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10.1109/TIE.2014.2367023, IEEE Transactions on Industrial Electronics
Abstract Understanding the need for steady-state and tran- r : electrical rotor angular position
sient performance improvement in an interior permanent magnet r : electrical rotor angular frequency
synchronous machine (IPMSM) drive, this paper exclusively J : moment of inertia
investigates the IPMSM incorporating damper bars in the rotor ac : ampere conductors per pole
of electric motor for electrified vehicles (EVs). Firstly, motivation Kw1 : winding factor
for the employment of damper bars in IPMSM is provided and Tph : turns per phase
justified with a case study. Thereafter, mathematical model of an Ad : total area of damper bars per pole
IPMSM drive with damper bars in the rotor has been developed d : current density value
based on dq axis theory and validated through experiments per- ad : cross-section of each damper bar
formed on a laboratory IPMSM containing damper bars. The dd : diameter of the damper bar
validated mathematical model has been then employed to arrive Nd : number of damper bars per pole
at satisfactory rotor bar parameters for an existing IPMSM on
board a commercially available EV. Moreover, a replica of the
existing onboard EV motor with and without incorporating I. INTRODUCTION
dampers have been designed and finite element analysis (FEA) Over the last decade, substantial investment, geo-political
has been performed to investigate various performance charac- interest, multiple motor topologies, cost reduction, varying
teristics. Comparative performance analyses of both the ma- performance, compact packaging and integration have been
chines with and without damper bars under steady-state and
some of the factors that have led to an increased interest in
transient conditions have been performed wherever necessary
and the results elicited have been discussed.
studying electric motors for electrified vehicles. By the end of
2018, it is predicted that the global demand for electric trac-
tion motors will rise to 8 million from the current 4.5 million.
Index Terms Dampers, dq axis, electrified vehicle, finite el- More than 61% of this volume will come from full-hybrid
ement analysis, interior, permanent magnet synchronous ma- non-plug-in-vehicles and 13% will come from battery electric
chine. vehicles. The electrified vehicle (EV) market including hy-
NOMENCLATURE brids and battery electrics will be the strongest in 2016 due to
the activation of the Corporate Average Fuel Economy
vds, vqs : d- and q-axis voltages
(CAF) standards. Hybrid variants of existing vehicles will be
ids, iqs : d- and q-axiscurrents
the primary driver of higher volumes of electrified vehicles
rs : stator resistance
Lmd, Lmq :d- and q-axis magnetizing inductances
until 2016, thereafter led by plug-in hybrid vehicles and bat-
Lds, Lqs : d- and q-axis synchronous inductances
tery electric vehicles. It has also been predicted that the per-
ikd', ikq' : d- and q-axis damper currents the referred to the stator side manent magnet synchronous motors (PMSM) will continue to
rkd', rkq' : d- and q-axis damper resistance the referred to the stator side dominate the market and other motor technologies will remain
Lkd', Lkq' : d- and q-axis damper inductance referred to the stator side as niche technologies with less than 5% market volume over
' : flux linkage developed by the magnets referred to the stator side the next five years [1].
p : differential operator d/dt On the other hand, enhanced dynamic and steady-state per-
Te : electromagnetic torque formance of the traction motor is of paramount importance to
P : number of poles uplift customer experience on acceleration, speed, noise and
vibrations, extended driving range, climbing capability and
Manuscript received June 3, 2014; revised August 30, 2014; accepted Sep-
tember 28, 2014.
cost of the vehicle.
Copyright (c) 2014 IEEE. Personal use of this material is permitted. Understanding the above, this paper exclusively puts an ef-
However, permission to use this material for any other purposes must be fort to investigate the steady-state and transient performances
obtained from the IEEE by sending a request to pubs-permissions@ieee.org. of a permanent magnet traction motor drive with damper bars
This work was supported by the Natural Sciences and Engineering Re-
search Council of Canada (NSERC).
in the rotor of the machine.
1
X. Lu, 2K. L. V. Iyer, and 5N. Kar are with the Department of Electrical
A. Background Literature Survey
and Computer Engineering at the University of Windsor, Ontario, Canada
N9B3P4. (1lu117@uwindsor.ca, 2iyerl@uwindsor.ca and 5nkar@uwindsor.ca) Most of the EVs use IPMSMs as their traction motors due
3
K. Mukherjee is with the Department of Electrical Engineering, Indian to their large power densities, higher efficiencies and capabili-
Institute of Engineering Science and Technology, Shibpur, India. ties to run over a large speed ranges with an almost constant
(3kmukherjee@ee.becs.ac.in)
4
K. Ramkumar is with the Department of Electronics and Instrumentation power output with zero maintenance [2]. These synchronous
at SASTRA University, Thanjavur, India. (4ramkumar@eie.sastra.edu) motors for such vehicle applications invariably run under self-
synchronous mode with rotor position feedback through a
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10.1109/TIE.2014.2367023, IEEE Transactions on Industrial Electronics
pulse-width modulated (PWM) inverter. Self-synchronous times continues for a long time. As this mode of operation also
operation or self-control of the synchronous motor cause the calls for speed control, it is performed by the speed controller
drive to be self-starting and rules out the probability of the of the drive by controlling the phase angle of the six-stepped
rotor falling out of step since the rotor-position synchronized phase voltage waveform with respect to the back EMF of the
switching of the inverter devices always keeps the rotor speed corresponding armature phase, as dictated by the MTPA con-
synchronous with the exciting currents in the armature [3]. trol strategy.
IPMSMs are known to be generally designed with an expec- It is imperative that when the VSC operates in the under-
tation of sinusoidal back EMF distribution [4], [5] and the modulation zone of the PWM strategy, the switching of the
inductances of the armature circuit of the conventional inverter devices of the same leg are more frequent than a
IPMSMs generally provide enough filtering to cause the ar- square wave operation. Hence, the value of the equivalent
mature currents to be sinusoidal in response to the PWM volt- inductance of the d-q equivalent circuits of the conventional
age pulses impressed by the inverter on the armature termi- IPMSM seems sufficient to make the armature current almost
nals. Hence, torque ripple should be zero if purely sinusoidal sinusoidal to cause negligible torque ripple, assuming the back
currents are injected into a PMSM with a purely sinusoidal EMF of the machine to be sinusoidally distributed. However,
back EMF distribution. Conventional wisdom, based on when the square wave, 180 conduction mode of operation of
above, tells us that dampers are not required in such motors the inverter prevails, the inverter devices switch at much
for such applications as operation will always be synchronous. slower rates. Consequently, lower order side-band harmonics
Dampers will therefore not be required - neither for starting start appearing along with the fundamental, and the authors
nor for pulling into synchronism for such synchronous motors. felt that in this operating mode, exploring the need of addi-
The above are generally the reasons why the IPMSMs em- tional dampers in the conventional IPMSMs to improve the
ployed in EVs never possess dampers. transient response of the motor and the converter by improv-
A line start PMSM (LSPMSM), on the other hand, operates ing the wave-shape of the armature current and air-gap voltage
without rotor position feedback and in order to be self-starting is justified. The idea to investigate such a case struck the
must possess dampers. The dampers for such applications minds of the authors when they thought of an analogous case,
should provide enough starting torque and should help to- where a 3-phase current source inverter (CSI), operating under
wards the pull-in phenomenon. Additionally, for such applica- 120 conduction, feeding a wound field 3-phase synchronous
tions, the design of the dampers should be such that while motor with dampers, has already been reported to yield im-
drastic load disturbances appear on the system and the transi- proved transient performance of the comprehensive drive [4].
ent operation of the machine becomes asynchronous, the The authors also intuitively believe that incorporation of
dampers should help in increasing the transient stability limit dampers can control the spatial distribution of the back EMF
of the machine. Hence, substantial amounts of research papers waveform of a conventional PMSM to provide transient and
to investigate the role of dampers for LSPMSMs have been steady state improvement in performance and can reduce the
written [6] [10]. effect of permanent magnet demagnetization under MTPA
Similarly, for any permanent magnet synchronous genera- regime of control of the PMSM drive of the vehicle.
tor (PMSG) which does not operate under rotor position feed- This paper therefore takes a combined approach to predict
back, dampers come into play during the transient asynchro- improved damper parameters for improved performances, and
nous durations and help in restoring stability. The damper de- also investigate the effects of incorporating dampers in
sign for such applications should solely concentrate towards IPMSM viewing the research problem from a dq axis model
restoring transient stability and researchers have worked on based approach and a finite element model based approach;
this also [11], [12]. thereby capitalizing on the mutual advantages of each. This
However, papers published until date, to the best of au- will be subsequently presented in the following sections.
thors knowledge, have not yet investigated the performance
C. Case Study for Illustrating Repeated Over-modulation
of IPMSM incorporating dampers bars for an EV application.
Operation Periods in IPMSM Drive
B. Motivation for the Proposed Investigation Samples of experimental data collected from performance-
Most of the PMSMs on-board commercially available EVs mapping test performed on a traction motor on-board a com-
have either a distributed or concentric winding arrangement in mercially available EV by Oak Ridge National Labs is pre-
their stators and permanent magnets in their rotor. They are sented in Table I [14]. The vehicle has an IPMSM with maxi-
mostly 3-phase interior permanent magnet synchronous ma- mum output power of 50 kW and a peak torque of 400 Nm. A
chines (IPMSMs) machines driven with maximum torque per DC-DC converter is connected between the battery pack and
ampere (MTPA) control strategy [13], [14]. The DC link volt- the inverter to maintain the input voltage to the inverter at a
age of the 3-phase voltage source converter (VSC) driving the level of 500 VDC as shown in the measurement data in Table
traction motor for such a vehicle remains constant and the I. The 3-phase VSC is switched based on space vector pulse-
inverter runs with under-modulation in the low-speed region width-modulation (SVPWM) technique.
and with over-modulation in the high-speed region of opera- The magnitude and frequency of the ac output depend on
tion of the motor drive [14]. As the speed becomes progres- the reference voltage space vector and the PWM. The funda-
sively higher, the back EMF of the motor keeps increasing and mental-frequency voltage magnitude increases proportionally
over a certain speed, the inverter starts operating as a pure with the reference voltage space vector magnitude in under-
square wave inverter, impressing a six-stepped phase voltage modulation (linear) region. However, on further increase in
at the motor terminals. For EVs, this mode of operation some- the required voltage level, the over-modulation mode is en-
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countered. In this mode, the voltage magnitude no longer var- II. MODELING AND ANALYSIS OF IPMSM DRIVE WITH
ies in proportion with the reference voltage and saturation DAMPER BARS IN THE ROTOR
starts creeping in. In order to:1) arrive at the rotor bar parameters which yield
Finally, beyond this region, the controller loses its control satisfactory machine performance, 2) incorporate them into
over the voltage amplitude and PWM degenerates into a the IPMSM drive on-board EV and 3) analyze the behavior of
square-wave inverter waveform. With a given DC link voltage the machine under steady-state and transient conditions, a
(VDC), the output line-to-line voltage fundamental RMS value model of the IPMSM with damper bars along with its drive
gets fixed at 0.78 times VDC.As seen from Table I, when the have to be developed based on the dq axis theory.
speed and torque of the motor are low such as data sets 1-1, 2-
1, etc., the output voltage level depends on the reference volt-
vds rs Lds p r Lqs Lmd p r Lmq ids 0
ages. As the speed increases, in sets 5-1, 6-1, etc., the output L 1
v r L p L L p i
voltage exceeds the linear region and the inverter operates in qs r ds s qs r md mq qs (1)
0 L p i ' r 0 ' 0
1800 conduction mode. As indicated from table in [14], for a md
0 r 'kd L 'kd p 0 kd
large number of operating conditions, the motor is controlled 0 0 Lmq p 0 r 'kq L 'kq p i 'kq 0
by a square-wave inverter during which the harmonic compo-
nents of the voltage signal is significantly high and the torque pr P 2J Te TL (2)
response depends mainly on the load angle command sent to
Te 3P 'iqs idsiqs ( Lds Lqs ) 3P Lmd i 'kd iqs L'mqi 'kqids (3)
the inverter. 4 4
pr r (4)
D. Paper Objectives
The volt-ampere equations of the LSPMSM can be written
Based on the practical performance characteristics, issues
as in (1), and the mechanical equations of the motor may be
and hypotheses discussed above, the authors derive motivation
written as in (2), (3) and (4), where symbols have their usual
to exclusively investigate steady-state and transient perfor-
meanings [15]. A parameter determination method to deter-
mance characteristics of the IPMSM with the employment of
mine the electrical circuit parameters of such a machine was
damper bars in the rotor for EV application.
proposed by the authors and the parameters were incorporated
Section III of the paper presents a mathematical model of
into the above machine model and validated using experi-
an IPMSM drive with damper bars in the rotor which has been
ments performed on a laboratory LSPMSM containing rotor
developed based on dq axis theory and validated through ex-
bars under steady-state and transient conditions [16].However,
periments performed on a laboratory IPMSM containing
the machine model and the parameters determined were vali-
damper bars. The validated mathematical model has been then
dated only under direct on-line starting.
employed to arrive at satisfactory rotor bar parameters for an
existing IPMSM drive onboard a commercially available EV. A. Experimental Validation of the Developed Machine Model
Comparative performance analysis between the onboard EV Driven bySquare Wave Inverter under Self-control
motor drive with and without dampers has been performed The machine model developed in [16] along with the drive
through dq axis models developed and results elicited have has been exclusively validated in this section with a laboratory
been discussed. Section III also presents the aforementioned LSPMSM. The LSPMSM has been operated in the self-
dq axis based modeling and transient state analyses activities controlled mode (with rotor position feedback) through a 3-
conducted in this paper. Section IV presents FEA based results phase square wave inverter as illustrated in the schematic
from investigations performed on three machines designed, shown in Fig. 1(a). As shown in the experimental setup in Fig.
replicating the existing onboard EV motor with and without 1(b), the test machine is equipped with a low-cost position
incorporating dampers. It also provides the machine design sensor indicating the position at every 60 and coupled with a
details and damper design approach employed to develop the dc machine (operating in the generator mode) as load. A 3-
machines. phase IGBT inverter stack is used as the voltage source con-
TABLE I verter, and a TMS320 series digital signal controller is used to
SAMPLE TEST DATA FROM PERFORMANCE MAPPING TEST [11] provide rotor position synchronized gate signals based on 180
Mechanical Inverter DC Inverter AC side conduction scheme to actuate the inverter.
Conditions link side (rms) per phase (rms) The DC link voltage is set as 132 V and the load angle is
Speed Torque Voltage Current Voltage Current controlled to be 60. The machine settles at a speed of 1125
Test #
(rpm) (Nm) (V) (A) (V) (A) rpm at a load torque of 7.8 Nm. The calculated current wave-
1-1 302 179.2 504.0 21.32 108.0 87.3 form, shown in Fig. 1(c), is in close agreement with the meas-
2-1 703 30.2 504.0 6.74 112.3 20.2 ured waveform, shown in Fig. 1(d). The amplitude of calculat-
ed current has been found a little higher than the experimental
3-1 1303 69.6 503.7 22.47 166.1 38.2 one for all cases of loads and load angles for which the drive
4-1 2104 70.4 504.4 34.83 204.5 38.8 is operated, because the mechanical and core losses are ne-
5-1 3804 98.6 499.0 91.37 241.0 95.6
glected in the calculations, as is generally done in typical dq
axis based models. Instantaneous current flowing into the ma-
6-1 5004 59.8 499.4 73.17 239.7 113.7 chine armature is considered positive in the presented wave-
7-1 6005 49.4 499.6 73.60 240.7 68.2 forms. The fact that the actual operating load angle is equal to
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TABLE II
SAMPLE STEADY STATE AND DYNAMIC PERFORMANCE DATA OF THE EXISTING AND PROPOSED MACHINES
(STATOR RESISTANCE TO DAMPER RESISTANCE RATIO 3:2, STATOR LEAKAGE INDUCTANCE TO DAMPER LEAKAGE INDUCTANCE RATIO 1:1)
Load An- Original on-board EV Proposed on-board EV
gle motor motor with damper
Speed (r/min) 3951 3952
Torque Ripple (%) 14 64
30
Stator Current (A) 47.1 47.1
THD in Current (%) 11.1 66.8
Speed (r/min) 5579 5577
Torque Ripple (%) 12 36
40
Stator Current (A) 61.7 61.7
THD in Current (%) 5.8 36.6
Transition Time (s) 1.255 0.59
Transition Max. Electromagnetic Torque (Nm) 90 340
Max. Stator Current (Nm) 76 255
TABLE III
SAMPLE STEADY STATE AND DYNAMIC PERFORMANCE DATA OF THE PROPOSED MACHINE WITH DAMPER KEEPING STATOR TO DAMPER RESISTANCE
RATIO OF 1:1 AND VARYING THE STATOR TO DAMPER LEAKAGE INDUCTANCE RATIO
Load An- Stator to Damper Leakage Inductances Ratio
gle 3:1 2:1 1:1 1:3 1:5 1:10
Speed (r/min) 5584 5580 5576 5572 5571 5570
Torque Ripple (%) 64 50 32 22 16 14
40
Stator Current (A) 61.5 61.6 61.6 61.6 61.6 61.6
THD in Current (%) 56.6 48.6 35.9 79.6 13.4 9.8
Transition Time (s) 0.88 0.901 0.898 0.885 0.853 0.847
Maximum Electromag-
480 430 334 200 150 125
Transition netic Torque (Nm)
Maximum Stator Cur-
373 410 317 155 142 118
rent (A)
TABLE IV
SAMPLE STEADY STATE AND DYNAMIC PERFORMANCE DATA OF THE PROPOSED MACHINE WITH DAMPER KEEPING STATOR TO DAMPER LEAKAGE
INDUCTANCE RATIO OF 1:5 AND VARYING THE STATOR TO DAMPER RESISTANCE RATIO
Load Stator to Damper Resistance Ratio
Angle 3:1 2:1 1:1 1:3 1:5 1:10
Speed (r/min) 5575 5572 5571 5570 5570 5570
Torque Ripple (%) 18 16 16 16 16 16
40
Stator Current (A) 61.6 61.6 61.6 61.6 61.6 61.6
THD in Current (%) 13.4 13.4 13.4 13.4 13.4 13.4
Transition Time (s) 0.424 0.499 0.853 1.022 1.151 1.188
Maximum Electromag-
155 150 150 160 159 145
Transition netic Torque (Nm)
Maximum Stator Cur-
143 142 142 121 121 114
rent (A)
As seen from Table II, for both machines, the final speeds speed of the machine does not change much with the added
of the machines are determined by the load angle. The speed damper. The fundamental current amplitude is not affected by
increases when the load angle increases. Because of the distor- the damper either. However, the damper increases the distor-
tion in the terminal voltage, now containing lower side band tion in current and consequently increases the torque ripple
harmonics, the phase current has high distortion, and causes significantly. As a result, it is necessary to design a damper for
higher torque ripple in the machine. The distortion is greater at traction motor in order to improve dynamic performance as
lower speed than that at higher speed. The current waveforms well as keeping satisfactory steady-state performance.
of both machine at a load angle of 40 is shown in Fig.2. The Further studies to investigate the effect of damper on ma-
maximum current and torque of the machines during transition chine performance are conducted to understand the role of
from one steady-state speed to another are greatly influenced damper in IPMSM for EV application. The operation condi-
by the damper. It can be seen from the transition time, (defined tions are kept same as mentioned previously.
as the time for the speed to reach 90% of the steady-state val- Firstly, the ratio between stator resistance and damper re-
ue) that by adding a damper, the machine responds faster to sistance is kept constant as 1:1, and the ratio between stator
changes and restores to a new steady-state faster. This fast leakage inductance and damper leakage inductance is varied as
dynamic response is desired in an EV application. The final shown in the cases presented in Table III. The steady-state
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ia [A]
0
mains almost same. -20
Based on the performance analysis in Table IV, stator to
-40
damper leakage inductance ratio of 1:5 is selected for the
-60
analysis of the effect of damper resistance as it yields satisfac-
tory performances out of the considered cases. From results -80
-20
current of the IPMSM without damper shown in Fig. 4(a). As
a result of the transient response of the current, the peak elec-
-40
tromagnetic torque developed in the machine with damper
-60
shown in Fig. 5 (b) is higher than that of the original machine
-80 presented in Fig. 5(a). The corresponding speed responses of
-100
17.5 17.502 17.504 17.506 17.508 17.51 the two machines are given Fig. 6. As the torque response of
time [sec] the finalized EV motor with damper is faster, speed of that
(b) motor also settles faster for the same load torque as evident
Fig.2. Current waveforms of the machines investigated driven by square-wave
inverter with rotor position feedback at a load angle of 40. (a) Original on- from Fig. 6. The torque and speed of the machine with damp-
board EV motor. (b) On-board EV motor with damper parameters correspond- er definitely shows a better dynamic response compared to the
ing to Table II. original machine.
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nm (rpm)
conditions using high rupturing capacity (HRC) fuses. The 4500
100
ia (A)
-100
4.5 5 5.5 6
(a)
(b)
Fig.7.Calculated responses under 3-phase symmetrical short-circuit fault for
100 original EV motor without damper and the finalized EV motor with damper.
(a) Machine terminal voltage. (b) Machine phase current.
ia (A)
0
III. DESIGN AND FINITE ELEMENT ANALYSIS OF PMSMS WITH
-100 AND WITHOUT DAMPER BARS IN THE ROTORS
ume, and materials in the stator, magnet & rotor have been
50 kept the same as that of the commercially available EV motor.
The only difference between the commercially available EV
0
4.5 5 5.5 6 motor and this motor lies in the configuration of the permanent
(a) magnets [20] and this causes the power and torque rating to be
almost the same as that of the commercially available one.
Machine B is the one with everything the same as machine A
but with the magnets buried deeper. Hence, torque rating of
100
this motor is expected to go down a little. Subsequent studies,
Te (Nm)
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and slot per pole per phase value to be 2. Tph is turns per phase
equaling 72.
6 I phT ph
ac (5)
p
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Torque [Nm]
150 With Damper (Machine C)
2
0
Torque [Nm]
100 -2 0 3 6 9 12 15
-4
50 -6 Time [ms]
Fig. 12.Cogging torques of Machines B and C.
0
0 50 100 150 200 250
Stator Current [A pk] torque than the other two machines due to the reason that the
Fig. 10. Developed magnet-induced average torque as a function of increasing concentration of magnet flux in the air-gap is more than that of
stator current for all three machines under a constant speed of 3000 rpm and the other two machines. The point to note is that the Machine
= 0. C tends to produce more magnet-induced average torque than
200 Machine C ( = 70 deg)
(Gamma = 70 deg) 350 Machine B, even though the magnet placements in both ma-
Torque [Nm] for Machines B&C
Machine C (= 45deg)
(Gamma = 45 deg) chines B and C are maintained the same. The increase in the
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