Preliminary power train design for a state-of-the-art electric vehicle

Power train designs which can be implemented within the current state-of-the-art were identified by means of a review of existing electric vehicles and suitable off-the-shelf components. The affect of various motor/transmission combinations on vehicle range over the SAE J227a schedule D cycle was evaluated. The selected, state-of-the-art power train employs a dc series wound motor, SCR controller, variable speed transmission, regenerative braking, drum brakes and radial ply tires. Vehicle range over the SAE cycle can be extended by approximately 20% by the further development of separately excited, shunt wound DC motors and electrical controllers. Approaches which could improve overall power train efficiency, such as AC motor systems, are identified. However, future emphasis should remain on batteries, tires and lightweight structures if substantial range improvements are to be achieved

Real-Time Hardware-in-the-Loop Simulation of Permanent Magnet Synchronous Motor Drives under Stator Faults

Hardware-in-the-loop (HIL) testing methods can facilitate the development of control strategies in a safe and inexpensive environment particularly when extreme operating conditions such as faults are considered. HIL methods rely on accurate real-time emulation of the equipment under investigation. However, no validated tools for real-time emulation of electrical drives under fault conditions are available. This paper describes the implementation of a high-fidelity real-time emulator of a Permanent Magnet Synchronous Motor (PMSM) drive in a platform suitable for HIL tests. The emulator is capable of representing the drive operation under both healthy conditions and during inter-turn stator winding faults. Nonlinearities due to saturation, higher order harmonics, slotting effects, etc. are accounted for using fourdimensional look-up tables obtained by finite element analysis (FEA). The proposed model is computationally efficient and capable of running in real-time in a FPGA platform and is validated against simulations and experimental results in a wide range of operating conditions. Potential applications of the proposed emulation environment to the development of drive control, fault detection and diagnostic algorithms are proposed

Design and Validation of a Variable Stiffness Three Degree of Freedom Planar Robot Arm

The need exists for robotic manipulators that can interact with an environment having uncertain kinematic constraints. A robot has been designed and built for proof of concept of a passive variable compliance control strategy that can vary joint stiffness to achieve higher performance dexterous manipulation. This novel planar robot incorporating variable stiffness actuators and common industrial controls allows the robot to comply with its environment when needed but also have high stiffness for precise motion control in free space. To perform both functions well, a high stiffness ratio (max/min stiffness) is required. A stiffness ratio up to 492 was achieved. The robot performance was evaluated with the task of turning a crank to lift a weight despite nominal positioning inaccuracy. The novel variable stiffness robot was able to complete the task faster and with lower constraint forces than a traditional force-controlled stiff robot. The time to complete the task using passive variable stiffness control was twenty-nine times faster with constraint forces less than one fifth those achieved using traditional active compliance control

Multi-Level Medium Voltage Inverter for Dc Distributed Wind Farm to Establish Grid Interface and Provide Ancillary Support

Wind energy has gained in popularity in recent years due to cost, security and environmental concerns associated with conventional energy sources like fossil fuels. However, the utilization of wind energy in power systems creates many technical and non-technical challenges that need to be addressed for successful integrations. The main technical issues related to wind energy are its uncertainty and variability and their impacts on stability, reliability and quality of the electric power. In systems with high wind energy penetrations, unlike conventional generations, sudden changes in active and/or reactive power demand cannot be supported by wind energy. This lack of demand support may create unwanted voltage and frequency variations in the grid. On the hand, the existing AC distributed wind farms have several drawbacks including complexity, higher cost, and lower efficiency. In this dissertation, a medium voltage direct current (MVDC) distribution system for wind farms is investigated. The proposed system offers higher reliability, lower cost, higher efficiency and more importantly grid support. It also allows for easier integration of energy storage systems at DC level. Design, control, implementation, and testing of a three-level medium voltage inverter are presented. The inverter can provide active and reactive power support to the grid in case of frequency and voltage droops. Simulation and experimental results are presented to verify the viability of the proposed system and control techniques

Rapid Battery Exchange (RBX) Charger Interface

As fossil fuel prices steadily rise and concerns associated with burning the fuels increase, electric vehicle sales continue to grow. According to the U.S. Department of Energy, EV sales “tripled from about 17,000 in 2011 to about 52,000 in 2012” [1]. In order to meet consumer transportation expectations—molded by fuel-powered vehicles—electric cars must have the ability to “refuel” quickly. Rapidly charging an EV’s traction battery poses one solution but doing so requires large power levels “five times as much as the average office consumes,” [2] making rapid charging less than ideal for the masses. Alternatively, swapping an EV’s depleted battery with a charged one eliminates the vehicle’s charging downtime and allows the battery pack to charge at an optimal rate while out of the vehicle

Closed-loop controller for eliminating the contact bounce in DC core contactors

The undesirable phenomenon of the contact bounce causes severe erosion of the contacts and, as a consequence, their electrical life and reliability are greatly reduced. On the other hand, the bounce of the armature can provoke re-opening of the contacts, even when they have already been closed. This paper deals with the elimination of the bounce in both contacts and armature of a commercial dc core contactor. This is achieved by means of a current closed-loop controller, which only uses as input the current and voltage of the contactor’s magnetizing coil. The logic control has been implemented in a low cost microcontroller. Moreover, the board control can be fed by either dc or ac, and either in 50 Hz or 60 Hz so as to extend its applicability. A set of data is obtained from the measurement of the position and velocity of the movable parts for different operating voltages, and the dynamic behavior of the contactor is discussed.Peer ReviewedPostprint (published version

Building an Electric Motorcycle: Design and Construction of a Zero Roadside Emissions Vehicle

This report details the process of building an electric drive system for a motorcycle, and covers some of the background information necessary for a full understanding of the components involved and their functionality. Topics discussed in this paper are: power estimates, compressed air power, battery chemistries, battery management systems, battery chargers, electric motors, motor controllers, direct sprocket drive, frame modifications, part mounting, and wiring. These topics are discussed in the context in which they apply to the project build, which is a conversion of a street motorcycle to fully electric drive. The complete electric drive system which resulted from this project was fully assembled on a sport motorcycle chassis, and has an estimated top speed and average range of 70 mph and 40 miles

Fault-Tolerant Control of a Flux-switching Permanent Magnet Synchronous Machine

Je jasné, že nejúspěšnější konstrukce zahrnuje postup vícefázového řízení, ve kterém každá fáze může být považována za samostatný modul. Provoz kterékoliv z jednotek musí mít minimální vliv na ostatní, a to tak, že v případě selhání jedné jednotky ostatní mohou být v provozu neovlivněny. Modulární řešení vyžaduje minimální elektrické, magnetické a tepelné ovlivnění mezi fázemi řízení (měniče). Synchronní stroje s pulzním tokem a permanentními magnety se jeví jako atraktivní typ stroje, jejíž přednostmi jsou vysoký kroutící moment, jednoduchá a robustní konstrukce rotoru a skutečnost, že permanentní magnety i cívky jsou umístěny společně na statoru. FS-PMSM jsou poměrně nové typy střídavého stroje stator-permanentní magnet, které představují významné přednosti na rozdíl od konvenčních rotorů - velký kroutící moment, vysoký točivý moment, v podstatě sinusové zpětné EMF křivky, zároveň kompaktní a robustní konstrukce díky umístění magnetů a vinutí kotvy na statoru. Srovnání výsledků mezi FS-PMSM a klasickými motory na povrchu upevněnými PM (SPM) se stejnými parametry ukazuje, že FS-PMSM vykazuje větší vzduchové mezery hustoty toku, vyšší točivý moment na ztráty v mědi, ale také vyšší pulzaci díky reluktančnímu momentu. Pro stroje buzené permanentními magnety se jedná o tradiční rozpor mezi požadavkem na vysoký kroutící moment pod základní rychlostí (oblast konstantního momentu) a provozem nad základní rychlostí (oblast konstantního výkonu), zejména pro aplikace v hybridních vozidlech. Je předložena nová topologie synchronního stroje s permanentními magnety a spínaným tokem odolného proti poruchám, která je schopná provozu během vinutí naprázdno a zkratovaného vinutí i poruchách měniče. Schéma je založeno na dvojitě vinutém motoru napájeném ze dvou oddělených vektorově řízených napěťových zdrojů. Vinutí jsou uspořádána takovým způsobem, aby tvořila dvě nezávislé a oddělené sady. Simulace a experimentální výzkum zpřesní výkon během obou scénářů jak za normálního provozu, tak za poruch včetně zkratových závad a ukáží robustnost pohonu za těchto podmínek. Tato práce byla publikována v deseti konferenčních příspěvcích, dvou časopisech a knižní kapitole, kde byly představeny jak topologie pohonu a aplikovaná řídící schémata, tak analýzy jeho schopnosti odolávat poruchám.It has become clear that the most successful design approach involves a multiple phase drive in which each phase may be regarded as a single-module. The operation of any one module must have minimal impact upon the others, so that in the event of that module failing the others can continue to operate unaffected. The modular approach requires that there should be minimal electrical, magnetic and thermal interaction between phases of the drive. Flux-Switching permanent magnet synchronous machines (FS-PMSM) have recently emerged as an attractive machine type virtue of their high torque densities, simple and robust rotor structure and the fact that permanent magnets and coils are both located on the stator. Flux-switching permanent magnet (FS-PMSM) synchronous machines are a relatively new topology of stator PM brushless machine. They exhibit attractive merits including the large torque capability and high torque (power) density, essentially sinusoidal back-EMF waveforms, as well as having a compact and robust structure due to both the location of magnets and armature windings in the stator instead of the rotor as those in the conventional rotor-PM machines. The comparative results between a FS-PMSM and a traditional surface-mounted PM (SPM) motor having the same specifications reveal that FS-PMSM exhibits larger air-gap flux density, higher torque per copper loss, but also a higher torque ripple due to cogging -torque. However, for solely permanent magnets excited machines, it is a traditional contradiction between the requests of high torque capability under the base-speed (constant torque region) and wide speed operation above the base speed (constant power region) especially for hybrid vehicle applications. A novel fault-tolerant FS-PMSM drive topology is presented, which is able to operate during open- and short-circuit winding and converter faults. The scheme is based on a dual winding motor supplied from two separate vector-controlled voltage-sourced inverter drives. The windings are arranged in a way so as to form two independent and isolated sets. Simulation and experimental work will detail the driver’s performance during both healthy- and faulty- scenarios including short-circuit faults and will show the drive robustness to operate in these conditions. The work has been published in ten conference papers, two journal papers and a book chapter, presenting both the topology of the drive and the applied control schemes, as well as analysing the fault-tolerant capabilities of the drive.

Unified power converter based on a dual-stator permanent magnet synchronous machine for motor drive and battery charging of electric vehicles

An electric vehicle (EV) usually has two main power converters, namely one for the motor drive system and another for the battery-charging system. Considering the similarities between both converters, a new unified power converter for motor drive and battery charging of EVs is propounded in this paper. By using a single unified power converter, the cost, volume, and weight of the power electronics are reduced, thus also making possible a reduction in the final price of the EV. Moreover, the proposed unified power converter has the capability of bidirectional power flow. During operation in traction mode, the unified power converter controls motor driving and regenerative braking. Additionally, during operation in battery-charging mode, with the EV plugged into the electrical power grid, the unified power converter controls the power flow for slow or fast battery charging (grid-to-vehicle (G2V) mode), or for discharging of the batteries (vehicle-to-grid (V2G) mode). Specifically, this paper presents computer simulations and experimental validations for operation in both motor-driving and slow battery-charging mode (in G2V and V2G modes). It is demonstrated that the field-oriented control used in the traction system presents good performance for different values of mechanical load and that the battery-charging system operates with high levels of power quality, both in G2V and in V2G mode.This work was supported by the Portuguese Foundation of Science and Technology (FCT) (in Portuguese, Fundação para a Ciência e Tecnologia) within the R&D Units Project Scope: UIDB/00319/2020. This work was also supported by the FCT Project DAIPESEV PTDC/EEIEEE/30382/2017 and by the FCT Project newERA4GRIDs PTDC/EEI-EEE/30283/2017. T.J.C.S. is supported by the doctoral scholarship SFRH/BD/134353/2017 granted by the FCT

Study of the electrical system of a commercial aircraft: development of a numerical simulation model

The need of electric power on aircraft has been growing from few VA of the engine ignition system of early aircraft such as the Wright flyer to almost 1 MVA for large long range commercial aircraft as for example the B747 or the A380. As aircraft is becoming more electric, the electric power system becomes increasingly critical. For this project I managed to study and develop a simulation model of the electrical system of a commercial aircraft, exactly based on the Airbus A320, to be used in electrical engineering and aerospace engineering courses in the near future