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Challenges for Electric Machines and Power Electronics in

Automotive Applications
Hector Zelaya De La Parra, Freddy Magnussen, Sjoerd Bosga
ABB Corporate Research
721 78 Vasteras, Sweden
E-mail: hector.zelaya@se.abb.com

Abstract: The paper is a review of the motor and drives developments in the automotive industry
related to electric and hybrid electric vehicles. The main challenges that the automotive industry faces
in the future are outlined highlighting the technological changes that are required to achieve the
targets of low cost, high power density and high ambient temperature.

Keywords: Hybrid electric vehicles; powertrains; electrical machines; power electronics.

1. Introduction electric vehicle, with both a conventional as


well as an electric drive-train, is a natural
A normal vehicle of today is equipped with an candidate for making the transition from the
internal combustion engine that runs on either conventional car towards the car of the future.
gasoline or diesel produced from oil. In all
In the late 1890’s electric vehicles (EV)
types of combustion processes carbon dioxide
outsold petrol engine cars ten to one, but due
emissions are produced, irrespective of
to technological limitations and the absence of
whether the fuels are based on fossil or
transistor-based converters the top speed of
renewable resources. Combustion of fossil
these early EVs was limited to about 30 km/h.
fuels increases the contamination of carbon
The introduction of volume production of
dioxide in the atmosphere. Fossil fuels are
petrol engine cars and the lack of electricity
taken from oil-, gas- and coal-reserves that are
infrastructure outside city boundaries quickly
million of years old and are obviously not
declined the availability of EVs in the market.
naturally part in an environmental cycle with a
In the early 1970’s there was a re-birth of the
short time span [1]. Burning of fuels that come
EV due to concern of pollution and the oil
from renewable energy sources is not regarded
embargo. In the early 1990’s a few car
to increase the amount of CO2 in the
manufacturers resumed the production of EVs
atmosphere, since the biomass is bounding an
(low volume) prompted by the California ZEV
equivalent amount of carbon dioxide during its
mandate. The mandate was weakened over the
growth. An increased contamination of CO2 in
years and this eventually stopped the
the atmosphere contributes to global warming
production of several EVs, like the GM EV1,
due to the green house effect, and has a
Ford Electric Ranger pickup and Toyota
dramatic influence on life on earth. The
RAV4-EV.
transport sector accounts for a considerable
part of the total green house gas emissions and
2. Automotive powertrains and
needs to change energy conversion methods
applications
into sustainable solutions. The fuel cell electric
and battery electric vehicles, are zero emission A. Commercial HEV market
vehicles (ZEV), and are sustainable transport
solutions, if the stored electric energy and The first commercial hybrid electric vehicle
hydrogen are produced with renewable energy, (HEV) was introduced in 1997 at the Tokyo
and regarded as cars for the future. The hybrid Auto Show by Toyota with the first version of
the Prius. At present the automotive market is
making rapid developments and there are a
number of commercially available HEVs
which include the Toyota Prius, Toyota Camry
Hybrid, Honda Civic Hybrid, Toyota
Highlander Hybrid, Ford Escape Hybrid,
Lexus RX 400h (Toyota), Nissan Altima
Hybrid, Saturn Vue Hybrid (GM), Mercury
Mariner Hybrid (Ford), Honda Accord Hybrid,
Figure 1: The GM Volt plug-in hybrid concept car.
Lexus GS 450h and Lexus LS 600h.
In Europe:
The electric system in automobiles has seen a
230 V AC, 10A (~1,8 kW) on board charger
continuous increase in vehicular power
400 V AC, 16A (~8,5 kW) external charger
requirement. Its voltage level started with a 6-
400 V AC, 30 A (~16 kW) on board charger
V system and at the beginning of the last
for larger vehicles (buses)
century to satisfy the demands of ignition,
cranking, and few lighting loads. More 2) Motor Power: Since PHEVs have a wider
complex loads that include power steering, and range of electric-only operation the
electric driven systems will force the present requirement in motor power is greater than that
day 12-V level to switch over to much higher for a HEV. A typical requirement for a family
voltage levels of 42 V, 300 V, or higher. The car is 50 kW, whereas for a bus it would be
rate of increase of automotive electric loads for 200 kW.
auxiliary equipment is assumed to be about 4% 3) Battery Capacity: The battery energy
per year. capacity for a PHEV car is 15 kWh and for a
bus it is 75 kWh.
B. Plug-in hybrid electric vehicle (PHEV)
C. HEV volumes and main players
In addition to the traditional architectures in
HEVs, i.e. series, parallel and power split, a HEV have been a niche market in Europe over
tremendous increase in the research activity of the last few years, with a penetration rate of
plug-in hybrids (PHEV) has been seen from less than 0,5%, regular diesel and petrol engine
2006 onwards, as exemplified with the GM vehicles still dominating the market. The main
Volt in Figure 1. The technological players in the HEV European market are:
implications of the development of PHEV can
• Toyota with its different variants of full
be summarized as follows:
hybrids (~100 kW).
• Combination of evolutionary and • PSA Group with the micro hybrids
revolutionary (~6kW)
• Increments on hybrid powertrains • Honda with mild hybrids (~12 kW)
• Ground-up designs
In the US the total demand for HEVs in 2007
• Reliance on Li Ion battery technology
was around 355 000 units and it is expected
• Diversity of energy management (according to Morgan Stanley Research) that it
strategies (electric-only vs. blended) will reach 1,2 million units by 2015. The main
As far as power electronics is concerned, there contenders could be GM with the Volt and of
are three main implications in the PHEV course Toyota with the Prius. In another
development: charging requirements, motor forecast analysis by The Freedonia Group, Inc.
power and battery capacity: (Cleveland, Ohio), the worldwide demand for
HEVs will be an estimated 1,6 million in 2010
1) PHEV technologies require charging and by 2015 it will have reached 4 million
converters integrated with the propulsion HEVs. According to this forecast, 68% of the
system. Although plug-in hybrids require expected demand will be in the US, 20% in
relatively low power charging, there is a wide Asia Pacific and 12% in other regions.
range of options that need to be fulfilled, for
instance: 3. State of the art in electric
In the USA: powertrains
120 V AC, 15 A (~1,4 kW)
120 V AC, 20 A (~1,8 kW) A. Electric machines
208 V AC, 30 A (~8,3 kW) The ideal machine operating diagram for any
vehicle is given in Figure 2. In the start-up
phase from standstill the machine torque speed ratio of roughly 3 [2]. The speed profile
should be high and constant in order to enable is characteristic for induction machines, which
a fast and smooth acceleration. When the has a limited upper speed in the constant
maximum rated power of the system is power region, and if wider constant power
reached, then the machine should deliver regions are needed then normally other electric
constant power until the maximum continuous machine types must be chosen, or the inverter
speed of the vehicle is reached without needs to be oversized. The same phenomenon
interruptive gear shifts. Finally, an over speed is also characteristic for synchronous
or high speed region with reduced power reluctance machines and switched reluctance
requirements should be available for safety machines, which similar to the induction
reasons regarding highway driving and machine are robust machine types without the
component mechanics. An internal combustion need of permanent magnets. The maximum
engine does not have these operating torque in the high speed region for all these
characteristics, since the engine does not three machine types is inversely proportional
produce adequate torque at low revolutions to the square of the speed. The peak torque
and the constant power region is very narrow, density at rated speed is 7,2 Nm/kg for the air
like a peak, which means that a multi-step gear cooled motor in the Tesla Roadster [2]. The
box is required as a supporting transmission continuous torque density is not specified, but
component, as illustrated in Figure 2. is normally around half of the peak value in
However, an electric machine can be designed this application. The continuous torque density
for the described performance characteristics of industrial induction motors in similar size is
with a gearless or a simple single step for comparison around 1,0 Nm/kg, but
transmission. The gearless direct-drive industrial motors normally run at lower
solution can be favourable using distributed in- temperature rise, have longer required lifetime,
wheel machinery, while the single step and is governed by many industrial standards.
solution is preferred in classical configurations
The state-of-the-art electric machine type used
for weight reasons. The width of the constant
in electric and hybrid electric vehicles is the
power region, or field-weakening region for
permanent magnet machine. The machine type
electric machines, depends on the required
is today totally dominating this market and is
performance of the corresponding vehicle and
used in the most popular commercial hybrid
also on the used transmission. Electric vehicles
electric vehicles like in the twelve named
with single step transmissions normally require
vehicles in section 2A. The combined annual
the widest constant power region, which
sales volume in 2007 of these twelve vehicles
typically has a speed ratio n2/n1 of up to four
in ranked order in the USA, which is by far the
(see Figure 2 for parameter definition). The
biggest market, is more than 352 000 [3].
base requirements of electric machines for
Toyota sold almost 278 000 in the USA and a
electric or hybrid electric vehicles are
total of 429 000 hybrid vehicles globally [4].
competitive cost, low weight and volume, high
fault-tolerance, wide field-weakening range,
high energy efficiency and high power factor.
The requirements should enable a vehicle
which has qualities like acceptable price,
compact, reliable, simple transmission, long
driving range and low inverter rating,
respectively.
One machine type candidate is the induction
machine, which for instance is used in the
battery electric vehicles Tesla Roadster and
Think, (see Figure 3) and was also used in the Figure 2: The ideal machine power operating
obsolete GM EV1 and Ford Electric Ranger diagram for any vehicle is shown, where the first
pickup. The induction motor in the battery axis represents the machine speed for using a single
powered electric super sports car Tesla step transmission system, which is directly
Roadster has for instance a maximum power of proportional to the vehicle speed. The typical
185 kW in the speed region 4 500-8 500 r/min, power output from an internal combustion engine
and a maximum speed of 14 000 r/min, giving for different gear steps is illustrated by the
a constant power range speed ratio of almost numbered curves.
two, followed by a maximum speed to rated
B. Drives
In all available applications of electric and
hybrid electric vehicles, the drive system
controlling the motor consists of a voltage
source inverter (VSI).
Figure 3: The battery electric cars Tesla Roadster
(left) and Think City (right). DC Voltage and Semiconductor Technology
The permanent magnet (PM) machine is the The DC voltage level varies quite considerable
preferred type in powertrains for hybrid depending on the size of the EV or HEV. The
electric vehicles of today, because of its high so called commuter cars like the Tango T600
torque density, potentially wide constant or Think City with a voltage level of 230 to
power range, and relatively small required 370 V. On the other hand, a HEV like the
inverter rating. The peak specific torque Prius, use a booster to increase the DC voltage
density is 8,9 Nm/kg for the electric motor in to 600 V with the obvious advantage of
the Toyota Prius and 10,0 Nm/kg in the Toyota reducing the burden on the motor by lower
Camry Hybrid, while their continuous specific field weakening requirements.
torque densities are 3,6 Nm/kg and 4,8 Nm/kg,
respectively. The constructions are based on In most cases the power electronics are liquid
interior permanent magnet machine designs cooled with a mixture of ethylene glycol and
with eight poles and distributed overlapping water (60:40). The inlet temperature is around
windings in 48 slots. The end-windings are 70°C and typical ambient temperatures in the
effectively cooled by oil spray in addition to electronics are between 70-80°C.
the water cooled housings [3, 5-7]. Unlike for
the earlier described machine types, the Power Output and Power Density
permanent magnet machine type can be A very good example of a powerful converter
designed for a theoretically infinitely wide used in an EV, is the Zilla Z2k used in the
constant power range, only practically limited Tango T600. This converter is capable of
by thermal and mechanical factors. The delivering 2000 A at 50°C heat sink
machine type is also very flexible in temperature (coolant temperature). The
construction, and can be designed with many continuous power at the same temperature is
pole numbers, with different air gap flux 192 kW with a peak power of 640 kW; this
directions like radial, axial or transversal flux, gives an overload capacity of 3,3 times the
or with different winding types like distributed nominal value for 2 minutes (common in most
or concentrated windings [8-9]. The Honda EV converters). The power density of this
Civic is equipped with one PM machine with converter is 25 kW/litre (calculated at
concentrated windings for its parallel HEV continuous power).
system. Characteristic feature of this machine
is short axial build through short end- The overload capacity for the Prius is 1,8 times
windings. The machine topology is a the nominal value for 18 seconds and the
crankshaft mounted integrated starter power density is 1,7 kW/litre (for one motor
generator (ISG), which has very high diameter drive and continuous power). The booster
to length ratio requirements regarding space. converter (DC to DC) which has become an
The concentrated windings can be form wound integral part of the HEV drive system has even
which enable high copper fill factor in slots. higher power densities at about 25 kW/litre.
The end-windings are shorter than in The main trends are:
distributed windings, which reduce the • Better and more advanced cooling
resistance as well as the material need. This techniques, pushing for better
type of winding is typically also used in performance in the semiconductor
servomotors for robotics and machine tools. area.
The random wound distributed windings • Integration techniques of passive
enable more sinusoidal magnetomotive force components allowing higher densities.
and therefore also less parasitic effects like • Higher overload capacities as a result
rotor losses and unbalanced magnetic forces. of the two factors above.
The reluctance torque component is also
greater, because of less flux leakage in the C. Additional Converters
stator. The end-windings are longer, which
makes them easier to cool, for instance with oil Due to the high voltage levels being used in
cooling, as in the Toyota Prius. HEVs, it becomes essential to have converters
to supply all the auxiliary loads on board the
vehicle. Although the DC/DC converter
technology is well developed for low-power
applications at lower cost, much work needs to
be done for high-power applications. There is
also the challenge to meet all the vehicle
standards for electromagnetic interference
(EMI) and electromagnetic compatibility
(EMC) as well as specifications of reliability
and packaging [10-12].
Figure 4: Power Control Unit in the Toyota Prius.
DC to DC converters are used mainly as
voltage boosters in HEV. The converter is Table 1: Energy Reservoir Comparison.
normally integrated with the DC/AC inverter. Energy Power Lifetime Efficiency
This is illustrated in Figure 4 that shows the (Wh/kg) (W/kg) (Cycles) (%)
PbAC 25-40 140-350 200-1500 70-75
power control unit of for the Toyota Prius. NiCd 25-40 500 800-1500 70-75
There is a considerable amount of develop- NiMH 40-55 500-1400 500-2000 70-80
Li-Ion 70-130 600-3000 800-1500 85-90
ment carried out just on the DC-DC converter Ultracapacitors 3-5 2000-10000 500k-1M 95-100
for the automotive industry [13] and the trend
for the power density is from a present value The rated generator power of the largest units
of about 25 kW/litre to 80 kW/litre. today is around 5 MW. The wind power
capacity increased by 20 GW in 2007 and the
D. Batteries total global capacity passed 100 GW in 2008.
Batteries are still the bottle neck in the The present annual market increase is 27%
successful development of EVs and HEVs. [14]. The requirements for energy savings in
The major contenders are the alkaline (NiCd, industry is also increasing the market share of
NiMH) and lithium based batteries due to their variable speed drive motor systems, and new
high power densities, number of cycles and suitable permanent magnet motor products
efficiency, albeit at a very high cost. The have recently been introduced by major
summary shown in Table 1 presents a industrial motor manufacturers like Leroy-
comparison of the main characteristics for Somer, Hitachi and WEG. The rail traction
several energy reservoir systems. market is also introducing permanent magnet
motors, especially in gearless intercity trains
4. Challenges in electric power trains with distributed motors on several axes, as
have been demonstrated by Alstom,
A. Electric machines Bombardier and Siemens. The permanent
magnet machine type for the industrial and the
The market dominance of the permanent
traction applications are still niche markets.
magnet machine will probably continue to last
Then there is an existing permanent magnet
for a while, but there are some future
motor market for servo applications, mainly
challenges to be faced ahead. The permanent
for robots and machine tools where GE Fanuc
magnet material that is used in almost all of
and Yaskawa are important manufacturers
these machines is based on rare-earth
with estimated annual servomotor sales of
Neodymium-Iron-Boron (NdFeB). Even
more than 500 000 each, which used to be the
though the material is not rare, like the name
largest market for permanent magnet
may indicate, there are some factors that can
machines, but which now is being overtaken
influence future utilization. The raw materials
by the hybrid electric vehicle market, with
are mainly from Chinese mines, and the tax
Toyota in the lead position and with in-house
and export regulation rules have not been
production of the electric machines. The
stable during the last ten years, which is
simultaneous increase of all these different
affecting the material price. But the most
permanent magnet machine markets will most
influential factor on the future price of NdFeB
likely have an effect on the future availability
magnets is the market demand. The increase of
and price of the NdFeB material.
the hybrid electric vehicle market is the most
important, but there are others. Permanent Limiting factors for enhanced torque density in
magnet generators for wind systems are electric machines are maximum allowable
growing in popularity, although the doubly-fed temperature of mainly the winding insulation
induction generator is still market dominating. and the permanent magnets. The maximum
continuous temperature with the normally
highest industrial class H winding insulation is been commercially used in this market, are
180°C in the hot spot and 165°C on winding among others flux-switching permanent
average. The winding temperature can magnet machines, synchronous reluctance
transiently pass 200°C, without insulation machines with permanent magnet assist and
failure. However, rules of thumb states that the memory motors. The flux-switching
insulation lifetime is doubled for every 10°C permanent magnet machine is proposed as a
temperature reduction in continuous operation. new potential machine candidate for aerospace
The NdFeB permanent magnets are sensitive applications, due to its inherit fault tolerance
to elevated temperatures and to demagnetizing capability [15]. The permanent magnets are
fields produced by stator currents. If the located on the stator side for easy cooling
demagnetizing fields are too severe, for arrangement and the coils are non-overlapping
instance in a short-circuit condition at high with small mutual inductance and influence in
temperature, the magnets risk permanent case of phase failure. The synchronous
demagnetization, with a resulting loss of reluctance machine with permanent magnet
machine power. The present NdFeB assist using ferrites is proposed as a cost
permanent magnet qualities that have the effective machine alternative with high
highest temperature tolerance, may have a efficiency and power factor [16-17]. Ferrites
operating temperature of maximum around are relatively weak magnets that cost only one
180°C in machine applications. Another tenth of the cost of NdFeB magnets per weight
permanent magnet material, namely the unit. The ferrites are mainly used for reducing
Samarium-Cobalt (SmCo), has higher the required inverter rating and for increasing
temperature tolerance and can be operated the constant power region. Memory motors are
above 200°C, but this material has in general electric machines that are equipped with
lower flux and is more than twice as expensive Aluminium-Nickel-Cobalt(AlNiCo) permanent
per weight unit. magnets in the rotor. AlNiCo magnets are
easily demagnetized, which is the whole point
Enabling factors for enhanced torque density with this machine type, since the magnetic flux
in electric machines are reductions of machine level of the magnets are continuously altered
losses, improved cooling for better heat by the stator currents depending on the
transfer, or increased temperature. Reductions operating conditions. This means that it
of machine losses can be achieved with proper changes from a high flux level at low speed to
selection of machine topology, for instance a low flux level at high speed in the constant
will synchronous machines eliminate slip power region, in order to minimize the
losses in the rotor as present in induction required current amplitude and corresponding
machines. The use of better steel grades and losses. A normal permanent magnet machine
thinner laminations will reduce hysteresis and with a winding with changeable number of
eddy-current iron losses. Improved cooling of turns has similar behaviour, if it would be
especially the winding system will reduce the practically feasible (has earlier been proposed
temperature and the resistance and therefore for rail traction applications). Siemens VDO,
also the joule losses. Direct-water cooling of now owned by Continental, is working on the
the copper conductors, which is seen in large memory motor concept and also academic
turbo-machinery, is complicated and expensive research is ongoing [18-19]. AlNiCo
and consequently not viable in small machines, permanent magnets have high thermal stability
but oil spray cooling as in Toyota Prius is a and can be operated above 500°C, so this
practical and good solution in hybrid electric particular property is superior compared to the
vehicle applications, since the oil pump system NdFeB magnets, even though the energy
is already implemented for the engine. Water product or magnetic strength is much lower.
cooling of the housing and forced air cooling
are other possible combinations. Heat pipes B. Drives
can be used to extract heat from a high tem-
perature area to a cooler area, in order to In conventional drives, low frequency and
increase the total performance. The possibility EMI filters are realized as assemblies of
of increasing the operating temperature is discrete components. These components are
further dependent on better knowledge of generally bulky and not designed to spatially
thermal behaviour, so that safety margins can fit with each other, which results in a large
be reduced. percentage of the converter volume being
occupied by air. The requirements in the car
Future potential electric machine candidates industry are more demanding; according to the
for vehicle powertrains, which have not yet European Centre for Power Electronics
(ECPE), the target for power density in the charger should ideally be aware of variations
HEV drives will be 10 kW/litre (including in kWh cost during the day, charging only
motor and drive) in 2010. The biggest jump, when cost is lowest. This requires
from today’s technology to the 2010 target will compatibility with a multitude of grid systems,
be achieved by integrating the motor and or the development and acceptance of related
power electronics. There are some prototypes standards. Last but not least, car owners will
already, like those developed by the ECPE, want some degree of control over when and
Tyco Electronics and Continental. how much to charge the battery, posing a
challenge on user interface design. Many
The targets shown above will require much
dream about a future where HEVs connected
higher power densities with lower energy loss,
to the grid would support the grid, releasing
smaller size and lower cost. It is difficult to
energy during peak hours and absorbing it at
realize such higher power density systems with
times of low consumption. The challenges in
Si-IGBTs, because of their material limits.
this area are mainly non technical. How would
Therefore, new power devices made of new
the HEV owner be compensated for this
materials need to be developed. Wide band-
service, how is battery life time ensured and
gap semiconductors such as SiC and GaN are
accounted, and how will optimal battery use be
two candidates being investigated for future
found for each specific HEV owner, his
drive systems in HEV applications. Toyota is
vehicle use and his grid connections?
involved in the development of GaN devices
[12]. The properties of SiC are ideal for HEV A typical (plug-in) HEV has several more
applications, i.e. high temperature operation, converters than "just" the main motor
high switching frequency and high breakdown converter and the charger. There is also a
voltage. converter related to the energy generation -
either a DC/DC converter connected to fuel
C. Additional converters cells and/or super capacitors, or a rectifier
Whereas the most important challenges for the connected to a generator. In the case of the
main motor converter, as outlined in the Toyota Prius, there are two inverters [5]. It
previous section, are power density and high- will remain a major challenge to find an
temperature operation, it has to be noted that a optimal combination of converters, storage
HEV is a true multi-converter system. This systems, motors, gears, generators, etc. for
first became apparent during the 1990’s, when each case. Of course, all these parts need to be
several authors attempted to integrate charger optimally dimensioned, considering failure
functionality into the motor converter. Even modes, safety, reliability, optimization of
the motor was in some designs used as an energy consumption, lifetime, etc.
inductance in the charger circuit [20]. Such Investigations have been started with regards
integration would be most beneficial, if fast to finding the main drivers behind MTTF
charging of a large battery is required, which is (mean time to failure) and cost of maintenance
less of an issue in today's HEV developments. [22].
Also research into inductive [21] or conductive Yet another challenge and increase of
couplings between (on board) charger and the complexity is the replacement of the
grid, as well as research on a charging station traditional single powertrain configuration by
infrastructure has lost much of its earlier several wheel motors. Investigations on
appeal. Today, battery-only powered vehicles control strategies in case one of these motors
are more seen as a niche than during last (or their converters) fail are still rare [23].
decade. On-road replaceable battery packs Without fault detection and diagnosis,
could still be an acceptable solution, but only immediately followed by control actions in the
if a significant infrastructure of battery non-faulty motor(s), a single failure could put
replacement stations were to be build up, and a the vehicle on an unavoidable collision course.
common standard for battery sizes, voltages
and capacities was defined and accepted. For 5. Conclusions
plug-in HEVs, typically a charger is included
inside the vehicle, with a standard plug The main technological challenges that have
connection to a residential power grid. This been outlined in this paper are:
requires the charger to be not only low-cost,
• The drive system power density in the HEV
but at the same time fulfilling each country' s
market is increasing at a fast pace when
voltage and current levels as well as EMI,
compared with the trends in traditional
EMC and safety standards. Furthermore, the
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can be identified: electromagnetic passive IAS Annual Meeting, Edmonton, Canada,
integration, film capacitors, transformer October 5-9, 2008.
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