High-Precision EV IPMSM and Loss Modeling for Real-Time Hardware-in-the-Loop Simulation Based on the Finite Element Method

To address the insufficient accuracy of conventional linear models for interior permanent magnet synchronous motors in electric vehicles under high-load conditions, this paper proposes a finite-element data-driven nonlinear modeling and loss-integration method. The approach generates multi-dimensional lookup tables for d-q axis flux linkages, torque, and iron-loss coefficients via parameterized FE scanning, enabling real-time table interpolation to reconstruct saturation, harmonic, and cross-coupling effects. The model further integrates an iron-loss equivalent circuit, copper-loss calculation, and inverter models that account for average voltage as well as conduction and switching losses, thereby supporting system-level efficiency optimization. The complete model is deployed on a hardware-in-the-loop platform with a simulation step size of 10 μs. Validation results show that the torque relative error is less than 0.5% compared with FE simulation, while the d-q axis current relative errors are below 2% and the efficiency map consistency exceeds 90% in comparison with experimental measurements on a physical prototype. The proposed method is well suited for motor control algorithm optimization and fault-injection testing, offering significant reductions in development cycle time and risk.