Multiple Objective Co-Optimization of Switched Reluctance Machine Design and Control

This dissertation includes a review of various motor types, a motivation for selecting the switched reluctance motor (SRM) as a focus of this work, a review of SRM design and control optimization methods in literature, a proposed co-optimization approach, and empirical evaluations to validate the models and proposed co-optimization methods. The switched reluctance motor (SRM) was chosen as a focus of research based on its low cost, easy manufacturability, moderate performance and efficiency, and its potential for improvement through advanced design and control optimization. After a review of SRM design and control optimization methods in the literature, it was found that co-optimization of both SRM design and controls is not common, and key areas for improvement in methods for optimizing SRM design and control were identified. Among many things, this includes the need for computationally efficient transient models with the accuracy of FEA simulations and the need for co-optimization of both machine geometry and control methods throughout the entire operation range with multiple objectives such as torque ripple, efficiency, etc. A modeling and optimization framework with multiple stages is proposed that includes robust transient simulators that use mappings from FEA in order to optimize SRM geometry, windings, and control conditions throughout the entire operation region with multiple objectives. These unique methods include the use of particle swarm optimization to determine current profiles for low to moderate speeds and other optimization methods to determine optimal control conditions throughout the entire operation range with consideration of various characteristics and boundary conditions such as voltage and current constraints. This multi-stage optimization process includes down-selections in two previous stages based on performance and operational characteristics at zero and maximum speed. Co-optimization of SRM design and control conditions is demonstrated as a final design is selected based on a fitness function evaluating various operational characteristics including torque ripple and efficiency throughout the torque-speed operation range. The final design was scaled, fabricated, and tested to demonstrate the viability of the proposed framework and co-optimization method. Accuracy of the models was confirmed by comparing simulated and empirical results. Test results from operation at various torques and speeds demonstrates the effectiveness of the optimization approach throughout the entire operating range. Furthermore, test results confirm the feasibility of the proposed torque ripple minimization and efficiency maximization control schemes. A key benefit of the overall proposed approach is that a wide range of machine design parameters and control conditions can be swept, and based on the needs of an application, the designer can select the appropriate geometry, winding, and control approach based on various performance functions that consider torque ripple, efficiency, and other metrics

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

Magnetic, Thermal and Structural Scaling of Synchronous Machines

A fast and accurate method for scaling the dimensions and the performance of Permanent Magnet Synchronous Machines (PMSMs) is proposed, based on the use of flux linkage maps. Starting from a reference design, the scaled machine is designed to comply new peak torque and power, maximum operating speed, voltage and current specifications in seamless computational time. A new design plane is introduced, permitting the minimization of the stack length of the scaled design. The analysis covers the scaling of losses and the rules for scaling the water-glycol stator cooling jacket, which is a common cooling setup for PMSMs in traction application. The torque versus speed characteristics, the efficiency map and the thermal limit of the scaled design are obtained in seamless computational time without need of dedicated finite-element simulations. The e-motor of the BMW i3 is the reference design and the moto-generator 2 of the 4-th generation Toyota Prius is the target application for showcasing the proposed method

Evaluation of the 2010 Toyota Prius Hybrid Synergy Drive System

Subsystems of the 2010 Toyota Prius hybrid electric vehicle (HEV) were studied and tested as part of an intensive benchmarking effort carried out to produce detailed information concerning the current state of nondomestic alternative vehicle technologies. Feedback provided by benchmarking efforts is particularly useful to partners of the Vehicle Technologies collaborative research program as it is essential in establishing reasonable yet challenging programmatic goals which facilitate development of competitive technologies. The competitive nature set forth by the Vehicle Technologies Program (VTP) not only promotes energy independence and economic stability, it also advocates the advancement of alternative vehicle technologies in an overall global perspective. These technologies greatly facilitate the potential to reduce dependency on depleting natural resources and mitigate harmful impacts of transportation upon the environment

Embedded Sensors and Controls to Improve Component Performance and Reliability: Conceptual Design Report

The overall project objective is to demonstrate improved reliability and increased performance made possible by deeply embedding instrumentation and controls (I&C) in nuclear power plant components. The project is employing a highly instrumented canned rotor, magnetic bearing, fluoride salt pump as its I&C technology demonstration vehicle. The project s focus is not primarily on pump design, but instead is on methods to deeply embed I&C within a pump system. However, because the I&C is intimately part of the basic millisecond-by-millisecond functioning of the pump, the I&C design cannot proceed in isolation from the other aspects of the pump. The pump will not function if the characteristics of the I&C are not embedded within the design because the I&C enables performance of the basic function rather than merely monitoring quasi-stable performance. Traditionally, I&C has been incorporated in nuclear power plant (NPP) components after their design is nearly complete; adequate performance was obtained through over-design. This report describes the progress and status of the project and provides a conceptual design overview for the embedded I&C pump