Generalized Parametric Design of an Integrated Electric Vehicle Drive System for Wide-Speed-Range Operation: Experimental Validation, Torque Control, and Performance Assessment

Existing research on electric vehicles (EVs) predominantly addresses component sizing for the electric vehicle drivetrain system (EVDS) without adequate validation of dynamic performance under integrated traction motor (TM) control. This paper addresses this gap by presenting a comprehensive validation framework encompassing steady-state characteristics and dynamic behavior of the EVDS, incorporating a generalized component sizing methodology and a proposed torque control system operating across the entire speed range. A parametric design procedure is first established for determining EVDS component ratings with 40% oversizing capability, tailored to prescribed EV specifications. This methodology is applied to a 4-passenger city EV as a practical case study, with detailed calculations and steady-state characterization validated against an Urban Dynamometer Driving Schedule (UDDS) cycle. Field-oriented control (FOC) with integrated field-weakening is then developed for TM torque regulation, enabling operation below and above the designed base velocity through rotor flux control and field-weakening, respectively. The simulated EV system incorporates dynamic models of the vehicle, Li-ion battery, TM, and road load forces. Dynamic behavior of the newly designed EVDS is analyzed and assessed under the UDDS cycle, demonstrating strong agreement between dynamic performance and static characteristics, thereby validating the proposed methodology. Finally, an experimental EVDS setup is implemented at Tanta University to validate the control strategy under various velocity profiles. The experimental results confirm robust performance across light and heavy loads, multi start-stop operation with varying acceleration rates, maximum velocity attainment, speed reversal, and smooth transitions between operational modes—all achieved without oversizing.