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Through analytical equations followed by a systematic optimization study using high-fidelity finite-element (FE) models, the torque capability of three common synchronous machine technologies—namely, a permanent magnet (PM) synchronous machine (PMSM) with V-shaped rare-earth rotor magnets, a PMSM with deep V-shaped ferrite rotor magnets, and a synchronous reluctance machine (SynRM) with four layers of conforming flux barriers are compared for an application in a 48-V mild hybrid electric car. The optimization of the deep V-shaped ferrite PMSM automatically resulted in a spoke-type PM layout for maximum torque production. Yet, an optimized SynRM with conforming flux barriers was achieved that could produce a higher torque than ferrite PMSM. One machine technology is selected and six variants of it, with two rotor PM layouts each with three alternative pole-slot combinations, are subsequently subjected to a large-scale FE model-based drive-cycle design optimization. Various pole-slot combinations are methodically compared in terms of drive-cycle losses, active material cost, torque ripple, and PM demagnetization level. More than 20 000 designs were analyzed over ten energy-centric torque-speed points to identify an optimal design solution. The results of multiphysics analysis incorporating electromagnetics, computational fluid dynamics, and structural analyses are provided, including a study on three different water jacket concepts. A final design is prototyped and primary experimental results are provided. [ABSTRACT FROM AUTHOR]

Develops an analytical approach based on a two-dimensional electromagnetic field to predict the inverter high frequency pulse width modulation (PWM) switching caused electric eddy-current losses in a permanent magnet brushless direct current motor. Significance of the ability to predict the performance and losses of the motor; Estimation of PWM switching ripples; Conclusion.

Presents a method for integrating a moving magnet relative velocity sensor directly into the shock absorber of a vehicle. Description of the integrated relative velocity sensor; Sensitivity to key design parameters; Self-energizing feature of the sensor.

Three stator cooling jacket concepts, including a new cooling jacket concept with parallel straight spiral channels, are evaluated for electric machine of mild hybrid electric car. Steady-state cooling jacket thermal flow analysis and transient-state full motor simulations with circumferential, axial, and spiral jacket concepts are carried out to predict their heat transfer performance and temperature distribution. A prototype motor has been made with the new jacket concept. Infrared thermography is performed to detect the transient temperature distribution of the motor stator windings and laminations for validation of the thermal flow analysis. [ABSTRACT FROM AUTHOR]

A large-scale finite element model-based design optimization algorithm is developed for improving the drive-cycle efficiency of permanent magnet (PM) synchronous machines with wide operating ranges such as those used in traction propulsion motors. The load operating cycle is efficiently modeled by using a systematic k-means clustering method to identify the operating points representing the high-energy-throughput zones in the torque–speed plane. The machine performance is evaluated over these cyclic representative points using a recently introduced computationally efficient finite element analysis, which is upgraded to include both constant torque and field-weakening operations in the evaluation of the machine performance metrics. In contrast with the common practice, which aims at enhancing the rated performance, the entire range of operation is considered in the present design optimization method. Practical operational constraints imposed by the voltage and current limits of the motor-drive system, excessive PM demagnetization, and torque ripple are accounted for during the optimization process. The convergence to the optimal design solutions is expedited by utilizing a new stochastic optimizer. The developed design algorithm is applicable to any configuration of sinewave-drive PM and synchronous reluctance motors over any conceivable load profile. Its effectiveness is demonstrated by optimizing the well-established benchmark design represented by the Toyota Prius Gen. 2 interior PM motor configuration over a compound operating cycle consisting of common U.S. driving schedules. Multiphysics electromagnetic, thermal, and mechanical performance of the optimized design solutions is discussed in a postdesign optimization stage. [ABSTRACT FROM PUBLISHER]

Future automobiles will be equipped with x-by-wire systems to improve reliability, safety, and performance. The fault-tolerant capability of these systems is crucial due to their safety critical nature. Three fault-tolerant inverter topologies for permanent magnet brushless direct current motor drives suitable for automotive x-by-wire systems are analyzed. A figure of merit taking into account both cost and postfault performance is developed for these drives. Simulation results of the two most promising topologies for various inverter faults are presented. The drive topology with the highest postfault performance and cost effectiveness is built and evaluated experimentally. [ABSTRACT FROM AUTHOR]

The demand for increased power and improved fuel economy are driving changes in alternator technology for automotive applications. To meet these demands requires a drive system with capabilities of torque assist, regenerative braking and power generation to supply vehicle loads while keeping the battery charged. Furthermore, to minimize add-on cost, the system must be air-cooled with minimal changes to the vehicle hardware and operate at 12 V with the same or smaller packaging footprint of the current alternator. In this paper, a low cost 12 V, 4 kW air-cooled permanent magnet-assisted synchronous reluctance machine drive system for a micro-hybrid vehicle is presented. The design and analysis in terms of machine, inverter, controller, and control algorithm are discussed in detail. Thermal performance of the system under different operating conditions, which is another key aspect for the harsh environment application, is also studied. Fuel economy analysis of the proposed low-cost micro-hybrid system for a Segment B vehicle shows significant reduction in fuel consumption resulting in a direct benefit to the customer. Finally, a prototype drive system was built and tested and found to meet the cost, performance, and packaging requirements. [ABSTRACT FROM AUTHOR]

Performance improvement of permanent magnet (PM) motors through optimization techniques has been widely investigated in the literature. Oftentimes the practice of design optimization leads to derivation/interpretation of optimal scaling rules of PM motors for a particular loading condition. This paper demonstrates how these derivations vary with respect to the machine ampere loading and ferrous core saturation level. A parallel sensitivity analysis using a second-order response surface methodology followed by a large-scale design optimization based on evolutionary algorithms are pursued in order to establish the variation of the relationships between the main design parameters and the performance characteristics with respect to the ampere loading and magnetic core saturation levels prevalent in the naturally cooled, fan-cooled, and liquid-cooled machines. For this purpose, a finite-element-based platform with a full account of complex geometry, magnetic core nonlinearities, and stator and rotor losses is used. Four main performance metrics including active material cost, power losses, torque ripple, and rotor PM demagnetization are investigated for two generic industrial PM motors with distributed and concentrated windings with subsequent conclusions drawn based on the results. [ABSTRACT FROM PUBLISHER]

Large-scale design optimization of electric machines is oftentimes practiced to achieve a set of objectives, such as the minimization of cost and power loss, under a set of constraints, such as maximum permissible torque ripple. Accordingly, the design optimization of electric machines can be regarded as a constrained optimization problem (COP). Evolutionary algorithms (EAs) used in the design optimization of electric machines including differential evolution (DE), which has received considerable attention during recent years, are unconstrained optimization methods that need additional mechanisms to handle COPs. In this paper, a new optimization algorithm that features combined multi-objective optimization with differential evolution (CMODE) has been developed and implemented in the design optimization of electric machines. A thorough comparison is conducted between the two counterpart optimization algorithms, CMODE and DE, to demonstrate CMODE’s superiority in terms of convergence rate, diversity and high definition of the resulting Pareto fronts, and its more effective constraint handling. More importantly, CMODE requires a lesser number of simultaneous processing units which makes its implementation best suited for state-of-the-art desktop computers reducing the need for high-performance computing systems and associated software licenses. [ABSTRACT FROM PUBLISHER]

A numerical prediction of electromagnetic interference (EMI) allows evaluation of EMI performances at the design stage and before prototyping. It can also help reduce the post-prototype electromagnetic compatibility cost by minimizing late redesign and modifications of a drive implementation. This paper describes two simulation approaches with time- and frequency-domain simulations and verifies them with experimental results. Both time- and frequency-domain simulation approaches are found effective as long as the noise source and propagation path are properly modeled. The three-dimensional (3-D) finite-element- analysis (FEA)-based parasitic parameter extraction tool—Ansoft Spicelink has been used substantially. To gain additional degree of confidence, the results obtained from FEA are verified with closed-form solutions and actual measurements. [ABSTRACT FROM AUTHOR]

The paper presents methodologies to detect and locate short-circuit faults on the stator winding of VSI-fed PM brushless dc motors. Normal performance characteristics of the motor are obtained through a discrete-time lumped-parameter network model. The model is modified to accommodate short- circuit faults in order to simulate faulty operation. Fault signatures are extracted from the waveforms of electromagnetic torque and phase-voltage summation using wavelet transform. Three independent detection techniques are introduced. Experimental measurements agree acceptably with simulation results, and validate the proposed methods. This work sets forth the fundamentals of an automatic fault detector and locator, which can be used in a fault-tolerant drive. [ABSTRACT FROM AUTHOR]

In this paper, a 12-V 1-kW permanent-magnet ac motor drive is tested extensively at a wide frequency range, and the frequency spectra are partitioned for identification of noise sources and their propagation paths. Switching characterization of the power MOSFET and its body diode reverse-recovery characterization are evaluated for circuit modeling. The parasitic components and common mode path are identified and measured with the time-domain reflectometry (TDR) method. The inverter circuit model is then constructed with major parasitic inductance and capacitance in device modules, passive components, leads, and interconnects. To verify the validity of the inverter model, a comparative study is performed with computer simulations and hardware experiments. The fundamental mechanisms by which the electromagnetic interference (EMI) noises are excited and propagated are analyzed, and the significant roles of parasitic elements coupling with device switching dynamics in EMI generation are examined. The results indicate that the identification of parasitic inductance through TDR measurement helps verify the voltage spike during turn-off, or vice versa. The conducted EMI noise caused by parasitic components of bus capacitor, dc bus, and devices is proven to be identifiable with the characterization and simulation techniques used in this paper. [ABSTRACT FROM AUTHOR]