MODELING AND SIMULATION OF PM MOTOR TESTING ENVIRONMENT TOWARDS EV APPLICATION CONSIDERING ROAD CONDITIONS

The electric vehicle (EV) performance testing is an indispensable aspect of the design study and marketing of electric vehicle. The development of a suitable electric motor testing environment for EVs is very significant. On the one hand, it provides a relatively realistic testing environment for the study of the key technologies of electric vehicles, and it also plays an essential role in finding a reasonable and reliable optimization scheme. On the other hand, it provides a reference to the evaluation criteria for the products on the market. This thesis is based on such requirements to model and simulate the PM motor testing environment towards EV applications considering road conditions. Firstly, the requirements of the electric motor drive as a propulsion system for EV applications are investigated by comparing to that of the traditional engine as a propulsion system. Then, as the studying objective of this work, the mathematical model of PMSM is discussed according to three different coordinate systems, and the control strategy for EV application is developed. In order to test the PM motor in the context of an EV, a specific target vehicle model is needed as the virtual load of the tested motor with the dyno system to emulate the real operating environment of the vehicle. A slippery road is one of the severe driving conditions for EVs and should be considered during the traction motor testing process. Fuzzy logic based wheel slip control is adopted in this thesis to evaluate the PM motor performance under slippery road conditions. Through the proposed testing environment, the PM motor can be tested in virtual vehicle driving conditions, which is significant for improving the PM motor design and control

Field Oriented Sliding Mode Control of Surface-Mounted Permanent Magnet AC Motors: Theory and Applications to Electrified Vehicles

Permanent magnet ac motors have been extensively utilized for adjustable-speed traction motor drives, due to their inherent advantages including higher power density, superior efficiency and reliability, more precise and rapid torque control, larger power factor, longer bearing, and insulation life-time. Without any proportional-and-integral (PI) controllers, this paper introduces novel first- and higher-order field-oriented sliding mode control schemes. Compared with the traditional PI-based vector control techniques, it is shown that the proposed field oriented sliding mode control methods improve the dynamic torque and speed response, and enhance the robustness to parameter variations, modeling uncertainties, and external load perturbations. While both first- and higher-order controllers display excellent performance, computer simulations show that the higher-order field-oriented sliding mode scheme offers better performance by reducing the chattering phenomenon, which is presented in the first-order scheme. The higher-order field-oriented sliding mode controller, based on the hierarchical use of supertwisting algorithm, is then implemented with a Texas Instruments TMS320F28335 DSP hardware platform to prototype the surface-mounted permanent magnet ac motor drive. Last, computer simulation studies demonstrate that the proposed field-oriented sliding mode control approach is able to effectively meet the speed and torque requirements of a heavy-duty electrified vehicle during the EPA urban driving schedule

Intelligent traction motor control techniques for hybrid and electric vehicles

This thesis presents the research undertaken by the author within the field of intelligent traction motor control for Hybrid Electric Vehicle (HEV) and Electric Vehicle (EV) applications. A robust Fuzzy Logic (FL) based traction motor field-orientated control scheme is developed which can control multiple motor topologies and HEV/EV powertrain architectures without the need for re-tuning. This control scheme can aid in the development of an HEV/EV and for continuous control of the traction motor/s in the final production vehicle. An overcurrent-tolerant traction motor sizing strategy is developed to gauge if a prospective motor’s torque and thermal characteristics can fulfil a vehicle’s target dynamic and electrical objectives during the early development stages of an HEV/EV. An industrial case study is presented. An on-line reduced switching multilevel inverter control scheme is investigated which increases the inverter’s efficiency while maintaining acceptable levels of output waveform harmonic distortion. A FL based vehicle stability control system is developed that improves the controllability and stability of an HEV/EV during an emergency braking manoeuvre. This system requires minimal vehicle parameters to be used within the control system, is insensitive to variable vehicle parameters and can be tuned to meet a vehicle’s target dynamic objectives

Model-based powertrain design and control system development for the ideal all-wheel drive electric vehicle

The transfer case based all-wheel drive electric vehicle (TCAWDEV) and dual-axle AWDEV have been investigated to balance concerns about energy consumption, drivability and stability of vehicles. However, the mentioned powertrain architectures have the torque windup issue or the wheel skidding issue. The torque windup is an inherent issue of mechanical linked all-wheel drive systems. The hydraulic motor-based or the electric motor-based ideal all-wheel drive powertrain can provide feasible solutions to the mentioned issues. An ideal AWDEV (IAWDEV) powertrain architecture and its control schemes were proposed by this research; the architecture has four independent driving motors in powertrain. The IAWDEV gives more control freedoms to implement active torque controls and traction mode controls. In essence, this research came up with the distributed powertrain concept, and developed control schemes of the distributed powertrain to replace the transfer case and differential devices. The study investigated the dual-loop motor control, the hybrid sliding mode control (HSMC) and the neural network predictive control to reduce energy consumption and achieve better drivability and stability by optimizing the torque allocation of each dependent wheel. The mentioned control schemes were respectively developed for the anti-slip, differential and yaw stability functionalities of the IAWDEV powertrain. This study also investigated the sizing method that the battery capacity was estimated by using cruise performance at 3% road grade. In addition, the model-based verification was employed to evaluate the proposed powertrain design and control schemes. The verification shows that the design and controls can fulfill drivability requirements and minimize the existing issues, including torque windup and chattering of the slipping wheel. In addition, the verification shows that the IAWDEV can harvest around two times more energy while the vehicle is running on slippery roads than the TCAWDEV and the dual-axle AWDEV; the traction control can achieve better drivability and lower energy consumption than mentioned powertrains; the mode control can reduce 3% of battery charge depleting during the highway driving test. It also provides compelling evidences that the functionalities achieved by complicated and costly mechanical devices can be carried out by control schemes of the IAWDEV; the active torque controls can solve the inherent issues of mechanical linked powertrains; the sizing method is credible to estimate the operation envelop of powertrain components, even though there is some controllable over-sizing

Active suspension control of electric vehicle with in-wheel motors

In-wheel motor (IWM) technology has attracted increasing research interests in recent years due to the numerous advantages it offers. However, the direct attachment of IWMs to the wheels can result in an increase in the vehicle unsprung mass and a significant drop in the suspension ride comfort performance and road holding stability. Other issues such as motor bearing wear motor vibration, air-gap eccentricity and residual unbalanced radial force can adversely influence the motor vibration, passenger comfort and vehicle rollover stability. Active suspension and optimized passive suspension are possible methods deployed to improve the ride comfort and safety of electric vehicles equipped with inwheel motor. The trade-off between ride comfort and handling stability is a major challenge in active suspension design. This thesis investigates the development of novel active suspension systems for successful implementation of IWM technology in electric cars. Towards such aim, several active suspension methods based on robust H∞ control methods are developed to achieve enhanced suspension performance by overcoming the conflicting requirement between ride comfort, suspension deflection and road holding. A novel fault-tolerant H∞ controller based on friction compensation is in the presence of system parameter uncertainties, actuator faults, as well as actuator time delay and system friction is proposed. A friction observer-based Takagi-Sugeno (T-S) fuzzy H∞ controller is developed for active suspension with sprung mass variation and system friction. This method is validated experimentally on a quarter car test rig. The experimental results demonstrate the effectiveness of proposed control methods in improving vehicle ride performance and road holding capability under different road profiles. Quarter car suspension model with suspended shaft-less direct-drive motors has the potential to improve the road holding capability and ride performance. Based on the quarter car suspension with dynamic vibration absorber (DVA) model, a multi-objective parameter optimization for active suspension of IWM mounted electric vehicle based on genetic algorithm (GA) is proposed to suppress the sprung mass vibration, motor vibration, motor bearing wear as well as improving ride comfort, suspension deflection and road holding stability. Then a fault-tolerant fuzzy H∞ control design approach for active suspension of IWM driven electric vehicles in the presence of sprung mass variation, actuator faults and control input constraints is proposed. The T-S fuzzy suspension model is used to cope with the possible sprung mass variation. The output feedback control problem for active suspension system of IWM driven electric vehicles with actuator faults and time delay is further investigated. The suspended motor parameters and vehicle suspension parameters are optimized based on the particle swarm optimization. A robust output feedback H∞ controller is designed to guarantee the system’s asymptotic stability and simultaneously satisfying the performance constraints. The proposed output feedback controller reveals much better performance than previous work when different actuator thrust losses and time delay occurs. The road surface roughness is coupled with in-wheel switched reluctance motor air-gap eccentricity and the unbalanced residual vertical force. Coupling effects between road excitation and in wheel switched reluctance motor (SRM) on electric vehicle ride comfort are also analysed in this thesis. A hybrid control method including output feedback controller and SRM controller are designed to suppress SRM vibration and to prolong the SRM lifespan, while at the same time improving vehicle ride comfort. Then a state feedback H∞ controller combined with SRM controller is designed for in-wheel SRM driven electric vehicle with DVA structure to enhance vehicle and SRM performance. Simulation results demonstrate the effectiveness of DVA structure based active suspension system with proposed control method its ability to significantly improve the road holding capability and ride performance, as well as motor performance

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

Traction control in electric vehicles

Tese de Mestrado Integrado. Engenharia Electrotécnica e de Computadores. Área de Especialização de Automação. Faculdade de Engenharia. Universidade do Porto. 201

Active variable geometry suspension for cars

This thesis investigates the characteristics and performance of a new type of active suspension for cars through modelling, simulation, control design and experimental testing. The Series Active Variable Geometry Suspension (SAVGS) concept is first put in context by reviewing the history and current trends in automotive suspensions. Its potential is then critically evaluated and work is carried out to maximise its performance for various suspension functions. A multi-model multi-software modelling and simulation approach is followed throughout the thesis in order to cross-check and substantiate simulation results in the absence of experimental data. The simpler linear models are used to inform the selection of suitable parameter sets for the case studies, to synthesise control systems and to qualitatively validate the more complex, nonlinear multi-body models. The latter are developed as a platform to virtually test the system and its control algorithms. When possible, these tests are based on standard open-loop test manoeuvres and on standardised external disturbances. The SAVGS-retrofitted suspension displays a very nonlinear behaviour, which is at the same time a liability and an opportunity from the point of view of control. Nevertheless, different linear control techniques are effectively applied to improve various suspension functions: PIDs are applied to the lower frequency suspension functions such as mitigation of chassis attitude motions, and the H∞ framework is applied to the higher frequency suspension functions such as comfort and road holding enhancement. In all cases, a cascade control approach is employed, and mechanisms are implemented to ensure that physical and design actuator constraints are always respected. This thesis also covers the design and construction of a quarter-car experimental test rig facility. Step-by-step recommendations for its refinement as well as a testing plan are also outlined.Open Acces