International Research Journal of Power and Energy Engineering IRJPEE

Vol. 3(2), pp. 118-124, November, 2017. www.premierpublishers.org, ISSN: 3254-1213x

Conference Paper

Assessment of BLDC Motor for EV Application

Considering Vehicle Design Strategy
*Chethan S1 and Abhijith Singh S2
1,2
School of Electrical & Electronics Engineering, REVA University, Bangalore, India

Brush less direct current (BLDC) motors have become a popular choice for electric vehicle (EV)
application in recent time because of their outstanding performance and control characteristics.
In this paper, a brief review of advantages of electric drive over internal combustion (IC) engine
for vehicles is done and a brief comparison is made between BLDC motor and the other motors
suitable for EV application. This paper describes the basic design considerations and
calculations that need to be followed when selecting the motor ratings for the desired vehicle.
Simulation results of Hall Effect sensor signals for controlling the brush less motor and motor
characteristics are obtained.

Keywords: BLDC motor, EVs, vehicle design, Permanent Magnet Synchronous Moto, AC Induction Motor

INTRODUCTION

Brush less direct current (BLDC) have become a vital part
of the present industry in wide variety of applications
starting from medical, computers, electric vehicles, position
control, aeromodelling and domestic use. The latest
advancement in embedded technology and dedicated
controllers available for motor control have eased the
control of BLDC motors which was earlier considered as a
challenge. The research and development in the magnet
material used in rotor design have resulted in obtaining a
greater power density with reduced cost
(https://www.ornl.gov/content/ornl-prototype-motor-
generates-75-more-power) which have further augment
the desire for BLDC motors.
LITERATURE REVIEW
The present demand for superior performance and
exceptional energy efficient motors is due to strict electricity
consumption standards and electricity prices. The demand
for energy-saving motors is in raise globally on the account
of growing demand for motors for cars, household
appliances and other motor drive systems. Moreover, to
improve the efficiency of the motor, globally the
manufacturers are encouraged to follow exacting design
and manufacturing standards resulting in energy-saving
motors. However, the lack of acknowledgement of the
advantages of energy-saving motors, and the high incipient
cost, are hampering the development of superior
performance motors
(http://www.todaysmotorvehicles.com/article/electric-
motor-market-revenue-motor-vehicles-51614/).
A. Electric drive
The electrical actuator is an electromechanical system,
which is a combination of electric motor acting as a prime
mover and a mechanism for motion or process control. The
common application of electric drives includes fans,
compressor pumps, excavators, cars and electric
locomotive (U.A.Bakshi and M.V.Bakshi, 2009). Typical
power drive systems include controllers, motor,
transmissions, and driven loads. The key difference
between distinct types of electric drive systems is the type
of controller.
*Corresponding author: Chethan S, School of Electrical
and Electronics Engineering, REVA University, Bangalore,
India. Email: chethans.eee@gmail.com Co-Author
Email: abhijithsinghs@gmail.com

Assessment of BLDC Motor for EV Application Considering Vehicle Design Strategy

Chethan and Abhijith 119
Specific DC motor controller (Herman and Stephen L,
2010) which includes motor starter, switches and operator
control or an electronic motor controller called a drive
controller that uses the semiconductor having electronic
circuitry and software to perform the same function of
different DC motor control components
(http://www.ohioelectricmotors.com/2015/07/a-guide-to-
electric-drives-and-dc-motor-control).
B. Choice of electric drive over IC engine
The main advantage of the motor over the IC engine is that
the full torque is provided by the motor at low speed and
the fleet rated power can be two or three times the rated
power of the motor. These are the features that allow the
vehicle to have a peerless acceleration of the nominal rated
motor. The motor produces high torque even at zero speed
and typically has a constant power characteristic over a
wide speed range. Therefore, the motor can be mounted
directly on the drive wheel and accelerate from zero speed
to the maximum speed (Husain and Iqbal, 1964).
Compared with other types of drive systems, electric drives
have the following advantages, such as: Control features
can be adapted to application requirements, Simple and
convenient speed control method. Electric brake can be
easily applied, no pollution, Wide range of speed, power,
torque rating, more efficient, Brief time overload capacity,
Fig 1 Structures of Different Types of Motors
Assessment of BLDC Motor for EV Application Considering Vehicle Design Strategy
Self-starting - No external boot device required, compared
with the hydraulic and diesel prime mover, it runs cleaner,
with less noise and less maintenance (U.A.Bakshi and
M.V.Bakshi, 2009).
Introduction to Various Motor Types
a. Brushed DC Motor
The brush DC motor converts the direct current in the
armature coil as shown in Fig 1(a) into an alternating
current by the commutator and brush arrangement. When
the current flows through the commutator through the
armature winding, the electromagnetic field repels the
magnet near the same polarity and causes the winding to
turn to attract the magnet with opposite polarity. When the
armature is rotated, the commutator reverses the current in
the armature coil to repel the nearby magnet, thereby
causing the motor to rotate continuously. The motor can be
driven by DC voltage and current, which is very attractive
for low cost applications. The limiting factor is the
commutator and brush arrangement causes arcing at the
brushes resulting in heat, mechanical losses and electro-
magnetic interference (EMI) problem
(https://www.monolithicpower.com/Portals/0/Documents/P
roducts/Documents/appnotes/Brushless%20DC%20Motor
%20Fundamentals.pdf).

b. Brushless DC (BLDC) Motor
The BLDC motor uses the internal rotor position feedback
for commutation to determine the switching sequence of
the phases of stator winding. The layout is unveiled in Fig
1. (b) Feedback normally requires additional rotary
encoders or Hall sensors. The windings of stator work in
unison with the permanent magnets on the rotor to produce
an almost uniform magnetic flux density in the air gap.
Thus, the stator coil is directed by a persistent DC voltage
(referred to as brushless DC), that switches directly from
one stator coil to the other to produce a trapezoidal shaped
voltage waveform
(https://www.monolithicpower.com/Portals/0/Documents/P
roducts/Documents/appnotes/Brushless%20DC%20Motor
%20Fundamentals.pdf ).
c. AC Induction Motor (ACIM)
A sinusoidal alternating current flow via the stator to
produce a variable rotating magnetic field which causes a
current in the rotor (usually built of a non-ferrous metal
material). The induced current that circulates in the bar of
the rotor which produces a magnetic field. These two
magnetic fields run at different frequencies (usually the
omega-s> -r of the motor) and generate torque. Fig
1(c)shows the motor layout
(https://www.monolithicpower.com/Portals/0/Documents/P
roducts/Documents/appnotes/Brushless%20DC%20Motor
%20Fundamentals.pdf).
d. Permanent Magnet Synchronous Motor (PMSM)
PMSM motors have some resemblance to BLDC motors,
but are made to run by sinusoidal signals by which lower
torque ripple is achieved. The sinusoidal conveyance of the
multiphase stator windings produces a flux density which is
sinusoidal that is different from the trapezoidal flux density
of the BLDC motor in the air gap. However, newer design
can be achieved by this sinusoidal flux density through a
concentrated stator winding and an improved rotor
structure. The position of rotor magnet can significantly
change the electrical characteristics of the PMSM. The
rotor magnet is mounted on the surface with the result that
the torque ripple is small and the magnet is buried Inside
the rotor structure increases the significance, thereby
increasing the reluctance torque motor
(https://www.monolithicpower.com/Portals/0/Documents/P
roducts/Documents/appnotes/Brushless%20DC%20Motor
%20Fundamentals.pdf). The structure of the PMSM is
shown in fig 1(d).
EV considerations
The choice of electric vehicle propulsion system depends
mainly on the driver's expectations which is defined by the
driving characteristics, including acceleration, top speed,
acclivity, braking and range
Assessment of BLDC Motor for EV Application Considering Vehicle Design Strategy
Int. Res. J. Power Energy Engin. 120
Vehicle constraints
Depend on vehicle type, vehicle weight and payload.
Energy source depends on batteries, fuel cells, capacitors,
flywheels and a variety of hybrid power sources.
The process of identifying the preferred features and
packaging options for power advance must be made at the
system level. The interaction between the subsystem and
the possible impact of the system trade-off must be
checked.
Concept of EV motors
The use of motors for EV application is quite different as
considered to typical application scenario, as it often
requires recurrent start / stop, intense acceleration /
retardation, excessive torque reduced speed climbing, flat
torque high speed cruising and extended operating ranges,
while industrial motors are often optimized for rated
conditions. Therefore, EV motors are unique, so they
should be formed as a separate class. In addition to
meeting the above specific requirements, EV motor design
also complies on the electric vehicle system technology.
From a technical point of view, the following key issues
should be considered:
1. single motor or multi motor configuration
2. fixed or variable transmission
3. gear or gearless
4. system voltage
Integrated motor and converter, controller, transmission
and energy integration is the primary focus. EV motor
designers must be completely aware of the characteristics
of these components, so in this given environment design
of the motor. And the normal industrial drive under the
standard power supply of ordinary standard motor is
completely different (Chan, C.C. and Chau, K.T, 2001).
D. MOTOR SELECTION FOR EV APPLICATION
The inherent advantages of BLDC give it more competitive
edge over other motors with low inertia, excessive torque,
and extended speed range.it exhibits efficient thermal
features, high efficiency and increased power density than
regular DC motors (S. K. Pillai, 2007). The miniature size
has resulted in compromise in its weight and high speed
range is attainable due to the absence of brush-
commutator arrangement. Lack of electrical and frictional
losses provides longer service life; absence of brushes and
mechanical commutator make the BLDC motor almost
maintenance-free and reduced EMI and noise. Highly
recommended for unsafe environments (dirt, oil, grease
and other foreign objects), because they can be enclosed
completely. Operative features comprise of high speed,
overload, high torque control, short periods of action and
high acceleration and deceleration ability.
Chethan and Abhijith 121

The superior performance features like low inertia and
quick response of the BLDC motor is the result of rotor
design and special permanent magnets used. Very
common reason for rotor design of the BLDC motor is to
connect the permanent "magnetic field" magnets axially to
the rotor shaft in a cylindrical or salient pole structure. The
armature coil of the motor is mounted on the stator housing
core (Dale R. Patrick and Stephen W. Fardo, 2000).
Comparing BLDC motors with other motor types
(https://www.monolithicpower.com/Portals/0/Documents/
Products/Documents/appnotes/Brushless%20DC%20Mot
or%20Fundamentals.pdf)
BLDC motor challenges
The cost of the BLDC motor and associated complexity in
design of the controller was the main hindrance for
extensive use of BLDC as a mechanical source, however
with the more advancement in electronics and embedded
technology the cost and complexity is reduced which has
augmented (Machine Design Magazine. Brushless DC
Motors. Penton Media, Inc., 2012) the use of BLDC motors
in all the fields like medical, computers, automotive and
domestic applications.

Assessment of BLDC Motor for EV Application Considering Vehicle Design Strategy

 Int. Res. J. Power Energy Engin. 122

The use of rare-earth magnets in BLDC motors has

increased the performance-to-cost ratio of motors (Jacek Step 5: Total Tractive Effort TTEis sum of all the obtained
F. Gieras, Rong-Jie Wang and Maarten J. Kamper. Axial results
Flux Permanent Magnet Brushless Machines. Springer,
2008. Page 96). TTE = RR + GR + FA+Fd
TTE = 166.9+2340+3100+307
Selection of motor rating based on Vehicle Design TTE = 5.92 KN
data
Step 6: Determine Torque required to accelerate the
The steps to choose a BLDC Motor capable of producing vehicle from rest (Mehrdad Ehsani, 2002).
enough torque to propel the example Vehicle
(https://www.mahindrae2oplus.com/pages/buyers- TW [N - m] = TTE* RW[M] * RF [-] (5)
guide/specifications) are discussed below. The various Where
design data of a vehicle are listed below: TW [N - m] = Wheel Torque
GVW: Gross Vehicle Weight (Vehicle + Passenger) = 1310 RW[M] = radius of the Wheel
Kgs.RW: Radius of wheel: 14 inches. Vmax: Desired Top RF = Co-efficient of rolling friction (0.01 for ordinary cars
Speed: 85 km/h (23.6 m/s). ta: Desired Acceleration Time: on asphalt)
10 s. : Maximum incline angle: 10.5. Gear ratio of 8.64:1 TW [N - m] = 5920 * 0.36 * 0.01*9.8 = 208.8 N-m

Step 1; Rolling Resistance (RR) force required to move a Step 7: Motor torque [MT] to be developed by the electric
vehicle over a surface motor to accelerate the car from rest. Considering the gear
ratio of 8.64:1
RR[N] = GVW[N] * Crr (1) (https://www.mahindrae2oplus.com/pages/buyers-
Where Crr= Rolling resistance co-efficient (car tires on guide/specifications) and including additional of 5 % for un
asphalt=0.013) accounted losses.
RR[N] = 1310*9.8* 0.031= 166.9 N
MT = (TW [N - m] *1.05*) /8.64(6)
Step 2: Grade Resistance (GR) force required to move a MTT= (208.8*1.05)/8.64
vehicle against a slope. MTT = 25.4 N m

GR[N] = GRW[N]*Sin() (2) Step 8: Motor selection

GR[N] = 1310*9.8*Sin (10.5)= 2.34 KN
After obtaining the above result we refer the BLDC motor
Step 3: Accelerating Force (FA) the force requires to bring manual for selecting the motor with required torque and
the vehicle to maximum speed from rest. speed. There are number of models of BLDC motors are
GVM [M]* VMAX m
available for this application out of which we are choice is
FA[N] =
s (3)
for Type: 72V3000W and Type: 48V3000W these models
run at a speed of Speed: 3000-5000 rpm and generate a
m
9.81 2 * t a (s)
s Rated torque:10 N.m and Peak torque: 25 N.m
13109.823.6 (http://goldenmotorcz.en.made-in
FA[N] = = 3.1KN china.com/product/DSXJArqMYfWu/China-Ce-Approved-
9.810
3kw-5kw-10kw-20kw-BLDC-Motor-for-Electri-Car-
Step 4: determining the effect of drag force Fd on the Motorcycle-Boat-Go-Carts.html).
vehicle (Chan, C.C. and Chau, K.T, 2001).

Fd= 0.5 * * Cd * A * (V + Vo)2 (4) SIMULATION RESULTS

Where A specific sequence of control signals is generated by
= Air Density 1.23 kg/m3 sensing the rotor position of BLDC motor using hall sensors
Cd = Aerodynamic Drag Co-efficient (for passenger car the embedded in the motor, these signals are used to control
is 0.2) the inverter module which further controls the operation of
A = Frontal Area m2 (Assuming 4 m2 of width) BLDC motor. Simulation is carried out in MAT lab Simulink
V = Vehicle Velocity m/s (assuming 85Km/h=11.1 m/s) environment for generating the control signals and the
Vo = Head Wind Velocity m/s (assuming 5 Km/h=1.38 m/s) results are shown as below.
2
Fd= 0.5 * 1.23 * 0.2 *4 * (23.6 + 1.38)
Fd = 307 N

Assessment of BLDC Motor for EV Application Considering Vehicle Design Strategy

Chethan and Abhijith 123

Fig 2. Matlab Simulink Model of BLDC Motor and Switching Sequence Circuit

Fig 5. Simulation Results: Stator Current

Fig 3. Simulation Results: Hall Sensor Signals

Fig 6. Simulation Results: Stator Back EMF

Fig 4. Simulation Results: Switching Sequence
Waveforms

Assessment of BLDC Motor for EV Application Considering Vehicle Design Strategy


Fig 7. Simulation Results: Rotor Speed in rpm &
Electromagnetic Torque
CONCLUSION REMARKS
A review of some of the motors used for EV applications
are compared with respect to EV considerations.
This paper throws light on the design considerations and
procedural steps to be followed for selection of motor for
EV applications. This paper can be referred for basic
design of different type of EV applications.
REFERENCES
Chan C.C, Chau, K.T (2001). Modern Electric Vehicle
Technology, 1st ed.; Oxford University Press: New
York, NY, USA, pp. 1628.
Dale R. Patrick and Stephen W. Fardo (2000). Industrial
Electronics: Devices and Systems, Second Edition.
CRC Press, page 610.
Herman, Stephen L (2010). Industrial Motor Control. 6th
ed. Delmar Cengage Learning. Page 1
http://goldenmotorcz.en.made-in
china.com/product/DSXJArqMYfWu/China-Ce-
Approved-3kw-5kw-10kw-20kw-BLDC-Motor-for-
Electri-Car-Motorcycle-Boat-Go-Carts.html.
http://ww1.microchip.com/downloads/en/AppNotes/00885
a.pdf
http://www.ohioelectricmotors.com/2015/07/a-guide-to-
electric-drives-and-dc-motor-control/
http://www.todaysmotorvehicles.com/article/electric-
motor-market-revenue-motor-vehicles-51614/
Assessment of BLDC Motor for EV Application Considering Vehicle Design Strategy
Int. Res. J. Power Energy Engin. 124
https://www.mahindrae2oplus.com/pages/buyers-
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generates-75-more-power
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(2008). Axial Flux Permanent Magnet Brushless
Machines. Springer. Page 96.
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Accepted 23 October, 2017
Citation: Chethan S and Abhijith Singh S (2017).
Assessment of BLDC Motor for EV Application
Considering Vehicle Design Strategy. International
Research Journal of Power and Energy Engineering, 3(2):
118-124.
Copyright: 2017. Chethan and Abhijith. This is an open-
access article distributed under the terms of the Creative
Commons Attribution License, which permits unrestricted
use, distribution, and reproduction in any medium,
provided the original author and source are cited.