the gear it is possible to
get e.g. 1520 times the motor torque for the drive train. If
the electric machine is designed by using tooth coils a high
torque density and the most compact size can be obtained at
the same time. An overall view of the motor package is
presented in Fig. 1. It can be seen that this kind of
978-1-4799-4389-0/14/$31.00 2014 IEEE

In Fig. 1 the cutaway of the system shows that there is a

ring gear, sun gear and planets inside the electrical machine
rotor which all need lubrication. That means, in practice,
that there must be oil inside the electrical machine.
Clutches which control the gear changing are operated with
voice coils. Naturally, due to the planetary gear box, there
starts to form also some magnetic mud which will be
collected by individual magnetic filters located next to oil
filters. In that way the filters can be changed at the same
time. This work studies, particularly, the motor design for
the combination of the electrical machine and the gearbox
and does not include the design of the planetary gearbox
itself.
The paper is divided into the following contents. Section
II introduces the boundary conditions for the design and the
overall system. The simulated results for the design are
divided to chapter III and chapter IV. Finally chapter V
concludes the paper.
II.

DESIGN OF A TRACTION MOTOR WITH TWO-STEP

PLANETARY GEARBOX

The main criterion for the design of the electrical

machine for vehicles or working machines is the load cycle
analysis. The traction load cycle which is used as a basis in
this study is presented in Fig. 2. Detailed information of the
design process of the traction motor has been given by the
authors earlier in [6], [7].

1069

70

5000

Hypoid 80W-140
EP 75W-90
Fluid E

4500

60

4000
3500
Power losses, [W]

Speed [km/h]

50
40
30
20

3000
2500
X: 3
Y: 1687

2000
1500

X: 3
Y: 864.1

1000

10

500
0

1000

2000

3000
4000
Time [s]

5000

6000

7000

Fig. 2. Bus speed cycle used in dimensioning of the electrical machine [8].

Now one can calculate the needed acceleration according

to Newtons second law when the mass, gear ratio and
inertia coefficients are known. After that it is possible to
approximate the rated power and maximum torque needed
for a short time e. q. in acceleration or during hill climbing.
This whole load cycle can be covered with two ca 40 kW
electrical machines. The bus cycle is used as an example
here to show that it is possible to use two 40 kW electrical
machines with planetary gearboxes to cover the cycle
which without a gearbox needs a 150 kW electric
motor.
Another important boundary condition is set to the
cooling system. As there will be the lubricating oil anyway
in the housing it can also be used also as a medium for heat
transfer. Viscous losses due to oil splashing in the air gap
can be calculated by

P=

4 2 r 3l 2

(1)

where is the dynamic viscosity of the oil, r the radius

measured in the middle of the machine air gap, l the
effective length of the machine, the mechanical angular
velocity of the machine and the air gap length [9]. In the
calculation three different oils at the temperature of 100 C
are analyzed. Oils are collected from the oil company
Teboils website [10]. The oil types compared are EP 75W90 synthetic transmission oil, Hypoid 80W-140 semisynthetic transmission oil and then Fluid E which is semisynthetic automatic transmission oil.
In case of totally oil immersed rotor the calculated results
for viscous loss as a function of air gap length are shown in
Fig. 3.

X: 3
Y: 486.9

1.5

2.5
, [mm]

3.5

Fig. 3. Viscous losses as a function of the air gap length.

The air gap length is chosen to be 3 mm because the

viscous losses are then reasonable and it does not sacrifice
the machine electromagnetic properties too much. It can be
seen that increasing the air gap any further does not give
that much benefits for the losses but needs more permanent
magnets to get the same air gap flux density which,
naturally, decreases the torque production of the machine.
In principle, oil friction losses are, however, lower because
only 1/3 of the machine is filled with the lubricating and
cooling oil. Estimation for the total mechanical losses is
around 300400 W. This should be the heat level that can
be easily removed by oil splashing cooling. We have
verified (1) with an earlier test machine and also found that
the heat transfer from the machine can reach high heat
transfer rates.
In practice the diameter of the planetary gearbox defines
the electrical machine rotor inner dimensions. This,
naturally, favours a large pole pair number to get a low
rotor yoke height. After that the outer diameter of the whole
machine and the axial length are kept as low as possible to
ensure a compact size and good performance at the same
time.
In the stator a double-layer three-phase tooth-coil
winding was chosen due to the very compact end-windings
of this winding type and while it also produces a smaller
harmonic content than a single layer winding. The rotor is
designed to have totally smooth surface to minimize the
viscous loss. It has embedded magnets as it utilizes the
saliency for the torque production and keeps the magnets
safe in both magnetic and mechanical ways. The robust and
easy-to-manufacture rotor uses only one magnet per pole.
Based on earlier studies [11], [12] the designs which
have a fairly small air gap leakage factor are selected for
further analysis due to their suitable leakage inductance. A
suitably low synchronous inductance is beneficial for high
torque production. Of course, the low synchronous
inductance value limits the speed range but for this machine
thanks for the gearbox it is needed to reach only 2.0 p.u.
maximum speed.
Table I shows the selection of parameters for the double
layer tooth-coil wound PMSMs with different slot and pole
combinations. In the table information about the number of
slots per pole per phase q, the air gap leakage factor ,
winding factor kw, and least common multiple (LCM) are
collected. Only the designs which have q 0.5 are

1070

collected in the table and the chosen design is highlighted

with bolded text.
TABLE I
PARAMETERS FOR DIFFERENT SLOT AND POLE COMBINATIONS OF DOUBLE
LAYER TOOTH-COIL WOUND PMSMS

2p
q

kw
LCM

0.5
0.46
0.866
12

kw
LCM

12

0.5
0.46
0.866
18

kw
LCM

10

0.25
4.8
0.866
12

0.2
26
0.5
30

0.375
1.2
0.945
72

0.3
2.4
0.945
90

0.5
0.46
0.866
24

12

14

16

0.142
53
0.5
42

0.125
22
0.866
48

0.214
0.46
0.617
126

0.188
71
0.328
144

0.4
0.96
0.933
60

0.286
2.9
0.933
84

0.25
4.8
0.866
48

0.5
0.46
0.866
30

0.357
1.4
0.951
210

0.313
2.1
0.951
240

0.43
0.83
0.902
126

0.375
1.2
0.945
144

0.5
0.46
0.866
42

0.438
0.8
0.89
336

0.25
4.8
0.866
36

a)
Harmonic Winding Factors

18

kw
LCM

0.5
0.46
0.866
36

0.9
X=7
Y = 0.902

0.8
0.7
Winding Factor

15

kw
LCM

0.6
0.5
0.4
0.3

21

kw
LCM

0.2
0.1
0

24

kw
LCM

0.5
0.46
0.866
48

10

15

20
25
30
Harmonic order

35

40

45

50

b)
Fig. 4. a) Geometry and winding structure of 18/14 machine and b)
harmonic analysis of the winding function. The operational harmonic of
the machine is the 7th one.

It can be seen that the 18/14 machine uses its 7th

harmonic as the operating harmonic as 18/14 configuration
is the base machine itself. It can be seen that very small
fundamental component also occurs.
The cross field principle defines the electromagnetic
torque in electrical machines

Unbalanced radial magnetic pull when used as base machine

Invalid configurations
q 0.5

It was decided to use the 18/14-machine configuration

because of its very sinusoidal back-electromotive force
(emf) and the inherently lowest torque ripple (large LCM).
A higher LCM would yield a lower peak value in the
cogging torque waveform but result in a higher frequency
fluctuation. Also this kind of machine has good properties
to produce torque since it has quite a high winding factor
and a relatively high number of slots per pole and phase.
With that kind of a winding structure also a wide
constant power speed range can be obtained. With q =
0.429 the air gap leakage inductance L = Lm is 0.83Lm
resulting in a moderate synchronous inductance Ld [11]. In
this case the inductance can be quite low as only twice the
rated speed is needed.
Despite its good properties the 18/14-machine has been
reported rarely in the literature compared to other types of
machines Previously 18/14-machine has been analyzed e. q.
in [13].
The geometry, winding structure and harmonic analysis
of the machine is presented in Fig. 4.

T=

3
p ( s i s ) ,
2

where p is the number of pole pairs,

(2)

s the stator flux

linkage vector and is the stator current vector. Furthermore,

in synchronous machines the torque can be calculated in
synchronously rotating reference frame as
T =

where

3
p ( d iq q id ) ,
2

d ,

q , id

(3)

and iq are the d- and q-axis stator flux

linkages and stator currents, respectively. Finally for a

PMSM the torque can be written as
T=

3
p{ PM ( )iq + (Ld ( ) Lq ( ))iq id }+ Tcog ( ) ,
2

(4)

where PM is the permanent magnet flux linkage and Ld, Lq

are the synchronous inductances of d- and q-axis,

1071

respectively and Tcog is the cogging torque of the machine.

All these components are functions of the rotor position .
Naturally, when possible cross saturation is analyzed the
flux linkages and inductances are also functions of the
stator current components. The torque equations are later
used in the analysis of the torque ripple.
The motor should give at least 3 p.u. torque at low speed
and at least approximately 0.5 p.u. at double speed 2400
min-1. The permanent magnet material has a remanent flux
density of 1.1 T and relative permeability of 1.05. The steel
material used in the magnetic circuit parts is M270-35A.

250
200

Induced voltage [V]

150
100
50
0
-50
-100
-150
-200
-250

III. CALCULATION RESULTS

0.012

As the basis of all computations the generally known

analytical methods [14] and d-q-vector analyses are used. A
set of finite element analyses was performed to evaluate the
characteristics of several motor designs. The first step is to
check the maximum output torque of the machine when the
coils are fed with direct current in static field calculation.
When sufficient torque value is gained dynamic simulations
are done to check the losses and overall performance of the
machine. The machine geometry with the flux densities in
different parts of the machine is shown in Fig. 5.

0.013

0.014

0.015

0.016
Time [s]

0.017

0.018

0.019

a)

250

Induced voltage [V]

200

150

100

50

10

15
Harmonic order

20

25

30

b)
Fig. 6. Calculated permanent magnet induced voltage a) waveform b)
harmonic spectrum. FEA results.

Calculated normal components of the flux density in the

air gap at no-load and at the rated load for the design
chosen are presented in Fig. 7. Harmonic analysis was also
made from the waveforms. It can be seen also that
analytical calculation of the air gap flux density is almost
similar as the FEA calculated waveform. Small differences
come probably from the fact that the analytical model used
gives better results for the rotor surface PMSM and only
gives good approximation for the embedded magnet
machines. The analytical model is based mainly on [15][17]. Only small differences due to embedded magnets are
done.

The highest PM leakage flux density values in the q-axis

region are around 2.1-2.3 T and the stator yoke and teeth
have flux densities between 1.0-1.6 T.
The FEA estimated induced voltage and its harmonic
content are presented in Fig. 6. It can be seen that the
waveform of the induced voltage is almost purely
sinusoidal and, hence, contains mainly its fundamental
component. The machine should, therefore, have a very
smooth torque output.

1.5

No load flux density (FEA)

No load flux density (Analytical)
Rated flux density (FEA)

1
Air gap flux density [T]

Fig. 5. Flux density plot of the 18/14-machine at the rated operation point.

0.5

-0.5

-1
0

500

1000
1500
Electrical angle [rad/s]

a)

1072

2000

2500

0.35

0.6

0.3

0.5

0.25
Cogging torque [Nm]

Flux density [T]

No load flux density (FEA)

No load flux density (Analytical)

0.4
0.3

0.15
0.1

0.2

0.05

0.1
0

0.2

10

15

20
25
30
Harmonic order

35

40

45

50

b)
Fig. 7. Flux density normal component waveform analysis a) comparison
of the air gap flux density curves at no load and at the rated load b)
harmonic spectra at no load.

Cogging torque and the torque ripple of the 18 slot 14

pole machine are analysed next. Their waveforms and
harmonic analysis are shown in the Figs. 8 and 9 both over
one electrical cycle.
From the cogging torque spectrum it can be seen that the
most crucial component is the 18th one which is actually the
tooth harmonic component in an 18 slot machine. Cogging
torque is almost negligible with the 18 slot 14 pole winding
configuration. If wanted, the cogging and, thus the torque
ripple, can be further decreased by skewing the slots,
decreasing the slot openings, increasing the air gap length
or by using semi magnetic slot wedges in the slots. Wedges
are to be used in the designed machine.

15
Harmonic order

20

25

30

Due to the almost sinusoidal back-emf curve the electric

torque ripple is small. It can be seen that among the
fundamental harmonic in the spectrum there are the 6th, 12th
and 18th harmonics present. Harmonic content is caused by
the iron saturation which usually exists in fractional slot
machines and, naturally, influences the saturation of the
inductances [18]. Saturation is the natural explanation as
the harmonic analysis of the synchronous inductances and
flux linkages include the 6th and 12th harmonic. Those
components affect the torque directly as it can be seen in
the second term of the torque equation (4). The 18th
harmonic to the torque ripple comes directly from the
cogging torque.

304

0.3
Torque ripple [Nm]

303

0.2
0.1
0

302

301

-0.1

300

-0.2

299
0.214

-0.3

0.033

0.034

0.035

0.036
0.037
time [s]

0.038

0.039

0.215

0.216

0.217
time [s]

0.218

0.219

0.22

a)

0.04
2.5

a)
2

Torque ripple [Nm]

-0.4

10

b)
Fig. 8. Cogging torque a) waveform b) harmonic spectrum.

0.4

Cogging torque [Nm]

1.5

0.5

10

15
Harmonic order

20

25

30

b)
Fig. 9. Torque ripple at nominal speed and torque (1.7 % peak to peak) a)
waveform b) harmonic spectrum.

1073

TABLE III
MACHINE LOSSES AT NOMINAL SPEED
Computed
Calculated
Analytically 2 D (rated)

IV. PERFORMANCE AND LOSSES

A 38.6 kW, 308 Nm machine with 18-slots and 14-poles
was designed in order to obtain information concerning the
winding configuration. The machine is designed for 400 V
AC voltage level. Current and current density in rated
operation are 67 A and 4 A/mm2, respectively. Table II
presents the final design machine parameters.
TABLE II
FINAL DESIGN PARAMETERS
Slots per pole and phase, q

0.43

Stator slots

18

Poles

14

Length of the stator stack [mm]

75

Stator outer diameter [mm]

444

Stator inner diameter [mm]

336

Number of coil turns in phase Nph

138

Phase resistance [p.u]

0.02

Induced voltage EPM [p.u]

0.84

Rated and max frequency

140/280 Hz

Rated current

67 A

Rated voltage

400 V

P copper [W]

991

991

P stator iron [W]

180

186

117

P rotor iron [W]

100

103

86

P magnet loss [W]

150

48

2.2

P mechanical [W]

400

400

400

Permanent magnet losses can be high due to eddy

currents if bulk magnets are used. Fig. 11. shows the
amount of permanent magnet losses as a function of the
number of magnet pieces.
1200

Permanen magnet losses [W]

1000

800

600

400

200

Fig. 10. shows the calculated efficiency map as a

function of the torque and rotational speed of the designed
machine and Table III presents the losses calculated
analytically and with FEA at the nominal speed. Good
correlation can be seen between the results. Analytically
calculated permanent magnet losses were estimated and
approximated according to [19]. Loss values differ with
FEA values as the used analytical approach was initially
designed for rotor surface magnet PMSMs. The efficiency
is high in whole speed range as shown in Fig. 10.
0.95
0.9
0.85

0.8

0.8
Efficiency

Calculated
2D (No-load)

3
4
5
6
Number of magnet pieces

Fig. 11. Permanent magnet losses due to eddy currents as a function of the
number of permanent magnet pieces.

It can be seen that six pieces seems to be good enough as

the amount of losses does not change any more rapidly by
increasing the number of magnet pieces further. Also fewer
pieces are possible to be used as the oil cooling surely takes
the heat out of the machine. In our university we have
previous knowledge of what comes the direct oil cooling.
This can be found in [11], [20].
Torque as a function of rotational speed is presented in
Fig. 12. Contours represent the constant power curves (in
Watts) and the black line shows the rated load operation.
The upper line represents the maximum torque inside the
voltage and current limitations.

0.75

0.6

0.7

0.4

0.65

0.2
1000

0.6
800
600
400
1000

200
Torque [Nm]

1500

2000

500

2500

0.55
0.5
0.45

Rotation speed [rpm]

Fig. 10. Calculated efficiency map.

Fig. 12. Torque as a function of speed for the 18 slot 14 pole machine.
Rated operation is shown and it can be seen that it is about 1/3 of the
maximum torque capability provided by the inverter. Parameter in the
figure is output power of the electric motor.

1074

V.

CONCLUSION

A new concept of the combination of a PMSM and a

two-step planetary gearbox was presented. Its advantages
were widely discussed and the benefits have been pointed
out. The design saves space due to its compactness and
allows full use of tooth-coil permanent magnet motors in
heavy vehicles and working machines such as buses, trucks,
tractors, military equipment and forest harvesters.
The selected design is an 18 slot 14 pole tooth-coil
machine and its main characteristics and properties were
discussed. The 18/14 construction was selected for
prototyping mainly due to its low torque ripple and cogging
torque, its most sinusoidal back-emf waveform compared to
other tooth-coil machines and its wide constant power
speed range.
The performance of the machine was validated with FEA
and the results seem good. The following step is to
manufacture a prototype and report the measured results.
VI. REFERENCES
[1]

[2]

[3]
[4]

[5]

[6]
[7]

[8]
[9]
[10]
[11]
[12]

[13]

[14]
[15]

[16]

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[17]

[18]

[19]

[20]

VII.

BIOGRAPHIES

J. Montonen was born in 1988 in Joutseno, Finland, received the Master

of Science (M.Sc.) degree from Lappeenranta University of Technology
(LUT), Finland in 2012 and Bachelor of Science (B.Sc.) in 2011. He is
currently doctoral student in LUT. His research interests are in electrical
machines and drives.
His research work focuses on permanent magnet motors, with a special
reference to different kinds of traction applications.
S. Sinkko was born in 1978 in Lemi, Finland, received the Master of
Science (M.Sc.) degree from Helsinki University of Technology (currently
Aalto University), Finland in 2004. He has worked several years in
industry, including product development work of agricultural tractors. He
is currently working as a Senior Lecturer in Saimaa University of Applied
Sciences, in the Degree Programme of Mechanical Engineering and
Production Technology, Finland, where he is engaged in teaching and
research of mechanical development of electric drives and transmissions.
His current interests include off-road machines electric transmissions
and hybrid technology.
P. Lindh (previously Salminen) born in Helsinki in 1969, received her
M. Sc. degree in energy technology in 1998 and her D. Sc. degree in
electrical engineering (Technology) in 2004 from Lappeenranta University
of Technology (LUT), Lappeenranta, Finland. She is currently serving as
an associate professor at the Department of Electrical Engineering in LUT
Energy, Lappeenranta, where she is engaged in teaching and research of
electric motors and electric drives.
Her research work focuses on permanent magnet motors, especially
concentrated winding machines.
J. Pyrhnen, a Member of IEEE, was born in 1957 in Kuusankoski,
Finland, received the Doctor of Science (D.Sc.) degree from Lappeenranta
University of Technology (LUT), Finland in 1991. He became an
Associate Professor of Electrical Engineering at LUT in 1993 and a
Professor of Electrical Machines and Drives in 1997. He is currently the
Head of the Department of Electrical Engineering, where he is engaged in
research and development of electric motors and electric drives.
His current interests include different synchronous machines and drives,
induction motors and drives and solid-rotor high-speed induction machines
and drives.

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Magnetics, vol. 29, n. 1, January 1993. pp. 124-135.
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J. Pyrhnen, H. Jussila, Y. Alexandrova, P. Rafajdus, J. Nerg,
Harmonic Loss Calculation in Rotor Surface Permanent Magnets
New Analytic Approach, IEEE Transactions on Magnetics, vol. 48,
n. 8, August 2012. pp. 2358-2366.
P. Ponomarev, M. Polikarpova, J. Pyrhnen, Thermal Modeling of
Directly-Oil Cooled Permanent Magnet Synchronous Machine,
ICEM, 2-5 September 2012, Marseille, France.