Overview of permanent-magnet brushless drives for electric and hybrid electric vehicles

With ever-increasing concerns on our environment, there is a fast growing interest in electric vehicles (EVs) and hybrid EVs (HEVs) from automakers, governments, and customers. As electric drives are the core of both EVs and HEVs, it is a pressing need for researchers to develop advanced electric-drive systems. In this paper, an overview of permanent-magnet (PM) brushless (BL) drives for EVs and HEVs is presented, with emphasis on machine topologies, drive operations, and control strategies. Then, three major research directions of the PM BL drive systems are elaborated, namely, the magnetic-geared outer-rotor PM BL drive system, the PM BL integrated starter-generator system, and the PM BL electric variable-transmission system. © 2008 IEEE.published_or_final_versio

Effects of Design Parameters on Performance of Brushless Electrically Excited Synchronous Reluctance Generator

Permanent magnet synchronous generators, doubly fed induction generators, and traditional electrically excited synchronous generators are widely used for wind power applications, especially large offshore installations. In order to eliminate brushes and slip rings for improved reliability and maintenance-free operation, as well as to avoid costly permanent magnets, a novel brushless electrically excited synchronous reluctance generator having many outstanding advantages has been proposed in this paper. The fundamental operating principles, finite element analysis design studies and performance optimization aspects have been thoroughly investigated by simulations and experimentally under different loading conditions. The effects of different pole combinations and rotor dimensions on the magnetic coupling capacity of this machine have been specifically addressed and fully verified by off-line testing of the 6/2 pole and 8/4 pole prototypes with magnetic barrier reluctance rotor and a new hybrid cage rotor offering superior performance

Switched Flux Permanent Magnet Brushless Machines for Electric Vehicles

This thesis investigates different topologies of switched flux permanent magnet (SFPM) machines and variable flux (VF) methods for high speed applications. Although several novel topologies of SFPM machines have been proposed and investigated recently, their torque-speed capability has not been studied systematically. Therefore, the torque-speed capability as well as the open circuit and electromagnetic performance of conventional SFPM machines with three different stator/rotor pole combinations, i.e. 12/10, 12/13 and 12/14, and three novel SFPM machine topologies, i.e. multi-tooth, E-core and C-core are analysed and investigated by the finite element (FE) method and experiments. Moreover, in order to improve the flux-weakening capability of these machines a variable flux method using flux adjusters (FAs) is employed and the corresponding electromagnetic performance of the machines are investigated, analysed and compared. Both FE and measured results show when the FAs are used the torque-speed capability of the three conventional machines can be improved significantly, while no improvement is shown in the three novel topologies primarily due to the large winding inductances. The technique of using flux adjusters has been improved by reducing the number of FAs. Thus, a new mechanical variable-flux machine topology, which uses only half of FAs outside the stator at alternative stator poles, is proposed, developed and analysed. Open circuit results, electromagnetic performance and torque- and power-speed curves of the 12/10, 12/13 and 12/14 stator/rotor pole SFPM machines with alternative FAs are predicted and compared by 2D and 3D-FE, and experimentally validated. Furthermore, a novel SFPM machine topology with radial and circumferential PMs is proposed, investigated and optimized. This topology reduces the stator flux leakage and offers high magnetic utilization. Moreover, this topology can also be developed as a mechanical variable flux machine. Finally, three SFPM machines with variable flux techniques, i.e. mechanically movable flux adjusters (MMFA), mechanically rotatable permanent magnet set (MRMS) and hybrid excitation with backside DC coils (HEBC) are analysed. Their open circuit results and electromagnetic performance with emphasis on torque-speed characteristic are investigated and compared. Additionally, the required power to switch between flux weakening and strengthening states, flux weakening capability and permanent magnet demagnetization withstand capability are predicted, analysed and compared. The influence of end-effect on the torque-speed capability in the conventional, multi-tooth, E-core and C-core SFPM machines is investigated. Measurements and 3D-FE are performed to obtain the torque-speed curve in order to validate the findings of the research. The 3D-FE predicted results match well with the measured results, while the 2D-FE predicted results are lower due to the high end-effect in the SFPM machines

Design and Application of Electrical Machines

Electrical machines are one of the most important components of the industrial world. They are at the heart of the new industrial revolution, brought forth by the development of electromobility and renewable energy systems. Electric motors must meet the most stringent requirements of reliability, availability, and high efficiency in order, among other things, to match the useful lifetime of power electronics in complex system applications and compete in the market under ever-increasing pressure to deliver the highest performance criteria. Today, thanks to the application of highly efficient numerical algorithms running on high-performance computers, it is possible to design electric machines and very complex drive systems faster and at a lower cost. At the same time, progress in the field of material science and technology enables the development of increasingly complex motor designs and topologies. The purpose of this Special Issue is to contribute to this development of electric machines. The publication of this collection of scientific articles, dedicated to the topic of electric machine design and application, contributes to the dissemination of the above information among professionals dealing with electrical machines

Analytical Optimal Design of a Two-Phase Axial-Gap Transverse Flux Motor

Transverse flux motors (TFMs) are being investigated to be used in vehicle traction applications due to their high torque density. In this paper, a two-phase axial-gap transverse flux motor is designed for an electric scooter, proposing a novel analytical design method. First, the dimensioning equations of the motor are obtained based on the vehicle requirements, and the stationary dq model is calculated. Then, the motor is optimized using a multiobjective genetic algorithm, and finally a 3D-FEM verification is made. Both the motor structure and the design method aim to have a low complexity, in order to favor the sizing and manufacturing processes through a low computation time and simple core shapes. This approach has not yet been explored in axial-gap TFMs

Flexible Energy Conversion Control Strategy for Brushless Dual-Mechanical-Port Dual-Electrical-Port Machine in Hybrid Vehicles

Due to the advantages of high torque density and compact mechanical structure, brushless dual-mechanical-port dual-electrical-port (BLDD) PM machine has become a promising-alternative in series-parallel HEVs. However, two sets of windings in the same core may also result in flux cross coupling, which deteriorate control performance. Through special design of the magnetic circuit, the two sets of windings in the stator side are decoupled. In this paper, the mathematical model of BLDD-PM machine is analyzed firstly. Then, based on energy management system and the model of machine, the decoupled vector control algorithm for outer and inner rotor is developed. Next, common operation states under city road condition for hybrid vehicles have been summarized. According to operation state of HEV, the power flow analysis in the BLDD-PM machine system has been done. To validate the analysis results, experimental test under different operation condition has been conducted. Test results show good control performance of the BLDD-PM prototype and verify the correctness of analysis. Index Terms-BLDD-PM machine, power flow analysis, HEV

In-wheel motors for electric vehicles

PhD ThesisThe in-wheel motor technology as the source of traction for electric vehicles has been researched recently because it is compact and ease-to-integrate. The motor is housed in the wheel. Since the room for the motor is tightly defined by the size of the wheel and there is no gearing system, the motor must have a high torque density to drive the vehicle directly and a high efficiency to keep cool. The existing motor uses a surface-mounted magnet topology. To make it more cost-competitive, the magnet material needs to be reduced while maintaining the torque performance at the rated operating condition. It is the motive of this Ph.D. research. The thesis starts with a brief introduction on the background of the electric vehicle. Then the major challenges of the in-wheel motor technology are summarised. With the derived specifications, an induction machine and a switched reluctance machine are then simulated and analysed. Still, the permanent magnet synchronous machine is proved to have the highest torque density. Change from surface-mounted to interior topology, six new magnet topologies are investigated. The V-shaped interior magnet topology shows superior torque-to-magnet-mass ratio and is easy-to-manufacture. It gives 96% torque while using 56% of the magnet mass compared to the existing motor due to the assist from the additional reluctance torque and the lower magnetic circuit reluctance. The key to use less magnet mass while avoiding the demagnetisation is the front iron shielding effect. The analytical explanation on the better resistance to demagnetisation in the V-shaped motor is provided. The magnet loss mechanism is discussed for proper segmentation. Detailed design adjustments are made to compromise between the torque-to-magnet-mass ratio and the manufactural practicality. Issues regarding to lower mechanical rigidity occurred in initial assembly of the prototype and solutions are proposed. Followed by successful assembly, experimental tests were conducted and results show good agreement with the simulation. A specific form of torque ripple is found in the V-shaped motor and occurs generally in all fractional-slot concentrated-winding machines with saliency. It is explained by an analytical model. This model is also extended to explain the generally lower reluctance torque in vi fractional-slot concentrated-winding machines. Potential design improvements are suggested and simulated for future versions.Protean Electri

Flux switching machine design for high-speed geared drives

Electrical machines capable of high-speed operation are key technology used in many modern applications, such as gas turbine electrical systems, high-speed fly-wheels, turbochargers, and computer numerical control (CNC) machines. The use of geared high-speed machines to replace low-speed high torque drives has not been adequately researched to-date. The rationale of this thesis is to investigate a candidate high speed machine, namely flux switching machines to be used together with new types of core material with mechanical gearing to deliver high-torque and low speeds. Modern developments in advanced material technology have produced new magnetic materials capable of dealing with high resulting in very low losses in high speed machines. However, such metals typically have low mechanical strength, and they are found to be brittle. In order to manufacture electromechanical device with such new materials, it has to be reinforced with a mechanically strong structure. The use of multiple types of magnetic materials referred as a MMLC has been proposed in this thesis for high-speed machine design. In this research, a generic method using magnetic equivalent circuit to model flux switching machines (FSMs) is investigated. Moreover modeling, based on machine dimensions for multiphase FSMs having any pole and slot number has been introduced. The air-gap permeance modeling to simplify the magnetic circuit calculation of FSMs was also investigated in this thesis. It is shown that the permeability of magnetic material can be adjusted with the use of MMLC material. Using this feature, the FSM mathematical model is used to show the impact on electromagnetic performance using MMLCs and is shown to be beneficial. In order the evaluate the weight benefits of using geared high speed FSMs, the planetary gear systems are studies and their design constraints have been identified. An abstract form of weight estimation for given torque and speed requirements has been developed and validated using commercially available planetary gear specifications. FSMs together with gear boxes have been considered and it is shown that significant weight savings can be achieved at higher diameter and at high speeds