Internal Model Loss Minimization Control of Permanent Magnet Synchronous Machine

Electric drives are very useful in propelling the wheels of hybrid electric vehicles (HEVs). They also play a central function in the electric power steering (EPS). This paper describes studies carried out on the efficiency optimization of an interior permanent magnet synchronous machine (IPMSM) for application in the EPS. An analytic loss- minimization algorithm for an IPMSM was derived and the optimization problem took into consideration copper, iron and stray losses. The proposed loss minimization algorithm is simple and cost effective to implement. From the simulations carried out, significant efficiency gains are possible with this model. The internal model control (IMC) method was employed to achieve current and speed control with acceptable sensitivity to machine parameters

A state-of-the-art review on torque distribution strategies aimed at enhancing energy efficiency for fully electric vehicles with independently actuated drivetrains

© 2019, Levrotto and Bella. All rights reserved. Electric vehicles are the future of private passenger transportation. However, there are still several technological barriers that hinder the large scale adoption of electric vehicles. In particular, their limited autonomy motivates studies on methods for improving the energy efficiency of electric vehicles so as to make them more attractive to the market. This paper provides a concise review on the current state-of-the-art of torque distribution strategies aimed at enhancing energy efficiency for fully electric vehicles with independently actuated drivetrains (FEVIADs). Starting from the operating principles, which include the "control allocation" problem, the peculiarities of each proposed solution are illustrated. All the existing techniques are categorized based on a selection of parameters deemed relevant to provide a comprehensive overview and understanding of the topic. Finally, future concerns and research perspectives for FEVIAD are discussed

Cal Poly Supermileage Electric Vehicle Drivetrain and Motor Control Design

The Cal Poly Supermileage Vehicle team is a multidisciplinary club that designs and builds high efficiency vehicles to compete internationally at Shell Eco-Marathon (SEM). Cal Poly Supermileage Club has been competing in the internal combustion engine (ICE) category of the competition since 2007. The club has decided it is time to expand their competition goals and enter their first battery electric prototype vehicle. To this end, a yearlong senior design project was presented to this team of engineers giving us the opportunity to design an electric powertrain with a custom motor controller. This system has been integrated into Ventus, the 2017 Supermileage competition car, bringing it back to life as E-Ventus for future competitions. The scope of this project includes sizing a motor, designing the drivetrain, programing the motor driver, building a custom motor controller, and finally mounting all these components into the chassis. The main considerations in this design are the energy efficiency measured in distance per power used (mi/kWh) and the whole system reliability. Driven train system reliability has been defined as the car starts the first time every time and can complete two competition runs of 6.3 miles each without mechanical or electrical failure. Drivetrain weight target was less than 25 pounds, and the finished system came in at 20 lbs 4 oz. Due to the design difficulties of the custom controller, three iterations were able to be produced by the end of this project, but there will need to be further iterations to complete the controller. Because of these difficulties our sponsor, Will Sirski, and club advisor, Dr. Mello, have agreed that providing the club with a working mechanical powertrain, powertrain data from the club chassis dynamometer using the programmed TI evaluation motor controller board, and providing board layout for the third iteration design for the custom controller satisfy their requirements for this project

Design of a vehicle for the World Solar Challenge

This project focuses on designing a theoretical prototype for the World Solar Challenge (WSC) that emphasizes energy efficiency, innovation, and sustainability. Extensive research and analysis of previous WSC designs have led to the development of a cutting-edge solar-powered vehicle prototype. The design incorporates a jet fighter airfoil, specifically the F15, to reduce drag, as well as lightweight carbon fiber materials and advanced Gallium arsenide solar panels. The prototype prioritizes energy efficiency by optimizing energy conversion and storage using a combination of Li-Ion batteries and a supercapacitors, ensuring sustained power supply even under challenging conditions. Compliance with regulations regarding security, ergonomics, and the environment is also a critical aspect of the design. Sustainability is a key consideration, as the solar-powered vehicle produces zero emissions during driving, thanks to the utilization of renewable energy sources. The vehicle achieves high speeds with minimal power consumption, employing a motor that combines axial and radial motor properties, resulting in a high initial torque and capable of maintaining speeds of around 100 km/h without overloading the motor. The aerodynamic analysis, performed using a detailed 3D design, yields an exceptional drag coefficient of 0.09819165, significantly surpassing that of the best commercial cars. The precise 3D model enables calculations of the center of mass and total mass, allowing a force diagram, and an analysis of the rear swingarm, and reducing its weight by 72%. Finally, a model has been created to provide a clear visualization and demonstration of the project's design achievements

Critical Aspects of Electric Motor Drive Controllers and Mitigation of Torque Ripple - Review

Electric vehicles (EVs) are playing a vital role in sustainable transportation. It is estimated that by 2030, Battery EVs will become mainstream for passenger car transportation. Even though EVs are gaining interest in sustainable transportation, the future of EV power transmission is facing vital concerns and open research challenges. Considering the case of torque ripple mitigation and improved reliability control techniques in motors, many motor drive control algorithms fail to provide efficient control. To efficiently address this issue, control techniques such as Field Orientation Control (FOC), Direct Torque Control (DTC), Model Predictive Control (MPC), Sliding Mode Control (SMC), and Intelligent Control (IC) techniques are used in the motor drive control algorithms. This literature survey exclusively compares the various advanced control techniques for conventionally used EV motors such as Permanent Magnet Synchronous Motor (PMSM), Brushless Direct Current Motor (BLDC), Switched Reluctance Motor (SRM), and Induction Motors (IM). Furthermore, this paper discusses the EV-motors history, types of EVmotors, EV-motor drives powertrain mathematical modelling, and design procedure of EV-motors. The hardware results have also been compared with different control techniques for BLDC and SRM hub motors. Future direction towards the design of EV by critical selection of motors and their control techniques to minimize the torque ripple and other research opportunities to enhance the performance of EVs are also presented.publishedVersio

Maintenance program for Electric Vehicles power train by Reliability Centred Maintenance

The reduction of environmental pollution is one of the greatest challenges for humanity, today and for the immediate future. Air quality is one of the most critical aspects in determining people’s health, particularly in big cities, and transportation emissions are currently considered accountable for almost 32% of total air contamination. The more widespread use of green vehicles could have important effects both on the environment and the economy, and this thesis work intends to focus on reliability and maintainability of pure-electric vehicles (EVs). The main objectives of this paper are: • To conduct research into state-of -art of pure-electric car powertrain technology, describing the functions and operations of its various components: mechanical, electrical and the control links between those components are all carefully considered. • To identify and define a long term maintenance plan for the power train system, utilising the RCM method. In order to achieve these targets and objectives, a wide literature review will be conducted on existing electric vehicle technology, taking already published and available information from similar technologies which are more mature than EVs one, but with comparable run conditions and operations. The method adopted for this maintenance study is Reliability Centred Maintenance (RCM): this logic will be reviewed and applied to the powertrain system, designing and completing proper worksheets (COFA worksheet and PM task worksheet) which will form the suggested maintenance plan. This proposed plan consists of various elements including: failure modes identification, failure effects on the vehicle, criticality classification of the components, failure causes identification and suggested preventive maintenance tasks with proper periodicity. In the final part of the paper, the results and outcomes of the analysis will be discussed, and possible future developments will be identified

Adaptive control of sinusoidal brushless DC motor actuators

Electrical Power Assisted Steering system (EPAS) will likely be used on future automotive power steering systems. The sinusoidal brushless DC (BLDC) motor has been identified as one of the most suitable actuators for the EPAS application. Motor characteristic variations, which can be indicated by variations of the motor parameters such as the coil resistance and the torque constant, directly impart inaccuracies in the control scheme based on the nominal values of parameters and thus the whole system performance suffers. The motor controller must address the time-varying motor characteristics problem and maintain the performance in its long service life. In this dissertation, four adaptive control algorithms for brushless DC (BLDC) motors are explored. The first algorithm engages a simplified inverse dq-coordinate dynamics controller and solves for the parameter errors with the q-axis current (iq) feedback from several past sampling steps. The controller parameter values are updated by slow integration of the parameter errors. Improvement such as dynamic approximation, speed approximation and Gram-Schmidt orthonormalization are discussed for better estimation performance. The second algorithm is proposed to use both the d-axis current (id) and the q-axis current (iq) feedback for parameter estimation since id always accompanies iq. Stochastic conditions for unbiased estimation are shown through Monte Carlo simulations. Study of the first two adaptive algorithms indicates that the parameter estimation performance can be achieved by using more history data. The Extended Kalman Filter (EKF), a representative recursive estimation algorithm, is then investigated for the BLDC motor application. Simulation results validated the superior estimation performance with the EKF. However, the computation complexity and stability may be barriers for practical implementation of the EKF. The fourth algorithm is a model reference adaptive control (MRAC) that utilizes the desired motor characteristics as a reference model. Its stability is guaranteed by Lyapunov’s direct method. Simulation shows superior performance in terms of the convergence speed and current tracking. These algorithms are compared in closed loop simulation with an EPAS model and a motor speed control application. The MRAC is identified as the most promising candidate controller because of its combination of superior performance and low computational complexity. A BLDC motor controller developed with the dq-coordinate model cannot be implemented without several supplemental functions such as the coordinate transformation and a DC-to-AC current encoding scheme. A quasi-physical BLDC motor model is developed to study the practical implementation issues of the dq-coordinate control strategy, such as the initialization and rotor angle transducer resolution. This model can also be beneficial during first stage development in automotive BLDC motor applications

Electric Vehicle Efficient Power and Propulsion Systems

Vehicle electrification has been identified as one of the main technology trends in this second decade of the 21st century. Nearly 10% of global car sales in 2021 were electric, and this figure would be 50% by 2030 to reduce the oil import dependency and transport emissions in line with countries’ climate goals. This book addresses the efficient power and propulsion systems which cover essential topics for research and development on EVs, HEVs and fuel cell electric vehicles (FCEV), including: Energy storage systems (battery, fuel cell, supercapacitors, and their hybrid systems); Power electronics devices and converters; Electric machine drive control, optimization, and design; Energy system advanced management methods Primarily intended for professionals and advanced students who are working on EV/HEV/FCEV power and propulsion systems, this edited book surveys state of the art novel control/optimization techniques for different components, as well as for vehicle as a whole system. New readers may also find valuable information on the structure and methodologies in such an interdisciplinary field. Contributed by experienced authors from different research laboratory around the world, these 11 chapters provide balanced materials from theorical background to methodologies and practical implementation to deal with various issues of this challenging technology. This reprint encourages researchers working in this field to stay actualized on the latest developments on electric vehicle efficient power and propulsion systems, for road and rail, both manned and unmanned vehicles

Field weakening and sensorless control solutions for synchronous machines applied to electric vehicles.

184 p.La polución es uno de los mayores problemas en los países industrializados. Por ello, la electrificación del transporte por carretera está en pleno auge, favoreciendo la investigación y el desarrollo industrial. El desarrollo de sistemas de propulsión eficientes, fiables, compactos y económicos juega un papel fundamental para la introducción del vehículo eléctrico en el mercado.Las máquinas síncronas de imanes permanentes son, a día de hoy la tecnología más empleada en vehículos eléctricos e híbridos por sus características. Sin embargo, al depender del uso de tierras raras, se están investigando alternativas a este tipo de máquina, tales como las máquinas de reluctancia síncrona asistidas por imanes. Para este tipo de máquinas síncronas es necesario desarrollar estrategias de control eficientes y robustas. Las desviaciones de parámetros son comunes en estas máquinas debido a la saturación magnética y a otra serie de factores, tales como tolerancias de fabricación, dependencias en función de la temperatura de operación o envejecimiento. Las técnicas de control convencionales, especialmente las estrategias de debilitamiento de campo dependen, en general, del conocimiento previo de dichos parámetros. Si no son lo suficientemente robustos, pueden producir problemas de control en las regiones de debilitamiento de campo y debilitamiento de campo profundo. En este sentido, esta tesis presenta dos nuevas estrategias de control de debilitamiento de campo híbridas basadas en LUTs y reguladores VCT.Por otro lado, otro requisito indispensable para la industria de la automoción es la detección de faltas y la tolerancia a fallos. En este sentido, se presenta una nueva estrategia de control sensorless basada en una estructura PLL/HFI híbrida que permite al vehículo continuar operando de forma pseudo-óptima ante roturas en el sensor de posición y velocidad de la máquina eléctrica. En esta tesis, ambas propuestas se validan experimentalmente en un sistema de propulsión real para vehículo eléctrico que cuenta con una máquina de reluctancia síncrona asistidas por imanes de 51 kW

Degradation control for electric vehicle machines using nonlinear model predictive control

Electric machines (motors and generators) are over actuated systems. In this paper, we show how to exploit this actuation redundancy in order to mitigate machine degradation while simultaneously ensuring that the desired closed loop performance is maintained. We formulate a multiobjective optimization problem with a cost function having terms representing closed loop performance and component degradation for an inverter-fed permanent magnet synchronous motor. Such machines are important as they are widely used as the prime mover of commercial electric vehicles. The resulting optimal control problem is implemented online via a nonlinear model predictive control (NMPC) scheme. The control framework is validated for standard vehicle drive cycles. Results show that the NMPC scheme allows for better closed loop performance and lower degradation than standard industrial controllers, such as the field-oriented control method. Hence, this paper demonstrates how the remaining useful life of a machine can be increased by appropriate controller design without compromising performance