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E-MOTOR TECHNOLOGIES FOR EV

MOTORS, CONTROLLERS AND DRIVERS

MONISHRAM V
EV/HEV ENGINEER
CONTENTS
Need for Electric Drivetrain

Motor and Controller Operation

Types of Traction motors

Advanced E-Motor technologies

Future Electric drivetrain options

Motor Certification requirement

E-drivetrain Characterization

Real-time Tuning
MOTORS IN EV/HEV
WHY DO WE NEED ELECTRIC POWERTRAIN?
Electric Motor - 5 times more energy efficient as compared to IC Engine
POWER TRANSIMSSION IN ELECTRIC VEHICLES
MOTOR OPERATING CHARACTERISTICS

• No Load Speed is the Maximum Speed


achievable by the motor.
• The Rated Operating Point will be the
Continuous Operating point typically
near the Base Speed.
• The Torque is directly proportional to
Current drawn by the motor.
• Stall Torque will be Maximum Torque
Achievable at Blocked Rotor condition.
• The Motor Operates at Peak Efficiency
near the Base Speed.
INVERTOR/CONTROLLER TOPOLOGY
• Speed and Torque has to be Varied
Continuously in EV Traction Motor.
• Various techniques are implemented in
Controller like Variable Frequency Drive
(VFD) , Field Oriented Control (FOC) etc.
for different drives.
• Closed loop Feedback control is required
to control Torque/Speed based on various
feedback variables.
• The Invertor Transistors operate on very
High switching Frequency for precise
control.( 5-20kHz)
• The Transistors are activated by Gate
Drivers.
MOTOR CONTROLLERS/DRIVERS

FUNDAMENTALS
OF
POWER
ELECTRONICS
CLASSIFICATION OF MOTORS FOR xEV
MOTOR CONSTRUCTION

AC INDUCTION PMAC
BLDC

PMDC SERIES
DC
CUT
SECTION

Induction Motor construction


INDUCTION MOTOR CONTROL STRATEGY
DETAILED COMPARISON OF VARIOUS MOTOR TYPES
• No permanent magnet
INDUCTION MOTOR (squirrel-cage rotor) • Asynchronous motor
• Robust
• Low cost
• Low efficiency
• Magnets are mounted on the surface of the rotor
SURFACE-MOUNTED PM MOTOR (SPM) • No reluctance torque
• Mechanically weak, especially at high speed
• Non-saliency characteristics of SPM (Ld=Lq)
• Magnets are buried inside the rotor
INTERIOR-BURIED PM MOTOR (IPM) • More robust than the SPM
• Good for high speed
• Reluctance and magnetic torque
• Saliency characteristics of IPM (Ld<Lq)
• Has less magnets compared to IPM
PM assisted SYNC RELUCTANCE MOTOR(PMASRM) • High reluctance torque than magnetic torque
• Cost efficient
• High efficiency
• High Saliency characteristics of PMASRM (Ld<<Lq)
PERMANENT MAGNET MATERIALS
IPM vs SPM – FUNCTIONAL DIFFERENCES
COGGING TORQUE AND SKEWING EFFECTS
ROTOR SLOT CONFIGURATIONS
D-Q REFERENCE FRAMES
FIELD OREIENTED CONTROL (FOC) – SPEED LOOP
FIELD OREIENTED CONTROL (FOC) – TORQUE LOOP
BLDC Motor construction

TYPICAL 2W HUB DRIVE


Switched Reluctance Motor Construction
TECHNICAL COMPLICATIONS OF SRM

DESIRED
RESULT
SRM INDIVIDUAL FIELD CONTROL
Axial flux Motor Construction
DIRECTION FOR FUTURE ELECTRIC POWERTRAIN
MOTOR POWER
TEST AS PER AIS041
• SPEED – POWER Characteristics
• 3 minute Warmup before the test
• Net Power test performed to find
peak power of motor within 5 minutes.
• 30min Power test performed to find
out the continuous power delivery
without power drop or thermal limits.
• 90% of peak power at the continuous
Power speed.
WHAT IS THE NEED FOR CHARACTERIZATION?
• Traction Motors intended to be used for Electric Vehicle application differ vastly
compared to the Conventional Industrial motors.
• Although there are standards for testing the industrial motors, it does not suffice to test
the motors rigorously as to simulate the Dynamic changes the Traction Motor experiences
when the EVs are subjected to Real-World conditions and driving practices.
• These Traction Motors are operated in their Peak Performance band Often as the vehicle
is accelerating or decelerating with a fairly vast varying torque region, where industrial
motors are operated at Rated Performance range mostly.
• Also, The conventional Electric Motor testing does not provide sufficient data needed for
the characterization of the EV Powertrain and its individual components such as Invertor,
Control systems and Batteries.
ELECTRIC DRIVETRAIN CHARACTERIZATION

• PEAK PERFORMANCE CHARACTERISTICS


• DERATING CHARACTERISTICS
• EFFICIENCY CHARACTERISTICS
• DRIVE CYCLE SIMULATION
• ROADLOAD SIMULATION
• ENDURANCE/DURABLITY VALIDATION
• TORQUE MAPPING BEHAVIOUR
WHAT ARAI CAN OFFER AS SERVICE FOR INDUSTRY?
DESIGN

VALIDATION/ BENCHMARKING OF ELECTRIC DRIVETRAIN READILY


CORRECT VALIDATE AVAILBLE IN MARKET WITH PERFORMANCE MAPPING

PROTOYPE
SIMULATE
ITERATION
ASSIST IN THE DEVELOPMENT OF INDIGENEOUS MOTOR/
CONTROLLER/ SOFTWARE AT EVERY STAGE OF THE PROCESS

RAPID PROTOTYPING

Development RAPID PROTOPYING METHOD WITH DEDICATED DVPs WHICH REDUCES


Time THE PRODUCT DEVELOPMENT TIME DRASTICALLY

Optimization
REAL-TIMECONTROLLER TUNING / OPTIMIZATION

CONTROLLER
MOTOR BENCHMARKING STUDY
 Number of Magnetic poles
 Each phase coil resistance
 Each phase coil inductance
 Torque Constant
 Back-EMF constant
 Motor Time Constant
 Rated Top Speed
 Rated Top Torque
E-DRIVETRAIN EVALUATION

Performance

Lifecycle Efficiency

Motor & Drive


Evaluation

Thermal
Safety
Mapping

Durability
THANK YOU
Please drop any business enquiry to
monishram.aed@araiindia.com

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