Study on Performance Characteristics of Interior Permanent Magnet Synchronous Motor Due to Rotor Configuration

This research study was conducted in an effort to understand what effects the rotor configuration has on the performance of a permanent magnet synchronous machine, independent of the stator configuration. Three motors were designed with different interior permanent magnet rotor configurations with the same stator laminations and were analyzed using a combination FEA dq -axis circuit model. The results show that the performance characteristics affected by the rotor configuration were synchronous and reluctance torque production, torque ripple, efficiency and parameter variation. The V-shaped rotor configuration produced the most torque at 70 Nm. The Flat rotor configuration had the second highest torque production at 67 Nm. The Radial rotor configuration had the highest efficiency but had the highest torque ripple. The parameter variation had an effect on the reluctance torque production capabilities of each rotor configuration due to the saturation in the machines

Traction axial flux motor-generator for hybrid electric bus application

Tato dizertační práce se zabývá návrhem původního motor-generátoru s axiálním tokem a buzením permanetními magnety, zkonstruovaným specificky pro hybridní elektrický autobus. Návrhové zadání pro tento stroj přineslo požadavky, které vedly k této unikátní topologii tak, aby byl dosažen výkon, účinnost a rozměry stroje. Tato partikulární topologie motor-generátoru s axiálním tokem je výsledkem literární rešerše, kterou následoval výběr koncepce stroje s představeným návrhem jako výsledkem těchto procesů. Přístup k návrhu stroje s axiálním tokem sledoval „multi-fyzikální“ koncepci, která pracuje s návrhem elektromagnetickým, tepelným, mechanickým, včetně návrhu řízení, v jedné iteraci. Tím je v konečném návrhu zajištěna rovnováha mezi těmito inženýrskými disciplínami. Pro samotný návrh stroje byla vyvinuta sada výpočtových a analytických nástrojů, které byly podloženy metodou konečných prvků tak, aby samotný návrh stroje byl přesnější a spolehlivější. Modelování somtného elektrického stroje a celého pohonu poskytlo představu o výkonnosti a účinnosti celého subsytému v rozmanitých operačních podmínkách. Rovněž poukázal na optimizační potenciál pro návrh řízení subsystému ve smyslu maximalizace účinnosti celého pohonu. Bylo postaveno několik prototypů tohoto stroje, které prošly intensivním testováním jak na úrovni sybsytému, tak systému. Samotné výsledky testů jsou diskutovány a porovnány s analytickými výpočty parametrů stroje. Poznatky získané z prvního prototypu stroje pak sloužily k představení možností, jak zjednodušit výrobu a montáž stroje v příští generaci. Tato práce zaznamenává jednotlivé kroky během všech fází vývoje elektrického stroje s axiálním tokem, počínaje výběrem konceptu stroje, konče sumarizací zkušeností získaných z první generace prototypu tohoto stroje.This thesis deals with a design of a novel Axial-Flux Permanent Magnet Motor-Generator for a hybrid electric bus application. Thus, the design specification represents a set of requirements, which leads toward a concept of a unique topology meeting performance, efficiency and dimensional targets. The particular topology of the Axial-Flux Permanent Magnet Motor-Generator discussed in this work is an outcome of deep literature survey, followed by the concept selection stage with the layout of the machine as an outcome of this processes. The design approach behind this so-called Spoke Axial-Flux Machine follows an idea of multiphysics iterations, including electromagnetic, thermal, mechanical and controls design. Such a process behind the eventually proposed design ensured a right balance in between all of these engineering disciplines. A set of bespoke design and analysis tools was developed for that reason, and was backed up by extensive use of Finite-Element Analysis and Computational Fluid Dynamics. Therefore, the actual machine design gained higher level of confidence and fidelity. Modelling of the machine and its drive provided understanding of performance and efficiency of the whole subsystem at various operational conditions. Moreover, it has illustrated an optimization potential for the controls design, so that efficiency of the machine and power electronics might be maximized. Several prototypes of this machine have been built and passed through extensive testing both on the subsystem and system level. Actual test results are discussed, and compared to analytical predictions in terms of the machine's parameters. As a lesson learned from the first prototype of this machine, a set of redesign proposals aiming for simplification of manufacturing and assembly processes, are introduced. This work records steps behind all phases of development of the Axial Flux Machine from a basic idea as an outcome of concept selection stage, up to testing and wrap-up of experience gained from the first generation of the machine.

Magnetic noise reduction of in-wheel permanent magnet synchronous motors for light-duty electric vehicles

This paper presents study of a multi-slice subdomain model (MS-SDM) for persistent low-frequency sound, in a wheel hub-mounted permanent magnet synchronous motor (WHM-PMSM) with a fractional-slot non-overlapping concentrated winding for a light-duty, fully electric vehicle applications. While this type of winding provides numerous potential benefits, it has also the largest magnetomotive force (MMF) distortion factor, which leads to the electro-vibro-acoustics production, unless additional machine design considerations are carried out. To minimize the magnetic noise level radiated by the PMSM, a skewing technique is targeted with consideration of the natural frequencies under a variable-speed-range analysis. To ensure the impact of the minimization technique used, magnetic force harmonics, along with acoustic sonograms, is computed by MS-SDM and verified by 3D finite element analysis. On the basis of the studied models, we derived and experimentally verified the optimized model with 5 dBA reduction in A-weighted sound power level by due to the choice of skew angle. In addition, we investigated whether or not the skewing slice number can be of importance on the vibro-acoustic objectives in the studied WHM-PMSM.Postprint (published version

Design Simulation and Experiments on Electrical Machines for Integrated Starter-Generator Applications

This thesis presents two different non-permanent magnet machine designs for belt-driven integrated starter-generator (B-ISG) applications. The goal of this project is to improve the machine performance over a benchmark classical switched reluctance machine (SRM) in terms of efficiency, control complexity, torque ripple level and power factor. The cost penalty due to the necessity of a specially designed H-bridge machine inverter is also taken into consideration by implementation of a conventional AC inverter. The first design changes the classical SRM winding configuration to utilise both self-inductance and mutual-inductance in torque production. This allows the use of AC sinusoidal current with lower cost and comparable or even increased torque density. Torque density can be further increased by using a bipolar square current drive with optimum conduction angle. A reduction in control difficulty is also achieved by adoption of standard AC machine control theory. Despite these merits, the inherently low power factor and poor field weakening capability makes these machines unfavourable in B-ISG applications. The second design is a wound rotor synchronous machine (WRSM). From FE analysis, a six pole geometry presents a lower loss level over four pole geometry. Torque ripple and iron loss are effectively reduced by the use of an eccentric rotor pole. To determine the minimum copper loss criteria, a novel algorithm is proposed over the conventional Lagrange method, where the deviation is lowered from ± 10% to ± 1%, and the simulation time is reduced from hours to minutes on standard desktop PC hardware. With the proposed design and control strategies, the WRSM delivers a comparable field weakening capability and a higher efficiency compared with the benchmark SRM under the New European Driving Cycle, where a reduction in machine losses of 40% is possible. Nevertheless, the wound rotor structure brings mechanical and thermal challenges. A speed limit of 11,000 rpm is imposed by centrifugal forces. A maximum continuous motoring power of 3.8 kW is imposed by rotor coil temperature performance, which is extended to 5 kW by a proposed temperature balancing method. A prototype machine is then constructed, where the minimum copper loss criteria is experimentally validated. A discrepancy of no more than 10% is shown in back-EMF, phase voltage, average torque and loss from FE simulation

Multi-physics Model Of Key Components In High Efficiency Vehicle Drive

Hybrid Electric Vehicles (HEVs) and Electric Vehicles (EVs) are crucial technologies for the automotive industry to meet society’s demands for cleaner, more energy efficient transportation. Meeting the need to provide power which sustains HEVs and EVs is an immediate area of concern that research and development within the automotive community must address. Electric batteries and electrical motors are the key components in HEV and EV power generation and transmission, and their performance plays very important role in the overall performance of the modern high efficiency vehicles. Therefore, in this dissertation, we are motivated to study the electric batteries, interior permanent motor (IPM), in the context of modern hybrid electric/electric drive systems, from both multi-physics and system level perspectives. Electrical circuit theory, electromagnetic Finite Element Analysis (FEA), and Computational Fluid Dynamic (CFD) finite volume method will be used primarily in this work. The work has total of five parts, and they are introduced in the following. Firstly, Battery thermal management design is critical in HEV and EV development. Accurate temperature distribution of the battery cells during vehicle operation is required for achieving optimized design. We propose a novel electrical-thermal battery modeling technique that couples a temperature dependent battery circuit model and a physics-based CFD model to meet this need. The electrical circuit model serves as a heat generation mechanism for the CFD model, and the CFD model provides the temperature distribution of the battery cells, which can also impact the heat generation of the electrical battery model. In this part of work, simulation data has been derived from the model respective to electrical performance of the battery as well iv as the temperature distribution simultaneously in consideration of the physical dimensions, material properties, and cooling conditions. The proposed model is validated against a battery model that couples the same electrical model with a known equivalent thermal model. Secondly, we propose an accurate system level Foster network thermal model. The parameters of the model are extracted from step responses of the CFD battery thermal model. The Foster network model and the CFD model give the same results. The Foster network can couple with battery circuit model to form an electric-thermal battery model for system simulation. Thirdly, IPM electric machines are important in high performance drive systems. During normal operations, irreversible demagnetization can occur due to temperature rise and various loading conditions. We investigate the performance of an IPM using 3d time stepping electromagnetic FEA considering magnet’s temperature dependency. Torque, flux linkage, induced voltage, inductance and saliency of the IPM will be studied in details. Finally, we use CFD to predict the non-uniform temperature distribution of the IPM machine and the impact of this distribution on motor performance. Fourthly, we will switch gear to investigate the IPM motor on the system level. A reduced order IPM model is proposed to consider the effect of demagnetization of permanent magnet due to temperature effect. The proposed model is validated by comparing its results to the FEA results. Finally, a HEV is a vehicle that has both conventional mechanical (i.e. internal combustion engine) and electrical propulsion systems. The electrical powertrain is used to work with the conventional powertrain to achieve higher fuel economy and lower emissions. v Computer based modeling and simulation techniques are therefore essential to help reduce the design cost and optimize system performance. Due to the complexity of hybrid vehicles, multidomain modeling ability is preferred for both component modeling and system simulation. We present a HEV library developed using VHDL-AMS

In-wheel motor vibration control for distributed-driven electric vehicles:A review

Efficient, safe, and comfortable electric vehicles (EVs) are essential for the creation of a sustainable transport system. Distributed-driven EVs, which often use in-wheel motors (IWMs), have many benefits with respect to size (compactness), controllability, and efficiency. However, the vibration of IWMs is a particularly important factor for both passengers and drivers, and it is therefore crucial for a successful commercialization of distributed-driven EVs. This paper provides a comprehensive literature review and state-of-the-art vibration-source-analysis and -mitigation methods in IWMs. First, selection criteria are given for IWMs, and a multidimensional comparison for several motor types is provided. The IWM vibration sources are then divided into internally-, and externally-induced vibration sources and discussed in detail. Next, vibration reduction methods, which include motor-structure optimization, motor controller, and additional control-components, are reviewed. Emerging research trends and an outlook for future improvement aims are summarized at the end of the paper. This paper can provide useful information for researchers, who are interested in the application and vibration mitigation of IWMs or similar topics

High efficiency sensorless fault tolerant control of permanent magnet assisted synchronous reluctance motor

In the last decades, the development trends of high efficiency and compact electric drives on the motor side focused on Permanent Magnet Synchronous Machines (PMSMs) equipped with magnets based on the rare-earth elements. The permanent magnet components, however, dramatically impact the overall bill of materials of motor construction. This aspect has become even more critical due to the price instability of the rare-earth elements. This is why the Permanent Magnet Assisted Synchronous Reluctance Motor (PMaSynRM) concept was brought to the spotlight as it gives comparable torque density and similar efficiencies as PMSM although at a lower price accredited for the use of magnets built with ferrite composites. Despite these advantages, PMaSynRM drive design is much more challenging because of nonlinear inductances resulting from deep cross saturation effects. It is also true for multi-phase PMSM motors that have gained a lot of attention as they proportionally split power by the increased number of phases. Furthermore, they offer fault-tolerant operation while one or more phases are down due to machine, inverter, or sensor fault. The number of phases further increases the overall complexity for modeling and control design. It is clear then that a combination of multi-phase with PMaSynRM concept brings potential benefits but confronts standard modeling methods and drive development techniques. This Thesis consists of detailed modeling, control design, and implementation of a five-phase PMaSynRM drive for normal healthy and open phase fault-tolerant applications. Special emphasis is put on motor modeling that comprises saturation and space harmonics together with axial asymmetry introduced by rotor skewing. Control strategies focused on high efficiency are developed and the position estimation based on the observer technique is derived. The proposed models are validated through Finite Element Analysis (FEA) and experimental campaign. The results show the effectiveness of the elaborated algorithms and methods that are viable for further industrialization in PMaSynRM drives with fault-tolerant capabilities.En últimas décadas, las tendencias de desarrollo de accionamientos eléctricos compactos y de alta eficiencia en el lado del motor se centraron en las maquinas síncronas de imanes permanentes (PMSM) equipadas con imanes basados en elementos de tierras raras. Sin embargo, los componentes de imán permanente impactan dramáticamente en el coste de construcción del motor. Este aspecto se ha vuelto aún más crítico debido a la inestabilidad de precios de los elementos de tierras raras. Esta es la razón por la que el concepto de motor de reluctancia síncrona asistido por imán permanente (PMaSynRM) se ha tomado en consideración, ya que ofrece una densidad de par comparable y eficiencias similares a las de PMSM, aunque a un precio más bajo acreditado para el uso de imanes construidos con compuestos de ferritas. A pesar de drive PMaSynRM resulta muy complejo debido a las inductancias no lineales que resultan de los efectos de saturación cruzada profunda. Esto también es cierto para los motores PMSM polifásicos que han ganado mucha atención en los últimos años, en los que se divide proporcionalmente la potencia por el mayor número de fases. Además, ofrecen operación tolerante a fallas mientras una o más fases están inactivas debido a fallas en la máquina, el inversor o el sensor. Sin embargo, el número de fases aumenta aún más la complejidad general del diseño de modelado y control. Está claro entonces que una combinación de multifase con el concepto PMaSynRM tiene beneficios potenciales, pero dificulta los métodos de modelado estándar y las técnicas de desarrollo del sistema de accionamiento. Esta tesis consiste en el modelado detallado, el diseño de control y la implementación de un drive PMaSynRM de cinco fases para aplicaciones normales en buen estado y tolerantes a fallas de fase abierta. Se pone especial énfasis en el modelado del motor que comprende la saturación y los armónicos espaciales junto con la asimetría axial introducida por la inclinación del rotor. Se desarrollan estrategias de control enfocadas a la alta eficiencia y se deriva la estimación de posición basada en la técnica del observador. Los modelos propuestos se validan mediante Análisis de Elementos Finitos (FEA) y resultados experimentales. Los resultados muestran la efectividad de los algoritmos y métodos elaborados, que resultan viables para la industrialización de unidades PMaSynRM con capacidades tolerantes a fallas.Postprint (published version

Advanced Non-Overlapping Winding Induction Machines for Electrical Vehicle Applications

This thesis presents an investigation into advanced squirrel-cage induction machines (IMs), with a particular reference to the reduction of the total axial length without sacrificing the torque and efficiency characteristics and analysis of recently found non-sinusoidal bar current phenomenon, which occurs under some certain design and operating conditions, and affects the overall performance characteristics of the IMs. As a first step, the most convenient method is determined by utilizing a fractional-slot concentrated winding (FSCW) technique, which has advantages such as non-overlapping windings, high slot filling factor, and simple structure. After implementing this technique, it is found that due to the highly distorted magnetomotive forces (MMFs) created by the FSCWs, significant high rotor bar copper loss occurs. In order to reduce the MMF harmonics without increasing the size of the machine, a new technique titled “adapted non-overlapping winding” is developed. This technique consists of the combination of the auxiliary tooth and phase shifting techniques, resulting in a stator with concentrated windings of two-slot coil pitches but without overlapping the end-windings. Thanks to this method a large number of the MMF harmonics are cancelled. Thus, a low copper loss IM with significantly reduced total axial length is obtained. Influence of design parameters; such as stator slot, rotor slot, and pole numbers, number of turns, stack length, stator and rotor geometric parameters, etc. on the performance characteristics of the advanced IM is investigated and a comprehensive comparison of advanced and conventional IMs is presented. This thesis also covers an in-depth investigation on the non-sinusoidal bar current phenomenon. It is observed that the rotor bar current waveform, usually presumed to be sinusoidal, becomes non-sinusoidal in some operation and design conditions, such as high speed operation close to synchronous speed, or fairly high electrical loading operation, or in the IMs whose air-gap length is considerably small, etc. Influences of design and operating parameters and magnetic saturation on the rotor bar current waveform and the performance characteristics of squirrel-cage IMs are investigated. The levels of iron saturation, depending on the design and operating parameters, in different machine parts are examined and their influences are also investigated, whilst the dominant part causing the non-sinusoidal rotor bar current waveform is identified. It is revealed that the magnetic saturation, particularly in the rotor tooth, has a significant effect on the bar current waveform

Vector Control and Experimental Evaluation of Permanent Magnet Synchronous Motors for HEVs

The 2004 Toyota Prius exceeded sales expectations and led the automotive industry to realize that there is a healthy market for hybrid electric vehicles (HEVs). The Prius uses two interior permanent magnet motors to manipulate power flow throughout the drive system. Permanent magnet synchronous motors (PMSMs) are most suitable for HEVs and full electric vehicles due to their high efficiency, high power density, and fast dynamic response. This thesis will present vector control theory for PMSMs, with focus on interior permanent magnet motors. The primary 50kW drive motor and inverter of the 2004 Toyota Prius Synergy drive system was removed for an intensive thermal, electrical, and mechanical evaluation in a dynamometer test cell at Oak Ridge National Laboratory. These evaluations include locked rotor, back-EMF, and motoring operation region tests. The resulting data is presented to reveal characteristics such as torque capabilities, thermal limitations, and motor efficiencies for all toque-speed operation points. One of the most challenging tasks of the evaluation was to solve problems related to electromagnetic interference (EMI). The pulse width modulation (PWM) driven high voltage converter/inverter is a large source of electromagnetic field radiation and nearby low level signals, including control circuitry for the hybrid system, will experience EMI if proper countermeasures are not taken. Methods to reduce electromagnetic field radiation and practices to prevent EMI are discussed

Semi-Analytical Approach Towards Design and Optimization of Induction Machines for Electric Vehicles

Electric machine design is a comprehensive task depending on the several factors, such as material resource limitations and economic factors. Therefore, an induction machine is a promising candidate because of the absence of magnetic material in the rotor. However, the conventional design approach can neither reflect the advances of the induction machine(IM) design nor exploit the trade-offs between design factors and the multi-physics nature of the electrical machine. Therefore, proposing fast and accurate novel methods to design, develop and analyze IMs using electromagnetic field oriented approaches is competitive to the old-fashion numerical methods. To achieve improved IM design from a baseline design to an optimal design, this dissertation: (1) Investigates the challenges of the high speed IM design specified for the electric vehicle application at the rated operating condition considering electromagnetic boundaries for the reasonable saturation level within a compact volume; (2) Proposes a new design approach of IM using modified equivalent circuit parameters to reduce spatial harmonics because of slotting effect and skewing effect; and also presents the importance of the 3-D analysis over 2-D analysis while developing the IM; (3) Proposes a novel electromagnetic field oriented mathematical model considering the slotting effect and axial flux variation because of skewing rotor bars to evaluate the IM performance with a lower and precise computational effort; (4) developed baseline IM is optimized with genetic algorithm incorporated in proposed subdomain model to improve the torque-speed profile. In order to further simplify the optimization procedure, a parametric and sensitivity based design approach is implemented to reduce the design variables. To evaluate the proposed optimal IM with extended constant power region and high torque density within a compact volume using novel 3-D subdomain model, the machine has been prototyped and tested from low to high speed under no-load and loaded condition. Electrical circuit parameter variation is demonstrated and compared to the one simulated in the FEA environment. This innovation can be applied to a family of electric machines with various topologies