Overview of Sensitivity Analysis Methods Capabilities for Traction AC Machines in Electrified Vehicles

© 2021 The Author(s). This work is licensed under a Creative Commons Attribution 4.0 License. For more information, see https://creativecommons.org/licenses/by/4.0/.A robust design in electrified powertrains substantially helps to enhance the vehicle's overall efficiency. Robustness analyses come with complexity and computational costs at the vehicle level. The use of sensitivity analysis (SA) methods in the design phase has gained popularity in recent years to improve the performance of road vehicles while optimizing the resources, reducing the costs, and shortening the development time. Designers have started to utilize the SA methods to explore: i) how the component and vehicle level design options affect the main outputs i.e. energy efficiency and energy consumption; ii) observing sub-dependent parameters, which might be influenced by the variation of the targeted controllable (i.e. magnet thickness) and uncontrollable (i.e. magnet temperature) variables, in nonlinear dynamic systems; and iii) evaluating the interactions, of both dependent, and sub-dependent controllable/uncontrollable variables, under transient conditions. Hence the aim of this study is to succinctly review recent utilization of SA methods in the design of AC electric machines (EM)s used in vehicle powertrains, to evaluate and discuss the findings presented in recent research papers while summarizing the current state of knowledge. By systematically reviewing the literature on applied SAs in electrified powertrains, we offer a bibliometric analysis of the trends of application-oriented SA studies in the last and next decades. Finally, a numerical-based case study on a third-generation TOYOTA Prius EM will be given, to verify the SA-related findings of this article, alongside future works recommendations.Peer reviewe

Magnetic Material Modelling of Electrical Machines

The need for electromechanical energy conversion that takes place in electric motors, generators, and actuators is an important aspect associated with current development. The efficiency and effectiveness of the conversion process depends on both the design of the devices and the materials used in those devices. In this context, this book addresses important aspects of electrical machines, namely their materials, design, and optimization. It is essential for the design process of electrical machines to be carried out through extensive numerical field computations. Thus, the reprint also focuses on the accuracy of these computations, as well as the quality of the material models that are adopted. Another aspect of interest is the modeling of properties such as hysteresis, alternating and rotating losses and demagnetization. In addition, the characterization of materials and their dependence on mechanical quantities such as stresses and temperature are also considered. The reprint also addresses another aspect that needs to be considered for the development of the optimal global system in some applications, which is the case of drives that are associated with electrical machines

Development of methods, algorithms and software for optimal design of switched reluctance drives

The aim of this thesis is to estimate the perspectives of integrated switched reluctance drives (I-SRDs), i.e. reluctance machines integrated with converters. It is assumed that such drive series can be manufactured in the power range of 0.75...7.5 kW and speed ranges of 300...3000 rpm and 600...6000 rpm for applications like pumps, fans, conveyors, compressors, extruders and mixers. Based on the performed research and design work it is stated that the new drives have to be developed according to their applications, which determine objective functions and constraints, and that the best possible design should be found as a solution of a synthesis task. Sizing equations are not applied at all. The approach used in the thesis is based on the virtual prototyping concept, i.e. the new I-SRD series is designed in a virtual environment. Therefore, mathematical models and the ways to verify them have to be elaborated. The concepts of multidisciplinary and multilevel modeling are applied. The multidisciplinary model is a combination of interconnected electromagnetic, thermal and noise models. The multilevel concept is the approach when different elements of the drive are described using different languages, i.e. on different levels. Several original solutions are introduced, like the electromagnetic model comprising SIMULINK block-diagrams and MATLAB script, expressions for the correction of the flux linkage due to end-effects, an original equivalent circuit for thermal analysis, which allows using a very simple and fast method to solve the circuit, together with the concept of a multi-layer equivalent cylinder for modeling the motor winding. For verification of the multidisciplinary model a database of test results has been collected using both testing of several reluctance machines in the laboratory and analyzing of test results published by other researchers. After verification the model can be considered as a virtual prototype and can be used in the synthesis process. Several methods of solving the synthesis task were tested. The method, proved to be best suited for solving this task in the proposed form, is the genetic algorithm in the vector form with alphabetic encoding. The genetic algorithm should be coupled with the experimental design method or with the Monte-Carlo method

Advances in the Field of Electrical Machines and Drives

Electrical machines and drives dominate our everyday lives. This is due to their numerous applications in industry, power production, home appliances, and transportation systems such as electric and hybrid electric vehicles, ships, and aircrafts. Their development follows rapid advances in science, engineering, and technology. Researchers around the world are extensively investigating electrical machines and drives because of their reliability, efficiency, performance, and fault-tolerant structure. In particular, there is a focus on the importance of utilizing these new trends in technology for energy saving and reducing greenhouse gas emissions. This Special Issue will provide the platform for researchers to present their recent work on advances in the field of electrical machines and drives, including special machines and their applications; new materials, including the insulation of electrical machines; new trends in diagnostics and condition monitoring; power electronics, control schemes, and algorithms for electrical drives; new topologies; and innovative applications

Design, Optimization and Modelling of High Power Density Direct-Drive Wheel Motor for Light Hybrid Electric Vehicles

Throughout the last few years, permanent magnet synchronous motors have been proven suitable candidates for hybrid electric vehicles (HEVs). Among them, the outer rotor topology with surface mounted magnets and concentrated windings seems to be very promising and has not been extensively investigated in literature. In this study, an overall optimization and modelling procedure is proposed for the design and operational assessment of high-power density direct-drive in-wheel motors, targeted towards a light HEV application. The analytical model of an HEV’s subsystems is then implemented for a more accurate evaluation of overall powertrain performance. Furthermore, a simple but effective cooling system configuration, which is taking into account the specific problem requirements, is also proposed

Backstepping Control of a Switched Reluctance Motor with Inter-Turn Short-Circuit

Improving the behavior of speed control in electric vehicles is currently a major challenge for re- searchers and engineers. For this study, we chose the context of a Switched Reluctance Motor (6/4 SRM) used in a hybrid Electric Vehicle with Extended Range (EREV). Speed regulation is an essential feature on long-distance trip. Speed regulators of backstepping type are very effective in this context given the non- linear nature of switched reluctance motors. The esti- mation of non-linear quantities, flux and inductance, uses Legendre polynomials. The control strategy uses four regulators, one for speed and three for stator cur- rents. It is based on the Torque Sharing Function (TSF) and the Torque Inverse Model (TIM). Our sim- ulation consists of studying the behavior of this type of control when an Inter-Turn Short-Circuit (ITSC) fault appears on one of the phases of the 6/4 SRM. In this paper, we are interested in temporal behavior of phasic currents and we will show the interest of these quanti- ties as fault indicators allowing the real time diagnosis of this type of controller-machine

Mathematical Models for the Design of Electrical Machines

This book is a comprehensive set of articles reflecting the latest advances and developments in mathematical modeling and the design of electrical machines for different applications. The main models discussed are based on the: i) Maxwell–Fourier method (i.e., the formal resolution of Maxwell’s equations by using the separation of variables method and the Fourier’s series in 2-D or 3-D with a quasi-Cartesian or polar coordinate system); ii) electrical, thermal and magnetic equivalent circuit; iii) hybrid model. In these different papers, the numerical method and the experimental tests have been used as comparisons or validations

Precision Control of a Sensorless Brushless Direct Current Motor System

Sensorless control strategies were first suggested well over a decade ago with the aim of reducing the size, weight and unit cost of electrically actuated servo systems. The resulting algorithms have been successfully applied to the induction and synchronous motor families in applications where control of armature speeds above approximately one hundred revolutions per minute is desired. However, sensorless position control remains problematic. This thesis provides an in depth investigation into sensorless motor control strategies for high precision motion control applications. Specifically, methods of achieving control of position and very low speed thresholds are investigated. The developed grey box identification techniques are shown to perform better than their traditional white or black box counterparts. Further, fuzzy model based sliding mode control is implemented and results demonstrate its improved robustness to certain classes of disturbance. Attempts to reject uncertainty within the developed models using the sliding mode are discussed. Novel controllers, which enhance the performance of the sliding mode are presented. Finally, algorithms that achieve control without a primary feedback sensor are successfully demonstrated. Sensorless position control is achieved with resolutions equivalent to those of existing stepper motor technology. The successful control of armature speeds below sixty revolutions per minute is achieved and problems typically associated with motor starting are circumvented.Research Instruments Ltd

Optimisation de la Conception du Moteur Synchrone à Excitation Hybride pour Véhicules Électriques à Haut Performance

Since 1970, the ever-growing concerns of human community for the life-threatening environmental changes have pushed the policy makers to decarbonize those sectors with high energy demands, including the transportation industry. Optimal designs of Electric Vehicles (EVs) can contribute to today’s exigent car market, and take the leading role for future sustainable transportation of human and goods. At the heart of electromechanical energy conversion lays the electrical machines, which have attracted lots of interests and efforts for efficiency increase and cost reduction. In this thesis, a methodology is proposed and implemented to design and optimize the cost and efficiency of a Hybrid Excitation Synchronous Machine (HESM) for a given vehicle and a desired driving cycle. Hybridization in the excitation system can combine the favorable qualities of high-torque at low-speed with superior overloading capability, exceptional flux weakening and extended Constant Power Speed Range (CPSR), high efficiency, and flexible controllability in motoring and generation modes. With HESM technology, we can also shift from the rare-earth magnets towards the cheap ferrite magnets and guaranty the supply for motor industry. The designed HESM in this work responds to three requirements of the vehicle, namely, the maximum cruising speed, acceleration time, and gradeability, with the least or null overdesign in the drivetrain. At the same time, it will have the maximum global efficiency over the driving cycle, and the minimum cost for the material. The optimization is conducted at either of the component and system levels. The optimization at component-level is developed based on the Non-dominated Sorting Genetic Algorithm-II (NSGA-II). A new formulation for the objective functions is proposed, which deals with the design optimization and cost minimization, simultaneously. To maximize the efficiency, a system-level search is conducted to find the optimum HESM with the highest global efficiency over a given driving cycle. Due to the 3D direction of magnetic flux in the selected HESM topology, the Finite Element Analysis (FEA) was very time- and process-consuming. To be able to evaluate the objective functions during the optimization, a new model has been developed based on a 3D Magnetic Equivalent Circuit (MEC) network. This model predicts well the non-linearity of magnetic materials, as compared with the FEA simulations. At last, the final optimized HESM is evaluated by the virtue of FEA technique.Depuis 1970, les préoccupations de l’humanité envers les changements climatiques ont poussé les chercheurs à faire des études approfondies pour optimiser les machines électriques pour avoir des véhicules électriques plus performants et moins énergivores. La conception optimale de véhicules électriques (EV) peut contribuer pour un marché automobile plus exigeant et jouer un rôle principal pour le futur du transport durable des biens et des personnes. Les machines électriques se trouvent au cœur de la conversion d'énergie électromécanique, qui ont suscité beaucoup d'intérêts et d’efforts pour augmenter leur rendement et réduire leur coût. Cette thèse propose une méthodologie et une mise en œuvre pour minimiser le coût et maximiser l’efficacité d’une machine synchrone à excitation hybride (HESM) pour un véhicule donné et un cycle de conduite sélectionné. L'hybridation du système d’excitation peut combiner les qualités favorables comme un couple élevé à basse vitesse avec une capacité de surcharge supérieure, un défluxage exceptionnelle et une plage de vitesse prolongée de puissance constante (CPSR), une efficacité élevée et une contrôlabilité flexible dans les modes de traction et de freinage régénératif. Avec la technologie HESM, nous pouvons également passer des aimants de terres rares aux aimants en ferrite bon marché, et garantir l’approvisionnement pour l’industrie automobile. Le HESM conçu dans ce travail répond à trois exigences du véhicule : la vitesse de croisière maximale, le temps d’accélération et la capacité de monter une pente, avec un surdimensionnement minimal ou nulle de la chaîne de traction. Une optimisation multiniveau avec une interaction entre la vision composant et la vision système est proposée et validée. L’optimisation au niveau du composant est développée sur la base de l’algorithme génétique de tri non dominé (NSGA-II). Une nouvelle formulation pour les fonctions objectives est proposée pour l’optimisation simultanée de la conception de la machine et de la minimisation de son coût. Après avoir optimisés onze HESM au niveau du composant, pour maximiser l’efficacité, une optimisation au niveau du système est réalisée pour trouver le HESM optimal avec le plus haut rendement global sur le cycle de conduite donné. Une validation de la conception finale de la HESM présente un meilleur rendement global sur le cycle de conduite de 18,65% en relation à une machine synchrone à excitation séparée équivalente et 15,8% en relation à une à aiment permanent. En raison de la direction 3D du flux magnétique dans la topologie HESM sélectionnée, l’analyse par éléments finis (FEA) prenait beaucoup de temps et de ressources computationnelles. Afin d’évaluer les fonctions objectives lors de l’optimisation, un nouveau modèle a été développé basé sur un réseau de circuits magnétiques équivalents 3D (MEC). Ce modèle prédit bien la non-linéarité des matériaux magnétiques, par rapport aux simulations FEA. Enfin, le HESM optimisé final est évalué grâce à la technique FEA