Editorial

4 pages, 189 KiB

Open AccessEditorial

Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles

by Syed Sabir Hussain Bukhari

World Electr. Veh. J. 2023, 14(6), 149; https://doi.org/10.3390/wevj14060149 - 04 Jun 2023

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Electrical machines are the key components in the ongoing energy transition and electrification and will be an integral part of people’s lives in a future low-carbon society [...] Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

Research

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16 pages, 5537 KiB

Open AccessArticle

Design and Performance Analysis of Super Highspeed Flywheel Rotor for Electric Vehicle

by Pengwei Wang, Tianqi Gu, Binbin Sun, Ruiyuan Liu, Tiezhu Zhang and Jinshan Yang

World Electr. Veh. J. 2022, 13(8), 147; https://doi.org/10.3390/wevj13080147 - 04 Aug 2022

Cited by 2 | Viewed by 2048

Abstract

The optimal design of a super highspeed flywheel rotor could improve flywheel battery energy density. The improvement of flywheel battery energy density could enhance the performance of the flywheel lithium battery composite energy storage system. However, there are still many problems in the [...] Read more.

The optimal design of a super highspeed flywheel rotor could improve flywheel battery energy density. The improvement of flywheel battery energy density could enhance the performance of the flywheel lithium battery composite energy storage system. However, there are still many problems in the structure, material and flywheel winding of super highspeed flywheels. Therefore, in this paper, electric flywheel energy and power density parameters are designed based on CPE (Continuous Power Energy) function and vehicle dynamics. Then, according to the design index requirements, the structure, size and material of the electric flywheel rotor are designed. Furthermore, the numerical analysis model of stress and displacement of multi-ring interference fit flywheel rotor under plane stress state is established. On this basis, the influence laws of flywheel rotor wheel flange numbers and interlaminar interference on stress distribution of flywheel rotor are analyzed, and the assembly form of wheel flange is determined. Finally, the stress check of the flywheel rotor is completed. The results show that the super highspeed flywheel rotor designed in this paper meets vehicle dynamics requirements in terms of energy storage and power. In terms of strength, it meets the design requirements of static assembly stress and dynamic stress at maximum speed. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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19 pages, 7890 KiB

Open AccessArticle

Dynamic Performance Enhancement of a Direct-Driven PMSG-Based Wind Turbine Using a 12-Sectors DTC

by Abdullah Eial Awwad

World Electr. Veh. J. 2022, 13(7), 123; https://doi.org/10.3390/wevj13070123 - 04 Jul 2022

Cited by 8 | Viewed by 2133

Abstract

This paper focuses on the performance analysis, modeling, and control of permanent magnet synchronous generator (PMSG)-based wind energy conversion. This work analyzes controllers for the machine-side converter (MSC) and grid-side converter (GSC) and presents a new direct torque control (DTC) scheme based on [...] Read more.

This paper focuses on the performance analysis, modeling, and control of permanent magnet synchronous generator (PMSG)-based wind energy conversion. This work analyzes controllers for the machine-side converter (MSC) and grid-side converter (GSC) and presents a new direct torque control (DTC) scheme based on a 12-sectors polygonal DTC for variable speed control of the PMSG. The proposed method solves the drawbacks faced by conventional six-sectors DTC control. The proposed method utilizes 12 sectors of 30° each compared to 60° in the conventional 6-sectors DTC. The 12-sectors technique was applied to voltages and flux vectors to increase the degrees of freedom for the selection of optimal vectors and, thus, reduce the torque ripple. This work analyzed the aforementioned DTC methods using MATLAB/Simulink, comparing the dynamic response of the proposed 12-sectors DTC with the conventional 6-sectors DTC control, and the results verified the effectiveness of the proposed DTC control. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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22 pages, 4225 KiB

Open AccessArticle

Comparative Study of BLDC Motor Drives with Different Approaches: FCS-Model Predictive Control and Hysteresis Current Control

by Mohamed Azab

World Electr. Veh. J. 2022, 13(7), 112; https://doi.org/10.3390/wevj13070112 - 24 Jun 2022

Cited by 9 | Viewed by 4275

Abstract

The control techniques of the brushless DC (BLDC) motor have gained a large amount of interest in recent years, with their use being implemented in order to achieve a high-performance drive, including quick transient response and high-quality waveforms at the steady state. This [...] Read more.

The control techniques of the brushless DC (BLDC) motor have gained a large amount of interest in recent years, with their use being implemented in order to achieve a high-performance drive, including quick transient response and high-quality waveforms at the steady state. This paper provides a comparative study between three control schemes of BLDC motors: the direct power control scheme using a finite control set model predictive control (FCS-MPC) approach, the stator current controlled scheme using an FCS-MPC approach, and the stator current controlled scheme using ON–OFF hysteresis current controllers. The three systems were studied and investigated under the same operating conditions. The comparative study included investigating the performance of the BLDC drive in both steady state and transient operations. Qualitative and quantitative analyses were performed on the results obtained with each control scheme. The obtained results demonstrate the validity and effectiveness of the three investigated schemes in controlling the motor speed to the desired value under sudden load changes and achieving satisfactory quick transient responses. However, the results indicate the superiority of the direct power control scheme using an FCS-MPC approach over the others in terms of its minimum torque ripple, lowest torque and speed pulsations, minimum active and reactive power ripples, and high-quality waveforms of the stator currents drawn by the motor with minimum THD. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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21 pages, 8755 KiB

Open AccessArticle

On the Development and Experimental Validation of a Novel and Intuitive Interior Permanent Magnet Synchronous Motor Controller for Electric Vehicle Application

by Muhammad Nur Yuniarto, Indra Sidharta, Yohanes Yohanes and Yoga Uta Nugraha

World Electr. Veh. J. 2022, 13(6), 107; https://doi.org/10.3390/wevj13060107 - 20 Jun 2022

Cited by 4 | Viewed by 1949

Abstract

This paper discusses the process of developing a novel and robust algorithm for an interior permanent magnet synchronous motor controller. This is necessary for the simplification of the setting of control parameters and maintaining the proper operation of the motor. A 3D torque [...] Read more.

This paper discusses the process of developing a novel and robust algorithm for an interior permanent magnet synchronous motor controller. This is necessary for the simplification of the setting of control parameters and maintaining the proper operation of the motor. A 3D torque lookup table was used in which two inputs were considered, i.e., accelerator movements and the motor rotational speed. These two inputs allowed the lookup table to generate a specified torque at any motor rotation, which was then fed-forward to the field-oriented control and space vector pulse width modulation algorithm. Modeling, simulation, and experimental tests were performed to design and validate the proposed controller. The experimental validation shows that the proposed controller worked as intended. This was indicated by its ability to control the motor to obtain a 7% higher torque output than in the simulation in the constant torque region. In the field-weakening region, the controller could make the motor reach a maximum speed of 5500 RPM. There was only an 8% difference compared to the simulation (6500 RPM). In terms of maximum power generated, the controller was able to match the simulation output with only a 5% difference. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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24 pages, 9462 KiB

Open AccessArticle

A New Hybrid Ant Colony Optimization Based PID of the Direct Torque Control for a Doubly Fed Induction Motor

by Said Mahfoud, Aziz Derouich, Najib El Ouanjli, Nguyen Vu Quynh and Mahmoud A. Mossa

World Electr. Veh. J. 2022, 13(5), 78; https://doi.org/10.3390/wevj13050078 - 29 Apr 2022

Cited by 16 | Viewed by 2597

Abstract

Due to its advantages, the Proportional Integral Derivative (PID) controller has been the most widely used controller in the industrial sector. It allows linear systems to have good performance, but if the system is subjected to physical variation conditions, the system’s behavior becomes [...] Read more.

Due to its advantages, the Proportional Integral Derivative (PID) controller has been the most widely used controller in the industrial sector. It allows linear systems to have good performance, but if the system is subjected to physical variation conditions, the system’s behavior becomes non-linear, in which case the PID controller is insufficient. The use of the PID controller for speed control in rotating machines, such as the doubly fed induction motor (DFIM) is widely used, but the non-linearity of the machine parameters allows for undesirable behaviors, resulting in overshoots and torque ripples. For this reason, several techniques have been adopted to increase the DTC’s robustness. One finds the integration of artificial intelligence as optimization algorithms. These algorithms are used to generate gains close to the optimum, converging the behavior of the DFIM to its optimum. In this work, an Ant Colony Optimization (ACO) algorithm was proposed to adjust the PID controller gains of the DTC control to control the DFIM, using a combined weighting cost function, to obtain efficient torque and speed control. This paper presents a new hybrid structure resulting from the intelligent ACO-DTC control implemented on Matlab-Simulink. The performance results extracted from the simulation showed the effectiveness of the intelligent ACO-DTC control, which provides satisfactory performance in terms of rapidity, stability, precision, and torque ripples compared to the conventional DTC. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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16 pages, 2601 KiB

Open AccessArticle

Multi-Objective Optimization and Test of a Tractor Drive Motor

by Mengnan Liu, Yanying Li, Sixia Zhao, Bing Han, Shenghui Lei and Liyou Xu

World Electr. Veh. J. 2022, 13(2), 43; https://doi.org/10.3390/wevj13020043 - 19 Feb 2022

Cited by 5 | Viewed by 2542

Abstract

The design objectives of the structural parameters of the tractor drive motor are diverse, and the constraints are complex. It is difficult to optimize the overall performance of the unit by using the empirical method and single-objective optimization method. This paper proposes a [...] Read more.

The design objectives of the structural parameters of the tractor drive motor are diverse, and the constraints are complex. It is difficult to optimize the overall performance of the unit by using the empirical method and single-objective optimization method. This paper proposes a multi-objective optimization method for tractor drive motors based on an improved Non-dominated Sorting Genetic Algorithm II (NSGA-II). Constraints are formulated according to the inherent characteristics of the motor itself and the characteristics of the tractor’s working conditions. The objective function was established with the heat loss of the drive motor and the total efficiency of the drive system. Based on the designed solution process of NSGA-II algorithm, an example optimization was carried out, and the tractor electromechanical drive system was carried out with the single-objective optimization results of the optimal energy use efficiency of the drive motor and the optimal mechanical transmission efficiency of the transmission system as the control group. The test results show that compared with the control group, the proposed multi-objective optimization method can make the overall tractor system efficiency the highest, and the maximum and rated values of the total efficiency

η_{q}

of the drive system of the multi-objective optimization design scheme. Compared with the optimal design scheme with

η_{me}

as a single objective, it was increased by 2% and 1.4%, respectively, and compared with the optimal design scheme with

η_{tr}

as a single objective, it is improved by 26.5% and 73.6%, respectively. It can provide an effective calculation method for the motor design problem in the subsequent development of the tractor electromechanical drive system. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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14 pages, 17710 KiB

Open AccessArticle

A Reference Voltage Self-Correction Method for Capacitor Voltage Offset Suppression of Three-Phase Four-Switch Inverter-Fed PMSM Drives

by Wei Chen, Sai Wang, Xinmin Li and Guozheng Zhang

World Electr. Veh. J. 2022, 13(2), 24; https://doi.org/10.3390/wevj13020024 - 19 Jan 2022

Cited by 3 | Viewed by 2066

Abstract

This paper proposes a capacitor voltage offset suppression method based on reference voltage self-correction for a three-phase four-switch (TPFS) inverter-fed permanent magnet synchronous motor (PMSM) drive system to improve the motor control performance. Firstly, the αβ-axis reference voltage deviation caused by capacitor voltage [...] Read more.

This paper proposes a capacitor voltage offset suppression method based on reference voltage self-correction for a three-phase four-switch (TPFS) inverter-fed permanent magnet synchronous motor (PMSM) drive system to improve the motor control performance. Firstly, the αβ-axis reference voltage deviation caused by capacitor voltage offset is analyzed, and the relationship between the voltage to be compensated and the offset is obtained. Then, the capacitor voltage offset is calculated according to the motor speed, rotor position, current vector amplitude, and capacitance on the capacitor bridge arm of the TPFS inverter. Finally, the reference voltage is corrected according to the voltage to be compensated and the capacitor voltage offset. This method is simple and easy to implement, and there is no need to add voltage sensors or filters in the system to extract the capacitor voltage offset, and there is no complex parameter adjustment. The effectiveness of the proposed method is verified by experiments on a 20 kW interior permanent magnet synchronous motor. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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12 pages, 4006 KiB

Open AccessEditor’s ChoiceArticle

A Novel Sub-Harmonic Synchronous Machine Using Three-Layer Winding Topology

by S M Sajjad Hossain Rafin, Qasim Ali and Thomas A. Lipo

World Electr. Veh. J. 2022, 13(1), 16; https://doi.org/10.3390/wevj13010016 - 04 Jan 2022

Cited by 15 | Viewed by 3319

Abstract

This paper proposes a novel brushless synchronous machine topology that utilizes stator sub-harmonic magnetomotive force (MMF) for desirable brushless operation. The sub-harmonic MMF component that is used in this novel topology is one fourth of the fundamental MMF component, whereas, in previous practices, [...] Read more.

This paper proposes a novel brushless synchronous machine topology that utilizes stator sub-harmonic magnetomotive force (MMF) for desirable brushless operation. The sub-harmonic MMF component that is used in this novel topology is one fourth of the fundamental MMF component, whereas, in previous practices, it was half. To achieve the brushless operation, the novel machine uses a unique stator winding configuration of two sets of balanced 3-phase winding wound in 3 layers. For the rotor, additional winding is placed to induce the sub-harmonic component to achieve the brushless excitation. Unlike its predecessors, it utilizes maximum allowable space in the stator to house conductors in all of its slots. To implement the topology, 8-pole, 48-slot sub-harmonic brushless synchronous machine model has been designed. A 2-D finite element analysis (FEA) is used to simulate and validate the performance of the novel machine as a motor. The proposed topology shows better average torque than the existing sub-harmonic wound rotor brushless synchronous machine topologies. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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12 pages, 4851 KiB

Open AccessArticle

I-SA Algorithm Based Optimization Design and Mode-Switching Strategy for a Novel 3-Axis-Simpson Dual-Motor Coupling Drive System of PEV

by Zhun Cheng

World Electr. Veh. J. 2021, 12(4), 221; https://doi.org/10.3390/wevj12040221 - 04 Nov 2021

Cited by 5 | Viewed by 1301

Abstract

Pure electric vehicle (PEV) equipped with a dual-motor coupling drive system can make full use of the high efficiency working range of the motor in order to improve vehicle efficiency. In order to further expand the application range of the system and to [...] Read more.

Pure electric vehicle (PEV) equipped with a dual-motor coupling drive system can make full use of the high efficiency working range of the motor in order to improve vehicle efficiency. In order to further expand the application range of the system and to improve its practical application, this paper designs and proposes a new dynamic coupling drive system of three axis-double working modes, which is based on the Simpson planetary gear train. The new system adopts two planetary gears (P1 and P2), and the two sun gears of double rows, planetary carrier of P1 and gear ring of P2 are bunded. The power output of the P1 gear ring (mode 1) and P2 planetary carrier (mode 2) is realized by a controlling wet clutch. This paper adopts the linear interpolation method, least square method and 5-fold CV cross validation method to establish the full load speed characteristics and efficiency characteristics models of two motors (13 and 30 kW). This paper proposes an optimization design method based on an improved simulated annealing (I-SA) algorithm for new system parameter matching and working mode switching strategy determination. The results show that the modeling accuracy of the two motors is high, and the mean value of MAPE is 4.337%. The proposed optimization design method achieves the demand goal of PEV effectively. The I-SA algorithm has good effectiveness and fast convergence, the mean efficiency of the optimized PEV is 83.91% under all working conditions, the maximum speed is 142.56 km/h and the power utilization rate of the dual-motor is 100%. This study proposes a new hardware system and a design optimization method on software and provides a direct reference for the research of PEV drive systems by combining hardware with software. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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7 pages, 1950 KiB

Open AccessCommunication

Cost-Effective Scheme for a Brushless Wound Rotor Synchronous Machine

by Ghulam Jawad Sirewal and Syed Sabir Hussain Bukhari

World Electr. Veh. J. 2021, 12(4), 194; https://doi.org/10.3390/wevj12040194 - 16 Oct 2021

Cited by 4 | Viewed by 1660

Abstract

This paper proposes a new scheme for a brushless wound rotor synchronous machine (WRSM) by generating an additional, two-pole component of magneto-motive force (MMF) with a series-connected additional three-phase winding with the armature three-phase winding. Unlike existing brushless excitation schemes, which use the [...] Read more.

This paper proposes a new scheme for a brushless wound rotor synchronous machine (WRSM) by generating an additional, two-pole component of magneto-motive force (MMF) with a series-connected additional three-phase winding with the armature three-phase winding. Unlike existing brushless excitation schemes, which use the inverter to inject harmonic currents in the stator windings, the proposed scheme uses series-connected additional winding on the stator with the armature winding in a two-pole configuration. Consequently, as the current flows in the armature winding, it creates a fundamental rotating air gap flux to interact with the field flux. At the same time, additional rotating flux is created from the additional three-phase winding, which cannot synchronize with the field winding. This additional flux can cause the induction of a voltage in a winding with exactly the same number of poles. For this purpose, a harmonic winding is installed in the rotor along with the field winding connected through a diode bridge rectifier, in order to feed the direct current (DC) to the field winding for rotor excitation without an input current from the brush-slip-ring assembly. The 2D finite-element analysis (FEA) was performed to validate the brushless operation of the proposed machine system. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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20 pages, 6190 KiB

Open AccessArticle

Back EMF Waveform Comparison and Analysis of Two Kinds of Electrical Machines

by Yingjie Cui, Munawar Faizan and Zhongxian Chen

World Electr. Veh. J. 2021, 12(3), 149; https://doi.org/10.3390/wevj12030149 - 08 Sep 2021

Cited by 3 | Viewed by 2983

Abstract

In this study, the back electromotive force (EMF) waveforms of a flux switching permanent magnet (FSPM) machine and variable flux memory permanent magnet (VFMPM) machine with same main dimension were researched. Firstly, the simulation result showed that the maximum amplitude of phase back [...] Read more.

In this study, the back electromotive force (EMF) waveforms of a flux switching permanent magnet (FSPM) machine and variable flux memory permanent magnet (VFMPM) machine with same main dimension were researched. Firstly, the simulation result showed that the maximum amplitude of phase back EMF waveform of FSPM machine was 245% larger than that of the VFMPM machine, and this was verified by the experimental result (243%). Secondly, the phase back EMF harmonics of the FSPM machine and VFMPM machine were compared, including the enhance flux condition and weaken flux condition of VFMPM machine. At last, the mutual demagnetization effect, which led to the difference amplitudes of maximum back EMF waveform between FSPM machine and VFMPM machine was analyzed. The comparison and analysis of the back EMF waveform will provide some qualitative advice for the future application research of the FSPM machine and VFMPM machine, such as application selection, optimization control method and so on. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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Review

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19 pages, 6040 KiB

Open AccessReview

A Study on Additive Manufacturing for Electromobility

by Dirk Schuhmann, Christopher Rockinger, Markus Merkel and David K. Harrison

World Electr. Veh. J. 2022, 13(8), 154; https://doi.org/10.3390/wevj13080154 - 13 Aug 2022

Cited by 11 | Viewed by 4214

Abstract

Additive manufacturing (AM) offers the possibility to produce components in a resource-efficient and environmentally friendly way. AM can also be used to optimise the design of components in mechanical and physical terms. In this way, functionally integrated, lightweight, highly efficient, and innovative components [...] Read more.

Additive manufacturing (AM) offers the possibility to produce components in a resource-efficient and environmentally friendly way. AM can also be used to optimise the design of components in mechanical and physical terms. In this way, functionally integrated, lightweight, highly efficient, and innovative components can be manufactured with the help of additive manufacturing in terms of Industry 4.0. Furthermore, requirements in the automotive industry for drivetrain components are increasingly being trimmed in the direction of efficiency and environmental protection. Especially in electromobility, the topic of green efficiency is an essential component. Exhaust emission legislation and driving profiles for evaluating vehicles are becoming increasingly detailed. This offers the potential to apply the advantages of AM to vehicle types such as conventional, utility vehicles, and nonroad mobile machinery (NRMM), independent of the electrical drivetrain technology (hybrid or fully electrical). AM also allows for us to produce optimally adapted components to the respective requirements and use cases. In this review, the intersections of AM and electromobility are illuminated, showing which solutions and visions are already available for the different vehicle types on the market and which solutions are being scientifically researched. Furthermore, the potential and existing deficit of AM in the field of electromobility are shown. Lastly, new and innovative solutions are presented and classified according to their advantages and disadvantages. Full article

(This article belongs to the Special Issue Design, Analysis and Optimization of Electrical Machines and Drives for Electric Vehicles)

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