T5-3 High Efficiency Electric Drives 2

Erasmus LLP Intensive Programme
High efficiency electric machines for EV

Associated professor Phd Jonas Valickas
KUT, Panevys division Jonas.valickas@ktu.lt

Powering the Future With Zero Emission and Human Powered Vehicles Terrassa 2011 1
References
1. Efficiency trends in electric machines and drives B.C. Mecrow, A.G. Jack; 2. Theodore Wildi. Electrical Machines, Drives, and Power Systems. Sixth Edition. Pearson Prentise Hall. 2006. 934 p. 3. Vedam Subrachmanyam. Electric Drives. USA. McGraw Hill. 2006. 715 p. 4. William Bolton. Mechatronics. Pearson Education Limited. Forth edition. 2008. 593 p.
Powering the Future With Zero Emission and Human Powered Vehicles Terrassa 2011
Electric Engine History

The first car electric engine was made by
James Starley in 1888.
(was an English inventor and "Father of the Bicycle Industry." )
First satisfactory results were achieved by Raeford

and Jantoe only in 1893.
They constructed an automobile with two batteries

located in the rear; Each of them was 200Ah with total weight 420 kg.
The engine power amounted 2.5 kilowatt by 1300 rpm.

By 1912 there were about 20 thousands automobiles
with electric drive.
Electric cars history
1935 - 1960
dead years for electric vehicle development and for use as personal transportation.
Electric cars history
The CitiCar was produced between 1974 and 1977 by a U.S. company called Sebring-Vanguard, Inc. , based in Florida.
Electric cars motors

Electric cars are driven by large electric motors usually
rated between 3.5 and 40 horsepower. 1 horsepower = 745.699872 watts The rating systems used for gas engines and electric motors are so different.
Gas engines are rated at their peak hp. Electric motors are rated at their continuous hp.
The peak hp of an electric motor is usually 8 to 10 times its continuous rating.
Classification
Electric cars motors
Electric vehicle drive motors can be divided into two basic groups:
DC or direct current motors; AC or alternating current motors.
DC motors
Have a long history in EV use
The most commonly used version is what is known as

- series-wound motor, which means the armature and field windings are wired in series; - shunt-wound motors; - compound-wound motors; - permanent magnet motors.
AC motors
At the present time AC motors are most commonly found in commercially built EVs.
An important condition:
They require more sophisticated and systems than DC motors.
complex control
What is a motor efficiency?

Electrical motor efficiency (m) is the ratio between the shaft output power - and the electrical input power. If power output is measured in Watt (W), efficiency can be expressed as:
m = Pout / Pin
where: m = motor efficiency Pout = shaft power out (Watt, W) Pin = electric power in to the motor (Watt, W)
Power in rotational motion (Pout )

Power in rotational motion (Pout ) can be written as:
Pout ,
where: - torque (moment); - rotational speed or angular velocity.
Torque (moment)
Torque, also called moment or moment of force is
the tendency of a force to rotate an object about an axis.
Rotational speed or angular velocity

When we supply the specified voltage to a motor, it
rotates the output shaft at some speed. This rotational speed or angular velocity, is typically measured in radians/second {rad/s}, revolutions/second {rps}, or revolutions/minute {rpm}.
1 revolution = 360 1 revolution = (2*) radians 1 radian = (180/) 1 = (/180) radians
Electrical power (Pin)
Pin V I ,
where: power Pin is in watts (DC); voltage V is in volts; current I is in amperes. If there is AC, look also at the power factor PF = cos , where = power factor angle (phase angle) between voltage and current.
Power units
UNITS of POWER SI English Watts {W}

newton-meters per second {Nm/s}
1 W = 1 Nm/s 1 W = 0.738 ftlb/s 1 W = 1.341E-03 hp foot-pounds per second {ftlb/s} horsepower {hp} 1 ftlb/s = 1.818E-03 hp 1 ftlb/s = 1.356
Electric motors
Motors are devices that convert electrical energy into mechanical energy.
Lorentz force
The Lorentz force is the force on a point charge due to
electromagnetic fields. It is given by the following equation in terms of the electric and magnetic fields:
where: F is the force (in newtons) E is the electric field (in volts per metre) B is the magnetic field (in teslas) q is the electric charge of the particle (in coulombs) v is the instantaneous velocity of the particle (in metres per second) is the vector cross product
Fleming's left hand rule (for electric motors) shows the direction of the thrust on a conductor carrying a current in a magnetic field.
DC ( Direct - current) MOTORS
Two-pole DC Motor Rotation

(Permanent magnet DC motor)
When the coil is powered, a magnetic field is generated around the armature.
The left side of the armature is pushed away from the left magnet and drawn toward the right, causing rotation.
When the armature becomes horizontally aligned, the commutator reverses the direction of current through the coil, reversing the magnetic field. The process then repeats.
DC motors design
A: shunt B: series C: compound f = field coil
Permanent Magnet DC Motor
DC Motor with wound stator
The most popular brands of DC motors for EVs are Advanced DC and NetGain.
Brushless DC Motor
As such they have no commutator, and tend to be more
efficient and more powerful than commutated motors. They do require a more complicated motor controller, although as the technology matures and costs come down they are becoming increasingly popular, particularly for smaller EV.
The main disadvantage for EV use is the cost of the

large permanent magnet(s) required for the rotor, and the added expense of the speed controller. Unfortunately, at prasent there are no economically viable BLDC options available for EV use.
Brushless DC Motor ("in-runner" type)
Two example manufacturers currently producing good brushless motors are UQM and Aveox.
DC motor speed torque characteristics
maximum power occurs at the point where = , and = .
DC motors speed control

Speed of the DC motor is directly proportional to armature supply:
60 Ea n , Z
where: - n speed of rotation ( r/min); - Ea armature voltage (V); - Z total number of armature conductors; - magnetic flux per pole.
Stopping of DC motors
Dynamic bracing;
Plugging ( reversing the direction of rotation).
DC Motors application features

There are four main types of DC motor, namely permanent
magnet, series, shunt and seperately excited.
Currently series DC are the most economical and commonly used

type of motor in electric vehicles.
Being a tried-and-tested technology, they are actually quite good

with efficiencies up to 90% and only needing servicing every 100,000kms or so.
However using a commutator is restrictive and a source of

inefficiency. Also, with series DC motors regenerative braking is very difficult to do.
AC motors
AC motors
In 1882 Nikola Tesla identified the rotating magnetic
induction field principle used in alternators and pioneered the use of this rotating and inducting electromagnetic field force to generate torque in rotating machines. He exploited this principle in the design of a poly-phase induction motor in 1883. In 1885, Galileo Ferraris independently researched the concept. In 1888, Ferraris published his research in a paper to the Royal Academy of Sciences in Turin.
,,Cage rotor inventor

Mikhail Osipovich Dolivo-Dobrovolsky
Michail Osipovich Dolivo-Dobrovolsky invented a three-phase "cage-rotor" in 1890. This type of motor is now used for the vast majority of commercial applications.
Diagram of the squirrel-cage (showing only three laminations)
Stator and rotor
Vector sum of the magnetic field vectors of the stator coils produces a single rotating vector of resulting rotating magnetic field
Sine wave current in each of the coils produces sine varying magnetic field on the rotation axis. Magnetic fields add as vectors.
Magnetic field vectors of the stator
Rotor magnetic field production
AC Induction Motor
The most popular brands for AC induction motors suitable for EVs are Siemens and Azure Dynamics.
Slip
NEMA
NEMA -National Electrical Manufacturers Association NEMA is responsible for several electric motor industry
"standards" Motor ratings (1/4 hp, 1/2 hp, 1 hp, etc.) Frame size diameter, length, shaft size, etc. Service factors Housing/protection types and ratings
Characteristics of the different design of the motor

The torque-speed characteristic of an induction motor can be significantly changed by designing different resistance values within the rotor bars. Figure shows the impact of different rotor resistance values.
Typical torque - speed curve of a 3 phase squirrel-cage induction motor
AC motors speed control

AC motor shaft rotation speed can being calculated:
n n0 (1 - s) f(1 - s)/p
where: 120 f n0 synchronous speed, r/min; n0 p s slip; f AC current frequency, Hz; p the number of pairs of motor poles.
Stopping of DC motors
Plugging ( reversing the direction of rotation).
Dynamic bracing;
The efficiency of an electrical machine

The efficiency of an electrical machine is a complex function of:
machine type,
size, speed of operation, loadings, materials, operating regime.
How to increase efficiency?

Variable-speed drives are created when a motor is
combined with a power electronic converter.
By introducing variable speed to the driven load, it is

possible to optimise the efficiency of the entire system, and it is in this area that the greatest efficiency gains are possible.
Understanding Regeneration
Electrical motors are reversible machines; they can function as motors or as generators. A motor receives electrical power from a battery and transforms it in torque developing a Counter Electromotive Force CEMF, which opposes the battery. A generator receives mechanical power from a mechanical actuator and transforms it in electrical power developing a Counter Torque, which opposes the actuator.
Electric motors efficiency

Induction fixed-speed motor efficiency typically ranges
is 76.2%;
Commutator machines efficiency is typically 50% or

less
The principal sources of loss in a induction machine are:

Stator winding loss. It is the dominant source of loss in small machines. It comprises around 60% of the
total full-load loss in the sub-1kW range, falling to 25% at 1MW and above.
lamination iron loss. It rice due to hysteresis and eddy currents, which accounts for approximately 20%
of full-load loss. This loss does not generally decrease during operation at reduced load.
Rotor winding loss. It is due to losses in the aluminium cage rotor, which are strongly load-dependent
and amount to approximately 20 % of full-load loss.
Stray losses. Are due to a number effects, including induced eddy currents in the stator frame.
These are insignificant in machines of less than10kW.
Friction and windage. includes bearing loss, which is less than 5% of total loss in machines
of 10kW
European CommissionJointResearchCentreonElectricMotorEfficiency,2004: /http://re.jrc.ec.europa.eu/energyefficiency/S (accessed June2008).
Motor energy balance flow diagram

Air gap
Input power Psup
Air gap power Pag
Developed power Pdev=3Irot2Rrot(1-s)/s
Output power Pout Ventilation and friction losses Rotor Copper loss 3 Irot2 Rrot Stator Iron loss 3 Vsta2/Rc
Stator Copper loss 3Ista2Rsta
Future advances to 2050 and beyond

The function of an electrical drive is to transfer electrical energy to
mechanical energy and vice versa.
This is currently achieved almost exclusively via a magnetic field.

Question is: Are there any new processes of energy conversion that may replace this method in the next one hundred years? The answer is simple: none are known of at the time of writing. Competing systems, such as electric fields are several orders of magnitude less power-dense or, in the case of ultrasonic motors, very inefficient. Electric motors will continue to use the same basic concepts for the foreseeable future.
Key challenges:
increase the adoption of variable-speed, high-efficiency
systems, with a revision of efficiency bands and possibly legislation replacing voluntary agreements;
extend the application areas of variable-speed drives

through reduction of power electronic and control costs;
integrate design of the drive and the driven load to

maximise system efficiency;
increase the efficiency of the electrical drive.
Drive efficiency improving
The key to improving motor efficiency lies in new materials and construction methods.
Winding loss reduction

Winding loss is reduced by increasing the conductivity of the winding. In the case of induction machines, recent advances in production methods are starting to allow the replacement of aluminium rotor cages with copper reducing machine losses by around 810%
Copper is already used for stator windings and is unlikely to be

replaced by a more conductive material at room temperature.
Superconducting electrical machines have been researched for

over 30 years, but with the advent of high-temperature superconductors, they are now close to introduction.
Iron loss reduction
Air-gap windings are employed, with an ironless stator, thereby also eliminating iron loss. However, substantial eddy currents are induced in the AC windings because they sit in the full magnetic field.
Eddy current losses reduction

Current losses in the soft iron material of a machines core can be reduced by either increasing the resistivity of the core material or reducing the amount of flux, which eddy currents can enclose. The former is achieved by the introduction of up to 6% silicon into the lamination material, which also reduces the coercivity and hence hysteresis loss.
Amorphous iron
Amorphous iron reduces the thickness of the
laminations and therefore the eddy current loss.
Because of the crystal structure resulting from very

rapid cooling, the hysteresis loss is also exceptionally low.
However, the material is expensive to produce and

limited in flux density.
Soft magnetic composites

Soft magnetic composites replace the laminations with100 m
diameter iron particles,which are pressed together.
This material has very low eddy current loss, but current products
have greater hysteresis loss.
Soft magnetic composites have, however, been shown to offer

significant efficiency gains because of their three-dimensional shaping properties.
New tooth shapes are possible, with much shorter winding lengths,
thereby reducing winding loss.
Hysteresis loss diminution possibility of the soft magnetic composites
Future soft magnetic composites will incorporate

special high-temperature powder coatings, which will lower hysteresis loss and make the material more attractive for energy-efficient systems.
Electromagnetic design tools

Electromagnetic design tools have advanced greatly
with the application of the finite element method.
Greater understanding of stray loss mechanisms is

required at the design stage
Improved understanding and modelling of iron loss mechanisms within the machine are also needed to replace the empirical scaling that continues to be adopted by manufacturers
Key engineering and scientific advances are required:

1. New soft magnetic materials giving lower iron loss at low cost; 2. Low-cost, high-temperature, high-energy magnets;
3.High-temperature insulation and magnets sytems (>400C).

4. New construction methods, including segmented stators, and
cast copper rotors where appropriate.
5. Bearing systems for ultra-high-speed operation. Reliable hightemperature superconducting designs at moderate cost.
6. Improved design tools.
Power electronics and control cost reduction.

New devices, materials and technology to produce
increased switching speeds and reduced conduction drops.
Increased integration. Reduced size of passive components.
Electric dives trends in future

In the future, electric drives will become integral to the
propulsion of road transport vehicles, and so the need for maximising their efficiency will become even more pressing than it is today
,,For internal combustible engine the time for retirement!
Thanks for attention
Questions
What types of motors used in EV ? How works DC motors ? How works an induction motors ? How to control the speed of the DC and AC motor ?
How to stop DC and AC motor ?

What is the motor efficiency ?

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Erasmus LLP Intensive Programme

High efficiency electric machines for EV

KUT, Panevys division Jonas.valickas@ktu.lt

Erasmus LLP Intensive Programme

Erasmus LLP Intensive Programme

Electric Engine History

James Starley in 1888.

(was an English inventor and "Father of the Bicycle Industry." )

Erasmus LLP Intensive Programme

Electric Engine History

First satisfactory results were achieved by Raeford

They constructed an automobile with two batteries

The engine power amounted 2.5 kilowatt by 1300 rpm.

Erasmus LLP Intensive Programme

Electric Engine History

Erasmus LLP Intensive Programme

Electric cars history

Erasmus LLP Intensive Programme

Electric cars history

Erasmus LLP Intensive Programme

Electric cars motors

The peak hp of an electric motor is usually 8 to 10 times its continuous rating.

Erasmus LLP Intensive Programme

Erasmus LLP Intensive Programme

Electric cars motors

DC or direct current motors; AC or alternating current motors.

Erasmus LLP Intensive Programme

The most commonly used version is what is known as

Erasmus LLP Intensive Programme

They require more sophisticated and systems than DC motors.

Erasmus LLP Intensive Programme

What is a motor efficiency?

Erasmus LLP Intensive Programme

Power in rotational motion (Pout )

Erasmus LLP Intensive Programme

Erasmus LLP Intensive Programme

Rotational speed or angular velocity

1 revolution = 360 1 revolution = (2*) radians 1 radian = (180/) 1 = (/180) radians

Erasmus LLP Intensive Programme

Electrical power (Pin)

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UNITS of POWER SI English Watts {W}

Erasmus LLP Intensive Programme

Erasmus LLP Intensive Programme

Erasmus LLP Intensive Programme

Erasmus LLP Intensive Programme

DC ( Direct - current) MOTORS

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Two-pole DC Motor Rotation

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Erasmus LLP Intensive Programme

A: shunt B: series C: compound f = field coil

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Permanent Magnet DC Motor

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DC Motor with wound stator

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The main disadvantage for EV use is the cost of the

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Brushless DC Motor ("in-runner" type)

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DC motor speed torque characteristics

maximum power occurs at the point where = , and = .

Erasmus LLP Intensive Programme