Basics of power electronics and

electric motors for hybrid and

electric vehicles

D.Sc. Tatiana Minav

Tatiana Minav
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CS Introdu CS Introdu
ction
term
Final Se
ction CS 7 submi
1&2 CS Matlab 4 CS Sim CS Sim Sim paper mi
Simuli ssion submis
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After After After After

Quiz Quiz Quiz Quiz
1&2 3 4 5

Pre- Pre- Pre- Pre-

Quiz Quiz Quiz Quiz

Calc.
ex 1

Calculus ex. 2

Calculus ex. 3

simulation ex. 1 deadline 22.3.2017

Writing paper in group

Learning objectives

Understand basic working principles of

Electric Machines (EM)
Know Electric machines types
Able to choose suitbale EM for application
Learn more Frequency converters

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Advantages of a electric motor in hybrid
driveline
Engine + motor = allows:
Smaller engine => less pollution
Blue motion => reduce engine idling when stopped

The vehicle uses regenerative braking and the internal combustion

engine to charge the energy storage

Electric motor used as a generator and storing the captured energy in

the battery.

Extra power during acceleration

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EM Four-Quadrant Operation

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Various Electric Machines

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 Electric Machines (EM)

DC Machines

Induction Machines

Permanent Magnet Machines

Switched Reluctance Machines

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 DC Machine

Widely used and simple electric motor

Technologically mature and simple to control

Operation principle:
F = BIL
T = BIL cos α

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Animation-DC motor

http://www.youtube.com/watch?v=Gzca2CbZ6EM

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Properties of DC Machine
Traditionally used in traction applications
– Trains, trams, electric cars
Only fully controllable EM before power electronics
~70’s
Phased out (in big power levels) due to wear of
commutator
– Commutator and slip ring brushes connects magnetization
circuit to rotor coils
• Increases need of maintenance
Low efficiency compared to other electric machines

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Induction Machine (IM)
• The most common

• In traction applications
usually ”squirrel-cage”

• Magnetization current is fed

by an inverter

• Slip (asynchronous machine)

• Simple and robust

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Animation

• http://www.youtube.com/watch?v=LtJoJBUSe28
Characteristics of Induction Machine
Benefits
Reliable and robust
Low maintenance, low cost and capability to operate in
extreme conditions
The most mature technology of AC machines

Drawbacks
High loss => relatively low efficiency
Low power factor
Low inverter using factor (overdimensioned inverter)
Losses in rotor (cooling problem in mobile applications)

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Operation modes of Induction machine

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Permanent magnet
machines (PM)
Permanent magnet rotor
– Axial flux rotor ------ >
– Radial flux rotor

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Animation

http://www.youtube.com/watch?v=H97HpwZNqZI
http://www.youtube.com/watch?v=ZAY5JInyHXY
https://www.youtube.com/watch?v=bCEiOnuODac

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 Permanent-Magnet Rotor Configuration
Affects to T-w Characteristics
• PRM Permanent-Magnet Assisted Reluctance Synchronous Machine
• RM Variable Reluctance Machine
• SPM Surface Permanent-Magnet Synchronous Machine
• IPM Interior Permanent-Magnet Synchronous Machine
• MR-PM Magnetic-ring Permanent-Magnet Machine

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M. Arata, N. Takahashi, K. Sakai, K. Hagiwara, T. Araki, Large Torque and High Efficiency
Permanent Magnet Reluctance Motor for A Hybrid Truck, EVS-22 Yokohama Japan, 2006
Characteristics of Permanent Magnet Machines
Advantages:
– Higher efficiency than in asynchronous machine
– Smaller apparent power rating for inverter
– Smaller and lighter design

Disadvantages
– More expensive than asynchronous or switched reluctance
machines
– Magnetic material & manufacturing technique

Torque is produced by
– Permanent magnets
– Reluctance

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Switched Reluctance Machine (SRM)
Wide speed operation area
wmax = 6 to 8 times wnom
Simple and robust
Iron core and air resistance losses in the
rotor machines

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R. Krishnan, Switched reluctance motor Drives; Modeling, Simulation, Analysis, Design, and
Applications, CRC Press, London, 2001
Switched Reluctance Machine (SRM)
http://www.freescale.com/webapp/sps/site/overview.jsp?c
ode=WBT_MOTORSRTUT_WP

SRM does not contain any permanent magnets.

The stator is similar to a brushless dc motor.
The rotor consists only of iron laminates.

The iron rotor is attracted to the energized stator pole. The

polarity of the stator pole does not matter.

Torque is produced as a result of the attraction between

the electromagnet and the iron rotor.

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Characteristics of the Switched
Reluctance Machine
Benefits
– Simple and rugged structure
– Fault-tolerant operation
– Simple control
– Very good torque-speed
characteristics
Drawbacks
– Acoustic noise
– Torque and current ripple
– Special converter topology
– Electromagnetic interference

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Switched Reluctance Machine with
Integrated Flywheel and Clutch

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Best attributes of electric machines
Robust and simple:
– Induction machine
– Switched reluctance machine (SRM)

Low cost
– Induction machine
– (SRM in the future)

Efficient
– Permanent magnet machines

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Comparison of electric machines
Great torque-speed characteristics
– Switched reluctance machine

Weight, Size à Power density

– Permanent magnet machines

Controllability-> applicable to vehicle applications

– DC-machine
– Induction machine
– PM machine

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Weaknesses in usefulness point of view

Short speed-operation range of permanent magnet

machines
– Need of gearbox if used in high speed vehicles

Limited availability of switched reluctance machines

Price:
– small market -> small production -> high cost

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Typical Efficiency Characteristics of HEV
Traction Motors
Accurate efficiency values depend from power, voltage ratings and
machine type
– Maximum efficiency usually around 90 to 95 %

Asynchronous machine Switched reluctance

machine

Surface-permanent
magnet machine Interior-permanent
magnet machine

26 S.S.Williamson, S.M.Lukic, A.Emadi, Comprehensive Drive Train Efficiency Analysis of Hybrid

Electric and Fuel Cell Vehicles Based on Motor-Controller Efficiency Modeling, IEEE Trans.
Power Electron., vol. 21, no. 3, pp. 730-740, May 2006
Research example:
Near-wheel motor (LUT)
The designed PMSM rotor structure comprises two
permanent magnet layers embedded inside the rotor
laminations. The PMSM can produce nominal torque
with the nominal current in a wide speed range. the
nominal torque is 240 Nm.

Tatiana Minav
Source: ICEM 2012 J.Nerg, Design of Direct-Driven Permanent Magnet Synchronous Motors for an Electric Sports
Car
 In-wheel motor/ hub motor
Like so many things, in-wheel motors have
already been done, but technology and our
ability to integrate them into wheels has
changed a lot since the first in-wheel motor
(also called a hub motor) was patented back in
1884 and, after disappearing for decades, they
are starting to creep back into vehicle.

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In-wheel motor
High-efficiency
Direct drive
Regenerative braking
Integration
No transmission or drive shafts

Example: Protean electronics:

-built-in inverter and control electronics

https://www.youtube.com/watch?v=2wP4F8MDuqw
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Source: http://www.proteanelectric.com/wp-content/uploads/2011/12/2012_HTUF_-_Hybrid-Retrofit_Opportunities1.pdf

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MOTOR CONTROL

Torque control in wide speed range

Speed control
Position control

POWER ELECTRONICS is required for motor control

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Related Topics

Electric Drives
– control of drives, choice of motor and converter
Industrial Electronics
– electronics, signal processing, measurement techniques, soft
computing
Electromechanics
Control engineering
Electromagnetics
Power Systems

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Electrical drive is:
Block diagram that illustrates the
principle of an electrical drive:

The input of an electrical drive

comprises electrical power and
operation reference.

The output is the mechanical

power given by the drive to the
load.

In principle, an electrical drive

comprises four parts: power
electronics, an electrical motor,
measuring equipment and a
controller

Lecture notes J. Pyrhönen, Electric drives

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Control of DC Machine

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Vector Control of AC Machines

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What is Power Electronics (PE) ?
Efficient use of electric drives and energy storages
Controllable current-voltage ratio
Electric has small inertia
Power electronic systems convert supply’s electric energy
into a form suitable for the load
DC to variable AC
– E.g. from battery to electric machine, and
AC to DC
– E.g. regenerative braking
– E.g. from generator to energy storage or DC link
DC to DC
– E.g. from battery to high voltage DC link

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Classification of Power Processors and
Converters

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 Power Electronics (PE)
Enabling technology for electric and hybrid vehicles
High efficiency in wide operation area
Control of electric machines
Motor and generator operation modes
– Regenerative braking
Challenges
– Cost -> Manufacturing
– Cooling -> size, lifetime
• Semiconductors max temperature 120 – 175 degC
– Need for additional cooling circuit

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Challenges in Power Electronics
High efficiency (low losses)
– power losses convert into heat, which yields to excessive
cooling and thermal sizing of components
– price of electric energy and cooling system
Small size of products
– high efficiency is crucial
• cooling elements are bulky and heavy
– packaging density, integration of power and control components
Competitive price

2nd gen. 3rd gen.

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What are Prius converters made of…

IGBT

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What are little inverter made of…

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What are little converters made of…

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Example: AC Motor Drive
Converter 1 rectifies line-frequency AC into DC
Capacitor acts as a filter and decouples the two converter circuits

Converter 2 produces variable-frequency AC for the motor

Polarity of DC voltage link remains unchanged

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DC–DC Converters

DC–DC converters are used in

– Between different DC voltage levels (e.g. energy storage and
regulated DC-link)
– Power supplies
– DC motor drives

The aim is to provide precisely controlled output voltage or

current

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DC–DC Converters

Single quadrant
– one active switch, one diode, inductance and smoothing
capacitance
– Buck, step down, vout ≤ vin
– Boost, step up, vout ≥ vin
– Buck-boost, combination
Two quadrant
– E.g. bidirectional boost converter
Four quadrant

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DC–DC Converter Applications in Vehicle
Environment
Battery charger / energy storage converter
Fuel cell converter
Heaters
Power supplies for
– control electronics
– auxiliary devices

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AC-DC RECTIFIERS AND DC-AC
INVERTERS are used in
Traction motor control
Generator control (engine series-hybrids)
Other AC-supplies
– Pumps
– Fans

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1-phase inverter

http://www.ipes.ethz.ch/ipes/e_index.html
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Four-Quadrant Converter (DC drive)

http://www.ipes.ethz.ch/ipes/MaschineDC/e_kreis.html

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Research example:
Electrical Transmission/Gear box
Conventional Gearbox is used to slow down the output
speed and increase torque.

In conventional car internal combustion engine typically

operate over a range of 600 to 7000 rpm, while the car's
wheels rotate between 0 rpm and around 1800 rpm.

T.A.Minav
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Transmission/Gear box

Electric equivalent

Dynamic machine operation

envelops electric torque
versus mechanical speed

a) b)
U U
a) Parallel connection
U of phases,
U
V b) series connection of
W
V phases

T.A.Minav
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Electrciacl Transmission/Gear box

non-salient permanent magnet

synchronous machine (PMSM)
with six phases of which three sets
of each two phases are driven with
the same current
This results in a balanced three-
phase machine structure

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Full-bridge is used for controlling this
6-phase PMSM machine

Schematic representation of the two coils per phase, full-bridge per coil
circuit capable of driving the coils individually or connected in series.

T.A.Minav
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Conclusion

Now you Know:

• what is EM
• What kind type of EM are available
• what controls EM

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Homework 1 (submit your answer before 6.3.2017 23.55)
Group 1: Batteries: Lead acid
Group 2: Batteries: Lithium
Group 3: Super capacitor
Group 4: Fuel cell
Group 5: Flywheel
Group 6: Hydraulic accumulator

read articles according to your group number and answer questions:

1. Advantages and Disadvantages of energy storage?
2. Price of energy storage? Availability on the market?
3. Possible applications? limitations?

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Homework 2

After lecture Quiz 3 submit your answer before 1.3.2017 23.55

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Homework 3

Calculation Exercises 2 available in MyCourses page

return before 6.3.2017 23.55

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Homework 4

Start writing and actively working on your paper!

– Deadline 1 March for topic selection
– Form a group(3-6 persons)!

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