Design and Trade-off Analysis of Electric Machines for High-Performance Automotive Braking Systems

The continuous evolution of automotive braking systems is driving the demand for more efficient, reliable, and high-performance solutions. In this context, Brake-by-Wire (BbW) technology represents a major step forward, replacing traditional hydraulic braking with electromechanical actuators. This transition enhances system responsiveness, increases modularity, and facilitates integration with advanced vehicle control systems. A crucial aspect of BbW systems is selecting the most suitable electric motor to drive the braking mechanism. This thesis, developed in collaboration with Brembo N.V., a global leader in automotive braking systems, focuses on the design, optimization, and comparative evaluation of three different types of electric machines for high-performance BbW applications: Surface Permanent Magnet (SPM) motors, Interior Permanent Magnet (IPM) V-type motors, and Synchronous Reluctance (SynRel) motors. The main objective is to determine the most suitable motor topology in terms of performance, size, and manufacturing costs. The study is divided into several phases. The first phase involves the sizing of an SPM motor, chosen as the benchmark due to its well-established high-power density and efficiency. This process is carried out using a dedicated design tool that provides optimized stator and rotor geometries. Considering the stator geometry of the SPM as the reference for the others, the second phase focuses on designing the IPM V-type motor and the Synchronous Reluctance motor. For the first, a customized iterative optimization algorithm was developed that allows optimizing the rotor geometry. In the case of the SynRel, a dedicated optimization tool for flux barrier geometries was employed. Once the three motor topologies are designed, a comparative analysis is performed based on specific design constraints. In addition, a simplified cost analysis is performed, considering only the materials usage of each motor, while manufacturing cost aspects are discussed in more general terms. The conclusions of this study aim to provide valuable insights for the future development of electric motors in BbW applications, offering a clearer understanding of the trade-offs between performance, cost-effectiveness, and feasibility for integration into high-performance automotive systems