CSIRO-EV-Research.pdf

Review of CSIRO Research in EVs

CSIRO MATERIALS SCIENCE AND ENGINEERING

Dr. Howard C. Lova- | Team Leader Electrical Machines (Some slides from Dr. Peter A Wa-erson) Plug In for Power 2012, Swinburne Hawthorn Campus, Melbourne, Australia

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CSIRO EV Research | Dr. Howard C. Lova- 2 |

Talk Overview AutoCRC A SpecicaMon for a Small 4 Wheel Drive Electric Vehicle (EV) Bicycle In-Wheel Motors Direct-Drive, In-Wheel Motors Solar Car In-Wheel Motors Prototype In-Wheel EV Motors Interior Permanent Magnet (IPM) Motors? Transverse Flux (TF) Machine? Switched Reluctance (SR) Motor?

Conclusions

AutoCRC


EducaMon & Training Supplier Improvement


A SpecicaBon for a Small 4 Wheel Drive EV Assume 4 wheel motors, peak total power 48 kW constant over 30 km/h - 120 km/h, 175/65 R14 tyres

High peak torque - 420 Nm up to 273 rpm Low mass - e.g. 15 kg 28 Nm/kg Small volume - e.g. OD 340 mm, length 75 mm 62 kNm/m3 High eciency - e.g. 90%, ideally enabling air cooling Robust to vibraMons Low cost minimum NdFeB use Flux weakening e.g. 4:1, but safe in the event of a fault

Bicycle In-Wheel Motors

Direct Drive Geared


www.value-e-bikes.com.au

In-Wheel Hybrid e-CVT

Planetary gear e-CVT like a Prius A design for a bicycle: ConMnuous rider power 200 W ConMnuous electric power 200 W 110 270 rpm Hub OD 190 mm Hub axial length 75 mm

Details: Wa-erson P.A., 11th InternaMonal Conference on Electrical Machines and Systems, ICEMS 2008, Wuhan

NexxtDrive patents similar


Solar Car In-Wheel Motors


Direct Drive In-Wheel Motor

Aurora Solar Car

In conjuncMon with University of Technology Sydney, Newcastle University (UK), and Aurora

Marand/CSIRO - Halbach Magnet Motor


Tyre

Axle

Magnet Ring

Winding

Copper Winding

Magnet Blocks

B

z

Axial ux

Marand/CSIRO - Halbach Magnet Motor


Axial ux Halbach magnet array 40 pole ConMnuous power 5 kW Eciency 98% Motor OD 360 mm Motor axial length 43 mm Motor mass 6 kg

Used by Aurora in World Solar Challenges, including 1st in 1999

Marand/CSIRO Surface Magnet Motor


Axial ux Magnets on surface of steel plate

40 pole ConMnuous power 4 kW Eciency 97% Motor OD 355 mm Motor axial length 45 mm Motor mass 10 kg

Used by 2nd, 3rd, and 4th cars in World Solar Challenge 2009

h-p://innovaMon2012.com.au/wp-content/uploads/2012/04/Marcel-Kamp.pdf

Mitsuba In-Wheel Motor


Radial ux Surface magnet 32 pole ConMnuous power 5 kW Eciency 97% Motor OD 260 mm Motor axial length 60 mm

Used by Tokai University, in winning World Solar Challenge 2009, 2011

Prototype In-Wheel EV Motors

12 |

General Motors axial ux, two-sided surface magnets 500 Nm peak

Rahman et al., IEEE Trans. Industry Applica3ons 42, 1185-1192, 2006; and US Patent 7,262,536

CSIRO EV Research | Dr. Howard C. Lova-


Mitsubishi MIEV radial ux, external rotor, embedded magnets,

600 Nm peak

TM4 radial ux, external rotor, surface magnets,

670 Nm peak, 40 kg

Wikipedia

Protean Electric Protean Drive PD18


Radial ux, surface magnets Peak torque 800 Nm ConMnuous torque 500 Nm, liquid cooled

Motor OD 420 mm Motor axial length 115 mm Hence peak 50 kNm/m3 Total motor mass 31 kg (including inverter?) Tests suggest unsprung mass not so criMcal

ProducMon 2014, Liyang, China

Surface PM Motor

Pros (parMcularly Halbach, Iron-less) Smallest Lightest Most ecient

Cons Motor cost (lots of magnets) Electronics cost (no eld weakening)


Interior Permanent Magnet (IPM) Motors


Wrotorslot elimin th

Mexpracro

Inslot paradensdistrpromcomto as

Fig. integr

Fharmare harmlosseharmwellwavis sh

Fig. 2

LCNWincreby t

-0.25

0

0.25

0

T

-0.5

-0.25

0

0.25

0.5

0

Where () ir position in and pole co

minates periodihe minimizatio

III. ARMAMMF ( ) pressed as fluxss an airgap o

n this paper mopening wid

ameter that wisity produceributed windinminent fund

mponents as shssume that the

1. Airgap flux wral slot DW mode

ractional slomonic field w

not at synchmonic compoes in the core

monics varies l as the numbeeforms produ

hown in Fig.2.

2. Airgap harmon

Losses in the W are generaease in MMF the derivation

100

Tesla

0 100

Tesla

s flux producelectrical rad

ombination baicity between on of peak to p

ATURE REACTIproduced by x density prodof surface area

machine geomedth is kept ill affect MMed by armngs generate

damental wihown in Fig. 1e airgap field i

waveform and hel.

ot CNW howhere large amhronous frequonent terms cas well as thewith differen

er of winding uced by an 18-

ics generated by

IV. wider speed

ally higher asharmonics co

n of eddy cur

0

0.1

0.2

0.3

200

200

ced by magnedians. An appased on the the slots and

peak cogging t

ION AND MMFthe stator c

duced by the a (Arot) with re

[A

etry includingconstant. Th

MF across the mature reacti

airgap wavefoith low le1. Thus it is ais completely

harmonic spectru

owever, genemount of harmuency [9, 10create increa magnets. The

nt slot and polayers [15, 16

-slot, double-l

18-slot double-la

LOSSES d region becoms compared toontent. This rerrent equation

0

1

2

3

0

Tesla

F

0

0.1

0.2

0.3

0

Tesla

ets and () iropriate choicLCM method

d poles thus retorque amplitu

F HARMONICScoils is gene

stator (Bs) lieluctance (Rair

A] (4

g airgap lengthherefore the

airgap is theion. Integralforms containieakage harma common prasinusoidal.

um produced fro

erates a rotmonic compon0]. These leased eddy cue amount of ai

ole combinatio6]. The airgaplayer CNW m

ayer CNW

mes significao DW due toelation can be n from the M

25 5

Fundamental term

25

Fundamental term

s the ce of d [2] esults ude.

S erally inked ).

4)

h and only flux l-slot ing a

monic actice

om an

tating nents akage urrent irgap on as p flux model

ant in o the seen

MMF

prodFarabe s

Wthe speecom

Ianalperfhereslot,and

Fig. conce

Iturnconseffecachesampara

50

m

50

duced. This daday and Maximplified and

Where arpossibility of

ed in the fieldmponents prese

VIn this paper,lysis is used formance chare are 84-slo, double-layer3b respectivel

(a)3. Flux distribu

entrated windings

In this compans per phase, stant. A widects of increaseeve a wide CP

me rotor and ameters are sho

TRateRate

Number of serWindinWindin

Airgap lNumb

BasMaximum

StacRotor and sta

Saturation maLaminat

ConductivityConductivity o

MagMagnet rema

Conductivity

derivation canxwell equation

put in terms o

re the wavefof operation ind weakening ent at frequenc

V. METHOD, time-stepped

to determineracteristics [1t, double-laye

r, concentratedly.

ution of a) 84-s

arison, the stainput curren

e airgap lengted airgap harmPSR as shown

magnet graown in Table

TABLE I KEY MACed power ed current ries turns per phang diameter ng resistance length (IPM)

ber of poles se speed

m desired speed ck length ator core materiagnetization of stetion thickness y of core materialof sintered magnegnet type anent flux densityof magnet materi

n be seen in [ns, the eddy cuof the airgap fl

orms in fig. 1 n excess of tregion, there

cies of several

DS AND RESULd, transient fie the machin8]. The two

er, distributedd windings as

-slot, distributed

ator outer diant and airgap th was chosenmonics producn in [19]. In aade was useI.

CHINE PARAMETE

ase AWG

428428

l N. eel 1.6

l 1.6ets 62

Sintey ial 62

17]. By the uurrent equationflux waveform

[W] (5)

and fig. 2. Dten times the

will be harml kilohertz.

LTS inite element ne parameters

models compd windings ands shown in fi

(b)d windings b) 1

ameter, numblength were

n to overcomced by CNW aaddition to thaed. Key mac

ERS 1kW

4.25A 270turns

G 21 (d = 0.723mm42.0/km

1.2mm 14poles

8.571rpm (50Hz)85.71rpm (500Hz)

75mm O. Silicon Steel

69T (@5000A/m)0.35mm

695X106 (-m)-1

25X103 (-m)-1

ered NdFeB (8seg1.26T

25X103 (-m)-1

use of n can

ms.

Due to base

monic

(FE) s and pared d 18-ig. 3a

18-slot

ber of kept

me the and to at the chine

m)

)

)

g.)

This section will show the modeled andcircuit parameters of an 800W, 14-pole, 18-sCW-IPM machine (fig. 2).

(a) Fig. 2. 800W, 14-pole, 18-slot double layer CW-IPM m(b) Manufactured prototype.

A. Electromotive Force The measured and modeled back EMF w

800W prototype at 428RPM are shown in fig.

Fig. 3. Back EMF waveform produced by the 800W CW

It is shown in fig. 3 that the 18-slot, 14-pconfiguration produced a near-perfect sinuswaveform. Both the modeled line to line anback EMF values were very close to the (with a 1.9% error in terms of RMS qcompared to an equivalent DW FE model, thachieved were 0.960 and 0.942 for the modelvalues respectively (based on the assumptwinding factor is achieved in the DW model).

B. Cogging Torque Due to the high frequency fluctuat

fractional-slot distribution, the shape of thewaveform cannot be accurately measured. Tassisted in achieving the exact shape of the wa

Fig. 4 shows the measured peak points suthe achieved FE waveform.

VL-N(Measured) = 89Vrms VL-N(FEA) = 92Vrms

VL-L(FEAVL-L(Me

d measured open slot, double-layer

(b) machine (a) FE model,

waveforms for the . 3.

W-IPM prototype

pole, double layer soidal back EMF nd line to neutral measured values uantities). When e winding factors led and measured tion that a unity .

tion created by e cogging torque Thus FE analysis aveform. uperimposed with

Fig. 4. Measured peak cogging torque pointthe CW-IPM prototype machine

In a comparison made with machines [13], cogging torque prmachines a much lower cogging trated torque produced (1.54%(peak 7%(peak to peak) produced by a DW-Isegmented magnets and 21.7%(peak IPM machine with sintered non-segm

C. Inductance and Saliency RatioLd and Lq is measured by the AC

both the FE model and experimentaltwo quantities as well as the salienshown in fig. 5.

Fig. 5. Measured and modeled dq-axis induCW-IPM machine

It can be seen that while Ld measrelatively similar to that of the resulelement model (between 0.2% and Lq values were higher than the estim(between 3.3% and 13.4% error). mutual-inductance and second harmachine than the finite element mod

VI. CONCLUSION ANDThis paper has shown that w

double-layer configuration the follow A near-perfect sinusoidal wavef

factor. Much lower cogging torque com

machines. Low saliency ratio of about 1.13

It is also shown that the experimthe prototype tallies very closely wit

With desired open-circuit charac

A) = 157Vrms easured) = 154Vrms

ts and FE estimated waveform of

two other UNSW IPM roduced by the CW-IPM torque as a percentage of

k to peak) as compared to IPM machine with bonded to peak) produced by a DW-mented magnets).

o C standstill test method in l setup. The values of these ncy ratio versus current is

uctances and saliency ratio of the

sured from the prototype is lts obtained from the finite 4.4% error), the measured

mated values at all currents This is due to a higher

rmonic term in the actual del.

D DISCUSSION with the 14-pole, 18-slot, wing has been achieved: form with a high winding

mpared to similar sized DW

is achieved. mental results obtained from

th the FE results achieved. cteristics attained, a strong

This section will show the modeled andcircuit parameters of an 800W, 14-pole, 18-sCW-IPM machine (fig. 2).

(a) Fig. 2. 800W, 14-pole, 18-slot double layer CW-IPM m(b) Manufactured prototype.

A. Electromotive Force The measured and modeled back EMF w

800W prototype at 428RPM are shown in fig.

Fig. 3. Back EMF waveform produced by the 800W CW

It is shown in fig. 3 that the 18-slot, 14-pconfiguration produced a near-perfect sinuswaveform. Both the modeled line to line anback EMF values were very close to the (with a 1.9% error in terms of RMS qcompared to an equivalent DW FE model, thachieved were 0.960 and 0.942 for the modelvalues respectively (based on the assumptwinding factor is achieved in the DW model).

B. Cogging Torque Due to the high frequency fluctuat

fractional-slot distribution, the shape of thewaveform cannot be accurately measured. Tassisted in achieving the exact shape of the wa

Fig. 4 shows the measured peak points suthe achieved FE waveform.

VL-N(Measured) = 89Vrms VL-N(FEA) = 92Vrms

VL-L(FEAVL-L(Me

d measured open slot, double-layer

(b) machine (a) FE model,

waveforms for the . 3.

W-IPM prototype

pole, double layer soidal back EMF nd line to neutral measured values uantities). When e winding factors led and measured tion that a unity .

tion created by e cogging torque Thus FE analysis aveform. uperimposed with

Fig. 4. Measured peak cogging torque pointthe CW-IPM prototype machine

In a comparison made with machines [13], cogging torque prmachines a much lower cogging trated torque produced (1.54%(peak 7%(peak to peak) produced by a DW-Isegmented magnets and 21.7%(peak IPM machine with sintered non-segm

C. Inductance and Saliency RatioLd and Lq is measured by the AC

both the FE model and experimentaltwo quantities as well as the salienshown in fig. 5.

Fig. 5. Measured and modeled dq-axis induCW-IPM machine

It can be seen that while Ld measrelatively similar to that of the resulelement model (between 0.2% and Lq values were higher than the estim(between 3.3% and 13.4% error). mutual-inductance and second harmachine than the finite element mod

VI. CONCLUSION ANDThis paper has shown that w

double-layer configuration the follow A near-perfect sinusoidal wavef

factor. Much lower cogging torque com

machines. Low saliency ratio of about 1.13

It is also shown that the experimthe prototype tallies very closely wit

With desired open-circuit charac

A) = 157Vrms easured) = 154Vrms

ts and FE estimated waveform of

two other UNSW IPM roduced by the CW-IPM torque as a percentage of

k to peak) as compared to IPM machine with bonded to peak) produced by a DW-mented magnets).

o C standstill test method in l setup. The values of these ncy ratio versus current is

uctances and saliency ratio of the

sured from the prototype is lts obtained from the finite 4.4% error), the measured

mated values at all currents This is due to a higher

rmonic term in the actual del.

D DISCUSSION with the 14-pole, 18-slot, wing has been achieved: form with a high winding

mpared to similar sized DW

is achieved. mental results obtained from

th the FE results achieved. cteristics attained, a strong

Comparison of Concentrated and Distributed Windings in an IPM Machine for Field Weakening ApplicaMons Chong, Du-a, Quang Dai, Rahman (UNSW), and Lova- (CSIRO)

Experimental VericaMon of Open Circuit Parameters of an IPM Machine with Concentrated Windings Chong, Du-a, Xiao, Rahman (UNSW), and Lova- (CSIRO)

Interior PM Motors

Pros Field weakening Reduced magnet volume

Cons SMll uses considerable magnet material

Weight Volume


Transverse Flux (TF) Motor?


Current

MoMon

Genesis:

Other TFM Patents


Bosch, WO 90/09697 Rolls Royce, US 5,886,449


Nissan/Renault, US 2007/0164628

Daimler-Chrysler Rail Systems, US 6,236,131

Servax TFM TorqueChampion


Up to 75 Nm peak

www.servax.com

CSIRO EV Research | Dr. Howard C. Lova-

22 |

TFM Example Parameter Value Wanted continuous torque (Nm)

400 210

peak torque (Nm) 600 420 active mass (kg) 14 15 active OD (mm) 270 340 active length (mm) 125 75

peak volume torque density (kNm/m3)

84, active parts

62, over all volume

peak mass torque density (Nm/kg)

43, active parts

28, over all mass

speed, power factor, inductance

not stated

Weh H., May H., & Shalaby M., InternaMonal Conf. on Electrical Machines, Cambridge USA, 13-15 Aug 1990, 1040-1045

In-Wheel Motors | Peter A. Wa-erson


TFM Advantages Disadvantages High torque density

proporMonal to pole number Low magnet mass, hence low material cost

Simple, cheap winding just one coil per phase

High inductance enabling ux weakening for constant power range

Many poles and many parts to assemble

Less robust to vibraMon Low rigidity may imply higher noise

Inductance can be too high Low eciency

Switched Reluctance (SR) Motor?

Advantages: Low cost no magnets Robust High temperature Good eld weakening

Disadvantages: Lower torque density


A typical SR motor

An SR In-Wheel Motor CSIRO/Latrobe/Swinburne/VPAC/AutoCRC Axial ux, two airgaps Goal peak torque 425 Nm Goal motor mass 25 kg Under development Details

Lova- H.C. et al., 37th Annual Conf. of the IEEE Industrial Electronics Society, 7-10 Nov. 2011, Melbourne, Australia


(not nal dimensions)

Conclusions


CollaboraMon PossibiliMes (AutoCRC, ARC, Tax IncenMves, Grants)

Direct-Drive, In-Wheel Motors Surface PM Motor (cost++) Interior PM Motor (cost and mass) Transverse Flux Machine (research) Switched Reluctance Motor (mass)

CSIRO Materials Science and Engineering Dr. Howard C. Lova- Team Leader Electrical Machines t +61 2 9413 7412 m +61 419 971 263 e [email protected] w www.csiro.au/science/ElectricMachines.html

CSIRO MATERIALS SCIENCE AND ENGINEERING

Thank you

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