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

On the Modeling, Analysis and Development of PMSM: For Traction and Charging Application

Permanent magnet synchronous machines (PMSMs) are widely implemented commercially available traction motors owing to their high torque production capability and wide operating speed range. However, to achieve significant electric vehicle (EV) global market infiltration in the coming years, the technological gaps in the technical targets of the traction motor must be addressed towards further improvement of driving range per charge of the vehicle and reduced motor weight and cost. Thus, this thesis focuses on the design and development of a novel high speed traction PMSM with improved torque density, maximized efficiency, reduced torque ripple and increased driving range suitable for both traction and integrated charging applications. First, the required performance targets are determined using a drive cycle based vehicle dynamic model, existing literature and roadmaps for future EVs. An unconventional fractional–slot distributed winding configuration with a coil pitch of 2 is selected for analysis due to their short end–winding length, reduced winding losses and improved torque density. For the chosen baseline topology, a non–dominated sorting genetic algorithm based selection of optimal odd slot numbers is performed for higher torque production and reduced torque ripple. Further, for the selected odd slot–pole combination, a novel star–delta winding configuration is modeled and analyzed using winding function theory for higher torque density, reduced spatial harmonics, reduced torque ripple and machine losses. Thereafter, to analyze the motor performance with control and making critical decisions on inter–dependent design parameter variations for machine optimization, a parametric design approach using a novel coupled magnetic equivalent circuit model and thermal model incorporating current harmonics for fractional–slot wound PMSMs was developed and verified. The developed magnetic circuit model incorporates all machine non–linearities including effects of temperature and induced inverter harmonics as well as the space harmonics in the winding inductances of a fractional–slot winding configuration. Using the proposed model with a pareto ant colony optimization algorithm, an optimal rotor design is obtained to reduce the magnet utilization and obtain maximized torque density and extended operating range. Further, the developed machine structure is also analyzed and verified for integrated charging operation where the machine’s winding inductances are used as line inductors for charging the battery thereby eliminating the requirement of an on–board charger in the powertrain and hence resulting in reduced weight, cost and extended driving range. Finally, a scaled–down prototype of the proposed PMSM is developed and validated with experimental results in terms of machine inductances, torque ripple, torque–power–speed curves and efficiency maps over the operating speed range. Subsequently, understanding the capabilities and challenges of the developed scaled–down prototype, a full–scale design with commercial traction level ratings, will be developed and analyzed using finite element analysis. Further recommendations for design improvement, future work and analysis will also be summarized towards the end of the dissertation

A Novel Rotor Topology for High-Performance Fractional Slot Concentrated Winding Interior Permanent Magnet Machine

This article presents a finite-element-based, multiobjective design optimization study of the fractional-slot, concentrated wound, permanent magnet synchronous machine (FSCW PMSM). Design objectives included maximization of efficiency, minimization of cost and low ripple without sacrificing torque density and wide constant power speed range. A large-scale optimization study revealed that while a V-type rotor provides high torque density, a spoke-type rotor has the benefit of low torque ripple. Quest for a design that can combine the goodness of both V-and spoke type rotors for an FSCW stator has led to a novel interior permanent magnet rotor topology referred here as Y-type. The goals of achieving maximum efficiency, minimum cost and wide CPSR were also accomplished in the proposed Y-type FSCW IPMSM. For experimental verification purpose, three fully optimized rotors-V-, spoke-and Y-type were constructed for a 12-slot/10-pole FSCW stator. Extensive experimental tests were conducted on three machines for a detailed comparison study. It will be shown that the proposed Y-type FSCW IPMSM outperforms both V and spoke-type configurations. A scaled-up version of the Y-type FSCW IPMSM shown to have satisfied many of the Freeedomcar 2020 targets, which is promising for application in electric vehicles

Design of non conventional Synchronous Reluctance machine

Synchronous reluctance (SyR) and Permanent magnet Synchronous Reluctance (PM-SyR) machines represent an answer to the growing emphasis on higher efficiency, higher torque density and overload capability of ac machines for variable-speed applications. Their high performance is particularly attractive in electric traction and industry applications. The SyR technology represents a convenient solution to obtain high efficiency machines at reduced cost and high reliability. The manufacturing costs are comparable to other existing technologies such as induction motors. Different SyR and PM-SyR machines with different ratings and applications were designed, for comparison with induction motors having equal frame. An accurate comparison between Induction motors, SyR and PM-SyR machines is reported, with reference to the IE4 and IE5 efficiency specifications that could become mandatory in the next years. Three studies are classified under the term ”Non-Conventional” machines: Line-Start SyR motor: is a special SyR machine designed for constant speed applications, line supplied. The rotor flux barriers are filled with aluminum, to obtain a squirrel cage that resembles the one of an induction motor. The manufacturing costs are comparable to those of the induction motor, and the efficiency is higher. Two prototypes were realized and tested. FSW-SyR: tooth-wound coils and fractional slot per pole combinations were investigated. They are of interest because they permit a simplification and higher degree of automatization of the manufacturing process. However, FSW-SyR machines are known for their high torque ripple, low specific torque and power factor. The number of slots per pole was optimized to maximize the torque density. Dealing with the torque ripple, a lumped parameters model was used together with optimization in SyRE. A design with minimized ripple was obtained, comparable to a distributed winding machine in this respect. This design was prototyped and tested. Mild Overlapped SyR: this study shows a new winding configuration applied to SyR and PM-SyR machines. The proposed case is in the direction to find a hybrid solution between distributed winding and tooth winding motors, that permits to reduce costs and improve performances. One limitation of this solution is that only number of pole pairs equal to five or higher are feasible, and this reduces the applicability of the solution to classical industry applications, where one to three pole pairs are normally used

Coupled Electromagnetic and Thermal Analysis and Design Optimization of Synchronous Electric Machines

A new technique for coupling the electromagnetic, thermal, and air-flow analysis is proposed for electronically controlled synchronous machines. A computationally efficient finite element analysis (CE-FEA) technique is employed for the electromagnetic field analysis. An equivalent circuit network is used for thermal and air-flow analysis. An iterative algorithm, which exploits the fact that the type of machines studied have very low rotor losses and also a relatively reduced dependency of core losses with temperature and load, has been developed. The overall computational time is significantly reduced in comparison with the conventional coupling method, such that the new technique is highly suitable for large scale optimization studies. An automated design optimization method based on differential evolution algorithms has also been developed and implemented on a multi-core computer system. Example case studies are provided for permanent magnet and for synchronous reluctance machines. Computational and experimental results from prototype motors are included

Advances in Rotating Electric Machines

It is difficult to imagine a modern society without rotating electric machines. Their use has been increasing not only in the traditional fields of application but also in more contemporary fields, including renewable energy conversion systems, electric aircraft, aerospace, electric vehicles, unmanned propulsion systems, robotics, etc. This has contributed to advances in the materials, design methodologies, modeling tools, and manufacturing processes of current electric machines, which are characterized by high compactness, low weight, high power density, high torque density, and high reliability. On the other hand, the growing use of electric machines and drives in more critical applications has pushed forward the research in the area of condition monitoring and fault tolerance, leading to the development of more reliable diagnostic techniques and more fault-tolerant machines. This book presents and disseminates the most recent advances related to the theory, design, modeling, application, control, and condition monitoring of all types of rotating electric machines

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

Mathematical Approaches to Modeling, Optimally Designing, and Controlling Electric Machine

Optimal performance of the electric machine/drive system is mandatory to improve the energy consumption and reliability. To achieve this goal, mathematical models of the electric machine/drive system are necessary. Hence, this motivated the editors to instigate the Special Issue “Mathematical Approaches to Modeling, Optimally Designing, and Controlling Electric Machine”, aiming to collect novel publications that push the state-of-the art towards optimal performance for the electric machine/drive system. Seventeen papers have been published in this Special Issue. The published papers focus on several aspects of the electric machine/drive system with respect to the mathematical modelling. Novel optimization methods, control approaches, and comparative analysis for electric drive system based on various electric machines were discussed in the published papers