Multiphase Hybrid Electric Machines: Applications for Electrified Powertrains

234 Pages·2021·10.484 MB·English

by  Ahmad S. Al-Adsani, Omid Beik

Ahmad S. Al-Adsani
Omid Beik
Multiphase
Hybrid
Electric
Machines
Applications for Electrified Powertrains
Multiphase Hybrid Electric Machines
(cid:129)
Ahmad S. Al-Adsani Omid Beik
Multiphase Hybrid Electric
Machines
fi
Applications for Electri ed Powertrains
AhmadS.Al-Adsani OmidBeik
DepartmentofElectricalEngineering DepartmentofElectricalandComputer
Technology,PublicAuthorityforApplied Engineering
EducationandTraining(PAAET) McMasterUniversity
CollegeofTechnologicalStudies(CTS) Hamilton,ON,Canada
KuwaitCity,Kuwait
ISBN978-3-030-80434-3 ISBN978-3-030-80435-0 (eBook)
https://doi.org/10.1007/978-3-030-80435-0
©SpringerNatureSwitzerlandAG2022
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Preface
Developmentofroadvehiclesthroughelectrifiedpowertrainswithoutcompromising
theirpowercapability,efficiency,performance,reliability,safety,drivingrange,and
costhasbeenthecenterofattentioninacademiaandindustry.Thisbookisauser-
friendly reference and attractive subject for researchers and undergraduate and
graduateengineerswhoareinterestedinmultiphase,permanentmagnetandhybrid
machine topologies with a specific application in electric and hybrid electric
vehicles.
This book begins with an overview and principals of classical electric machine
operation, magnetic modeling, and characteristics of materials. Various classical
electric machine topologies,includingbrushedDC,anddifferentACmachinesare
discussedinChap.1.
Chapter 2 discusses hybrid electric machine concept together with a review of
differenthybridmachinetopologies,indicatingtheiroperationalphilosophy,advan-
tages,anddisadvantages.
Chapter3presentsahybridpermanentmagnet(HPM)machinetopologythatis
selected and analyzed in terms of its geometry, excitation field technique, back-
EMF, and developed electromagnetic torque for both no-load and on-load opera-
tions.TheHPMtopologyconsistsoftwodifferentsynchronousmachines,aperma-
nent magnet (PM) and a wound field (WF) machine that are coupled on the same
rotorshaft,rotatewiththesamespeed,andsharethesamemultiphasestator.
Chapter 4 discusses an overview of multiphase electric machines. AC and
rectified DC output voltage waveforms of three- and nine-phase systems with
associated power electronics are presented. A comparison of three- and two nine-
phase machine winding, rectification characteristics, and losses for both HPM and
PMmachinetopologiesispresentedinChap.4.
Chapter 5 presents an overview of electric vehicles (EVs) and hybrid electric
vehicles(HEVs),theirpowertrains, andon-boardenergy sources.Differentbattery
technologiesarediscussed,andinthecaseofHEVsthefeasibilityofdisconnecting
theinternalcombustionengine(ICE)fromtheelectricdrivetrainisstudied.Driving
range,fueleconomy,andemissionsareevaluatedoverdifferentdrivingcycles,and
atdifferentvehiclepowertrainhybridizationratios(HR)inChap.5.
v
vi Preface
InChap.6,adynamicmodelofvehiclepowertrainthatincludesaHPMgenerator
integrated into an ICE in an SHEV while considering a load demand is presented.
TheICE/HPMgeneratoroutputpowercontrolschemeismodeledwhilemaintaining
ICE efficiency within its optimal region. Several operating scenarios for the HPM
generator excitation scheme are assessed, and the HPM generator is characterized
utilizinga32-phasebrushlessexcitationscheme.Inaddition,differentcases,suchas
normal,boost,andbuckfunctionalityofHPMmachineoperation,areanalyzed,and
a choice of the most appropriate operation mode has been selected to regulate the
totalback-EMFviaaWFexcitationcurrentcontrol.
Dr. Al-Adsani wishes to express his sincere gratitude toward his wife, and the
authors extend special thanks to Dr. Nigel Schofield at the University of Hudders-
fieldforhisvaluableinputsandtotheteamatSpringerfortheircareduringthebook
production.
KuwaitCity,Kuwait AhmadS.Al-Adsani
Toronto,ON,Canada OmidBeik
Contents
1 GeneralElectricMachineTheory. . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 MagneticCircuitPrinciples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 MagneticFieldDistributionandFluxDensity. . . . . . . . . 1
1.1.2 FerromagneticMaterialsandMagnetizationCurves. . . . . 3
1.2 ElectricMachineFundamentals. . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 OverviewofClassicalElectricMachineTopologies. . . . . . . . . . . 6
1.3.1 BrushedDCandACMachines. . . . . . . . . . . . . . . . . . . . 7
1.3.2 BrushlessACMachines. . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.3 SwitchReluctanceMachines. . . . . . . . . . . . . . . . . . . . . 11
1.4 WFandPMSynchronousMachineExcitationFields. . . . . . . . . . 13
1.4.1 MagneticFluxPathRepresentationofWF
SynchronousMachines.. . . . .. . . . .. . . .. . . . .. . . . .. 13
1.4.2 MagneticFluxPathRepresentationofPM
SynchronousMachines.. . . . .. . . . .. . . .. . . . .. . . . .. 14
2 HybridElectricMachineConcept. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 HybridElectricMachineClassification. . . . . . . . . . . . . . . . . . . . . 17
2.3 DifferentHybridMachineTopologies. . . . . . . . . . . . . . . . . . . . . 18
2.3.1 PMSynchronousMachinewithClawPole
FieldExcitation(PSCPF). . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.2 Toroidal-StatorTransverse-FluxMachine(TSTFM). . . . . 21
2.3.3 HybridExcitationSynchronousMachine(HESM). . . . . . 23
2.3.4 SynchronousPermanentMagnetHybridAC
Machine(SynPM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.5 ConsequentPolePermanentMagnetHybrid
ExcitationMachine(CPPM). . . . . . . . . . . . . . . . . . . . . . 27
2.3.6 FieldControlledTorus-NS(FCT-NS)Machine. . . . . . . . 29
2.3.7 Dual-RotorMachine. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.8 ImbricatedHybridExcitationMachine(IHEM). . . . . . . . 33
vii
viii Contents
2.3.9 SeriesDoubleExcitedSynchronousMachine
(SDESM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.3.10 SwitchReluctanceMachinewithStatorField
Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3.11 Dual-StatorHybridExcitedSynchronous
WindGenerator(DSHESG). . . . . . . . . . . . . . . . . . . . . . 39
2.4 SummaryofSurveyedLiteratureonHPMMachines. . . . . . . . . . . 43
3 HybridPermanentMagnetMachineDesign. . . . . . . . . . . . . . . . . . . 45
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2 MachineVolumeEnvelopeConsideration. . . . . . . . . . . . . . . . . . 45
3.2.1 PMMachineDimensions. . . . . . . . . . . . . . . . . . . . . . . . 47
3.2.2 PMMachineStatorWindingLayout. . . . . . . . . . . . . . . . 47
3.2.3 StatorWindingFillFactorandResistance. . . . . . . . . . . . 50
3.2.4 FiniteElementMethodProgram. . . . . . . . . . . . . . . . . . . 52
3.2.5 MachineBack-EMFPrediction. . . . . . . . . . . . . . . . . . . . 55
3.2.6 PMMachineAnalysisViaEMCModel. . . . . . . . . . . . . 56
3.3 WFMachine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.3.1 WFRotorDesign.. . . . . . .. . . . . . .. . . . . . .. . . . . . .. 62
3.3.2 WFtoPMSplitRatio. . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.3 ComparativeAnalysisofWFRotorDesigns. . . . . . . . . . 65
3.4 HPMMachineParameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.4.1 TorquePredictionandSaturation. . . . . . . . . . . . . . . . . . 69
3.4.2 SynchronousInductanceandWindingResistance. . . . . . 73
3.5 HPMMachineFinalDesignModelAnalysis. . . . . . . . . . . . . . . . 75
3.5.1 RotorPMDemagnetization. . . . . . . . . . . . . . . . . . . . . . 75
3.5.2 CoreLossPrediction. . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.6 HPMMachineThermalModel. . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.6.1 GeneralPrincipleoftheLumpedParameterMethod. . . . . 81
3.6.2 ConductionHeatTransfer. . . . . . . . . . . . . . . . . . . . . . . . 82
3.6.3 ConvectionHeatTransfer. . . . . . . . . . . . . . . . . . . . . . . . 84
3.6.4 RadiationHeatTransfer. . . . . . . . . . . . . . . . . . . . . . . . . 86
3.6.5 HPMMachineThermalModel. . . . . . . . . . . . . . . . . . . . 86
3.7 ComparisonBetweenPMandFourHPMMachine
Topologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.8 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4 MultiphaseHPMGeneratorSystems. . . . . . . . . . . . . . . . . . . . . . . . 95
4.1 OverviewonMultiphaseMachines. . . . . . . . . . . . . . . . . . . . . . . 95
4.1.1 MultiphaseWindingsPrinciples. . . . . . . . . . . . . . . . . . . 96
4.1.2 RectifiedVoltageduetoThree-andNine-Phase
HPMGeneratorSystems. . . . . . . . . . . . . . . . . . . . . . . . 96
4.2 Nine-PhaseHPMGeneratorParameters. . . . . . . . . . . . . . . . . . . . 101
4.2.1 Nine-PhaseWindingLayoutandBack-EMF. . . . . . . . . . 101
4.2.2 Back-EMFandTorqueWaveformHarmonics
Prediction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Contents ix
4.2.3 SynchronousInductancePrediction. . . . . . . . . . . . . . . . . 107
4.2.4 ConstructionofHPMMachinesPrototype. . . . . . . . . . . . 111
4.2.5 ResistanceandInductanceMeasurements. . . . . . . . . . . . 114
4.3 AnalysisModels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.3.1 GeneraldqMathematicalModelofHPMGenerator. . . . . 115
4.3.2 SimulationModel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.4 Three-andNine-PhaseHPMGeneratorSystemStudies. . . . . . . . 119
4.4.1 ImpactonSynchronousInductanceandRectifier. . . . . . . 121
4.4.2 SystemSensitivitytoGeneratorSynchronous
Inductance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.4.3 DC-LinkVoltageQuality. . . . . . . . . . . . . . . . . . . . . . . . 130
4.5 LossAuditofGeneratorSystems. . . . . . . . . . . . . . . . . . . . . . . . . 134
4.5.1 Introduction. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 134
4.5.2 CoreLossPrediction. . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.5.3 PassiveandActiveConverterLossforHPM
andPMGeneratorSystems. . . . . . .. . . . . . . . . . . . . .. . 136
4.6 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5 ElectricandHybridElectricPowertrains. . . . . . . . . . . . . . . . . . . . . 143
5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.2 OverviewofEVs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.2.1 EVPowertrainConfiguration. . . . . . . . . . . . . . . . . . . . . 145
5.2.2 BatteryTechnology. . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.3 OverviewofHEVs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.3.1 HEVPowertrainConfigurations. . . . . . . . . . . . . . . . . . . 148
5.4 VehicleDrivingCycles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.5 SeriesHybridElectricVehicle(SHEV). . . . . . . . . . . . . . . . . . . . 151
5.5.1 ZEBRABattery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.5.2 InternalCombustionEngine(ICE). . . . . . . . . . . . . . . . . 156
5.5.3 Engine-MountedMultiphaseHPMGenerator. .. . .. . . .. 159
5.6 ElectricVehicleRangeExtender. . . . . . . . . . . . . . . . . . . . . . . . . 159
5.6.1 Introduction. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 159
5.6.2 LiteratureReviewofEVRangeExtenderStudies. . . . . . . 160
5.7 ICE/HPMGeneratorRangeExtenderinSHEVs. . . . . . . . . . . . . . 162
5.7.1 VehicleTractionMachineTorque. . . . . . . . . . . . . . . . . . 163
5.7.2 HybridizationRatio. . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.7.3 RangeExtenderSizinginSHEVPowertrain. . . . . . . . . . 165
5.7.4 StudyCases. . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . 169
5.8 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6 OperationandCharacterizationofMultiphaseHPM
GeneratorinSHEVPowertrain. . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.2 HPMMachineBack-EMFControlStrategy. . . . . . . . . . . . . . . . . 173
6.2.1 ControlStrategyAnalysis. . . . . . . . . . . . . . . . . . . . . . . . 174
6.2.2 DC-linkDesignOptions. . . . . . . . . . . . . . . . . . . . . . . . . 178
x Contents
6.3 HPMMachineOutputPowerControl. . . . . . . . . . . . . . . . . . . . . 181
6.3.1 Introduction. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 181
6.3.2 HPMGeneratorOperatingScenarios. . . . . . . . . . . . . . . . 184
6.3.3 EnergyLossPredictionforTwoDrivingCycles. . .. . . .. 187
6.3.4 SolvingFinalChoicewithFullSimulationModel. . . . . . 189
6.3.5 ThermalAnalysisResultsoftheInvestigated
HPMMachine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
6.4 HPMMachineCharacterizationUsingBrushlessExcitor. . . . . . . . 194
6.4.1 32-PhaseBrushlessExcitationScheme. . . . . . . . . . . . . . 197
6.4.2 PerformanceCurves. . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.4.3 EfficiencyMapping. . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221