Three-Dimensional Surface High-Precision Modeling and Loss Mechanism Analysis of Motor Efficiency Map Based on Driving Cycles

Abstract

Amid fossil-fuel depletion and worsening environmental impacts, battery electric vehicles (BEVs) are pivotal to the energy transition. Energy management in BEVs relies on accurate motor efficiency maps, yet real-time onboard control demands models that balance fidelity with computational cost. To address map inaccuracy under real driving and the high runtime cost of 2-D interpolation, we propose a driving-cycle-aware, physically interpretable quadratic polynomial-surface framework. We extract priority operating regions on the speed–torque plane from typical driving cycles and model electrical power (Formula presented.) as a function of motor speed (Formula presented.) and mechanical power (Formula presented.). A nested model family (M3–M6) and three fitting strategies—global, local, and region-weighted—are assessed using (Formula presented.), RMSE, a computational complexity index (CCI), and an Integrated Criterion for accuracy–complexity and stability (ICS). Simulations on the Worldwide Harmonized Light Vehicles Test Cycle, the China Light-Duty Vehicle Test Cycle, and the Urban Dynamometer Driving Schedule show that region-weighted fitting consistently achieves the best or near-best ICS; relative to Global fitting, mean ICS decreases by 49.0%, 46.4%, and 90.6%, with the smallest variance. Regarding model order, the four-term M4 (Formula presented.) offers the best accuracy–complexity trade-off. Finally, the region-weighted fitting M4 (Formula presented.) polynomial model was integrated into the vehicle-level economic speed planning model based on the dynamic programming algorithm. In simulations covering a 27 km driving distance, this model reduced computational time by approximately 87% compared to a linear interpolation method based on a two-dimensional lookup table, while achieving an energy consumption deviation of about 0.01% relative to the lookup table approach. Results demonstrate that the proposed model significantly alleviates computational burden while maintaining high energy consumption prediction accuracy, thereby providing robust support for real-time in-vehicle applications in whole-vehicle energy management.