Characterization of Advanced Drive System for Hybrid Electric Vehicles Wei Xu1, Jianguo Zhu1, Yongchang Zhang1, Yi Wang1, Guangyong Sun2 1. School of Electrical, Mechanical and Mechatronic Systems, University of Technology, Sydney, NSW, Australia 2. State Key Laboratory of Advanced Design and Manufacture for Vehicle Body, Hunan University, Changsha, China. E-mail: weixuhappy@ieee.org; joe@eng.uts.edu.au Abstract — The electric drive is a key component in a plug-in hybrid electric vehicle (PHEV). The ideal tendency is to use the electric machine over the entire torque/speed range. This paper presents the characterization of the electrical drive suitable for a recently proposed PHEV powertrain, and the design optimization of the electric machine. The newly proposed PHEV powertrain has only one electric machine functioning as either a motor or generator at a time, an energy storage unit consisting of battery and super-capacitor banks for fast charging/discharging during regenerative braking and fast acceleration/deceleration, and a transmission line consisting of two power split devices and a gearbox. The electric machine must be designed for frequent start/stop, fast acceleration/deceleration, high torque and power densities, and high efficiency at all speeds. The drive system was modeled and characterized by using MATLAB/SIMULINK and PSAT, while the machine design was conducted through electromagnetic field analysis by using ANSYS. The design optimization was carried out for four different electric machines, including a double salient permanent magnet (DSPM) machine, a hybrid excitation DSPM (HEDSPM) machine, and two fluxswitching permanent magnet (FSPM) machines of two different pole arrangements. The results show that the 6/7 pole FSPM machine has the best performance. the electricity is produced from a clean energy source, such as wind and solar, the CO2 emission of a PHEV is then even smaller. Although these advantages are well recognized, commercial development has been handicapped. This is for various reasons, mainly due to the lack of optimal electrical drive systems which can best meet the requirements as the major driver for PHEVs. In general, the HEV powertrains can be classified as the series, parallel, and series-parallel [1-5]. The series powertrain is the simplest in structure, but perhaps the most expensive as it requires the full capacity ICE, generator, and motor. The parallel powertrain couples the ICE and motor in parallel. Once the electricity runs out, the ICE drives the car directly and a full capacity ICE is required. The series-parallel system incorporates the merits of both the series and parallel systems, i.e., high efficiency and compact volume, and has been applied widely in HEVs. Battery DC/DC G Rectifier I. INTRODUCTION With the rapid increase in world population and economy, vehicles driven by internal combustion engines (ICEs) are depleting fast the oil supply and causing heavy air pollutions in cities. As reported in [1], transportation in a typical city accounts for up to 41% of the CO2 emission. Hybrid electric vehicles (HEVs) jointly powered by ICEs and electric motors can dramatically improve the fuel efficiency resulting in a huge reduction of carbon emission. In an HEV, the electric motor variable speed drive is employed to implement the regenerative braking to recover the kinetic energy stored during acceleration and the electronic continuous variable transmission (e-CVT), which allows the ICE to be operated at the constant speeds of highest fuel efficiency. The recent breakthrough in battery technology has enabled the development of plug-in HEV (PHEV). In a typical PHEV, the high energy density battery tank is charged from the grid, and the electric motor is the prime mover whereas the ICE is only required to provide the extra torque when the vehicle accelerates fast and climbing a hill and to drive the generator when the battery state-of-charge is low [2]. According to the American National Renewable Energy Laboratory [2], if charged by the electricity from coal fired power plants, the emission of a PHEV is 76-136 g/mile of CO2, less than half of that by an ICE-driven car (250-300 g/mile). If Grid Supercapacitor DC/DC Inverter Inverter/ Rectifier Charger Battery DC/DC M M/G Engine Power split device Engine Gear Power s plit device Gear Wheel Fig.1. Toyota hybrid system configuration. Wheel Fig.2. Proposed PHEV system configuration. Fig.1 shows the typical structure of the series-parallel system of the Toyota Prius launched in 1997 [3]. The wheels are driven by the engine and the electric motor M while the battery is charged through the generator G that is driven by the ICE using a power split unit. During the regenerative braking, both M and G can be controlled to charge the energy storage units. The powertrain is designed to well suit the need of an HEV in which the ICE acts as the prime mover. However, the configuration requires two electric machines, which increases the system cost, and additional power losses. A novel PHEV powertrain, which uses only one electric machine, was proposed in 2008 [4]. As illustrated in Fig.2, it consists of an energy storage unit comprised of batteries and super-capacitors, a power control unit including the DC link, DC/DC converters and a back to back inverter/rectifier, an electric machine, MG, functioning as either a motor or a generator, and an ICE working mostly during fast acceleration to provide the extra torque required. The system operation is governed by a special energy management strategy as illustrated in Fig.3, where SOC stands for the state of charge of the energy storage unit, and EM the electric machine. At the starting, it is assumed that the battery and super-capacitor banks are fully charged (SOC high) from the grid, and the capacity of the energy storage is designed such that the car should be able to cover a reasonable long range, e.g. 150km, per full charge. In the normal operation mode (high SOC and moderate load), the EM works alone as the prime mover of the car. When there is a need of extra toque for fast acceleration or hill climbing, the ICE will provide the assistance. When the SOC drops, the ICE will recharge the battery while the system is idle, e.g. waiting at traffic lights, and if the load is high and SOC very low, e.g. after a long distance drive, the ICE will work alone to drive the car, same as a conventional car. The braking is performed jointly by the regenerative braking and mechanical braking. Braking High Mechanical braking mode Moderate SOC Low Regenerative braking mode terminal voltage increases linearly with the speed. At the base speed, both the voltage and current reach the limits (the rated values). In Region II, a flux weakening scheme is employed to extend the operating speed range under the condition that the voltage and current do not exceed the rated values, resulting in constant power or inversely decreasing torque versus speed curves. In Region III, the torque and power collapse because of ineffective field weakening – there is insufficient supply voltage to drive the system and this region should be avoided. In relation to the road speed limits in Australia, the base speed would typically be 50 km/h, and the critical speed 200 km/h. Cruising EM only mode EM only or ICE recharge mode ICE recharge mode ICE and EM assist mode Fig.4. Torque and power versus speed curves. ICE only mode Negative Moderate High Power Demand of Vehicle Fig.3. The energy management strategy for proposed PHEV. This paper presents the design optimization of the electric machine for the proposed PHEV. The machine specifications are determined from the practical requirement of drive performance, and confirmed by the numerical simulations by the powertrain system analysis toolkit (PSAT) for three typical driving cycles: the urban drive schedule (UDDS), extra-urban drive cycle (EUDC), and highway fuel economy drive schedule (HWFET). Section II determines the rated power of the electric machine according to the required dynamic performance. After a brief qualitative comparison, section III presents the design optimization of four electric machines including a double salient permanent magnet (DSPM) machine, a hybrid excited DSPM (HEDSPM) machine, and two flux switching permanent magnet (FSPM) machines of two different pole arrangements. In section IV, a numerical comparison of commonly used indices, such as power or torque density, efficiency, and flux weakening ability, shows that the 6/7 pole FSPM machine has the best performance. II. DETERMINATION OF SPECIFICATIONS As shown in Fig.4, the typical torque and power versus speed curves of the proposed PHEV have three regions: (I) the constant torque region (below base speed), (II) the constant power region (between the base and critical speeds), and (III) the reduced power region (above critical speed). In Region I, the maximum torque capability is limited by the thermal or current rating of the electric drive system while the machine On the other hand, the resistance experienced by a vehicle running at speed V (m/s) is mainly due to the rolling resistance and air drag, as expressed below (1) Fr = M v g ( f r cos α + sin α ) + 0.5ρ a C D AV 2 2 where Mv is the vehicle mass (kg), g the gravity (9.81 m/s ), fr the rolling resistance coefficient, the road gradient, V the vehicle speed (m/s), a the air mass density (1.205 kg/m3), CD the aerodynamic coefficient, and A the front area of the vehicle (m2). The corresponding power required to overcome the resistance, Pr (W), can be expressed as (2) Pr = M v g ( f r cos α + sin α )V + 0.5ρ a CD AV 3 By Newton’s law, to accelerate a vehicle from one speed to another, the traction force required, Ftr, is Ftr = M v dV dt + M v g ( f r cosα + sin α ) + 0.5ρ a C D AV 2 (3) and the corresponding traction power required is Ptr = M v VdV dt + M v g ( f r cos α + sin α )V + 0.5ρ aCD AV 3 (4) The time it takes to accelerate a vehicle from one speed to another can then be calculated as V2 Mv ta = ³ dt (5) V1 P V − M g ( f cos α + sin α ) − 0.5ρ C AV 2 tr v r a D The rated power of the prime mover should be chosen to meet the required vehicle performance: (1) at the critical speed, Vc, the vehicle should still have certain capability for further acceleration, i.e. Prated > Pr; and (2) the acceleration time to typical cruise speeds should be acceptable. Table I list an estimate of the component weights of the proposed PHEV. It is assumed that the vehicle will carry a driver and four passengers of 80 kg each. The total weight of the vehicle is 1,600 kg. TABLE I WEIGHT OF THE PROPOSED PHEV (unit: kg) Mechanical accessory 35 Motor 85 Clutch/Torque converter 25 Motor controller 15 Super-capacitor 30 Gearbox 75 Vehicle body 470 Final drive 20 Battery 150 Wheel axle 100 Power converter-energy storage 30 Electrical accessory 15 Power converter-electrical accessory 30 Engine 120 Payload 400 Total 1600 100 3 90 is 50 km/h. The base and critical motor speeds are 3,000 rpm and 12,000 rpm, respectively. Based on the above analysis, if we choose the rated power of the motor as 75 kW, the acceleration time is 4.3 s from standstill to 50 km/h with an average acceleration of 3.2 m/s2, and acceleration distance of 29.8 m, and 7.0 s from 50 km/h to 100 km/h with an average acceleration of 1.8 m/s2 and acceleration distance of 150 m. As a comparison, Toyota Prius uses a 50 kW interior permanent magnet (IPM) motor, and it takes 4.8 s to accelerate from 0 to 50 km/h, and 8.2 s from 50 to 100 km/h. For the parameters specified above, the proposed PHEV performance was simulated by using PSAT for three typical drive cycles and very satisfactory results were obtained [4]. 2.5 80 III. DESIGN OPTIMIZATION Resistance power (kW) 2 70 1.5 60 1 50 0.5 40 0 30 0 10 20 30 40 50 Rolling resistance Total resistance 20 10 0 0 20 40 60 80 100 120 140 160 180 200 Vehicle speed (km/h) Fig.5. Resistance power versus vehicle speed. 14 (1) (1)x=10,Ptr=68.7kW (2)x=8,Ptr=70.1kW (3)x=6,Ptr=73kW (4)x=4,Ptr=81.4kW (5)x=2,Ptr=126.7kW Thrust on driven wheels (kN) 12 (2) 10 (3) 8 (4) 6 (5) 4 2 0 0 20 40 60 80 100 120 140 160 180 200 Vehicle speed (km/h) Fig.6. Thrust force versus speed for different gear ratio and traction power. Fig.5 plots the resistance power to the proposed PHEV 2 with the following parameters: Mv = 1600 kg, A = 2.23 m , CD = 0.26 and fr = 0.01. The rolling resistance power is the black dashed line and the aerodynamic resistance is the difference between red line (total resistance) and the black line. From the curves, it can be seen that the rolling resistance power is the higher resistance loss representing 70% of the total resistance at 50 km/h. At higher speeds, the aerodynamic resistance increases in proportion to the cube of the speed. At the critical speed, 200 km/h, the rolling resistance is 14% of the aerodynamic resistance, and the total resistance power is 70 kW, i.e. Prated > 70 kW. Fig.6 depicts the thrust force versus vehicle speed at different gearbox speed ratio, x, and traction power. As shown, if we choose x = 5, and Ptr = 75 kW, the base speed For the proposed PHEV, a desired electric machine should have high efficiency, high power or torque density, high controllability, strong flux weakening ability for a wide speed range (ratio of critical and base speed), mechanical robust structure for reliable maintenance free operation, and so on. The electrical machines commonly employed for EV propulsions are DC machines, induction machines, switched reluctance machines (SRMs), and permanent magnet (PM) machines, each with their own specific merits and demerits. DC machines have excellent controllability and performance, such as linear torque/speed curve and low torque ripples, but because of the use of brushes and commutators, the reliability and power or torque density are low. Induction machines, especially squirrel cage induction machines, have strong rotor structures (high reliability), and low manufacturing cost, but the efficiency and power or torque density are also low. In addition, the induction machine speed control is complicated and sensitive to machine parameters. SRMs have very robust construction and outstanding flux weakening ability, but they have problems of low power density, large torque ripples, and large noise because of their salient structures. PM machines have high power density, high efficiency, high controllability and fast dynamic response. The major weaknesses are the delicate rotor structure because of the low mechanical strength of PMs and narrow speed range due to the difficulty to weaken the field of PMs. To overcome the weakness of rotor structure and retain the merits of the PM machines, several variations of the machine topology can be obtained by placing the PMs on the stator and employing a solid salient rotor similar to that of the SRM [6]. Fig.7 depicts the recently proposed topologies in this category, including the DSPM, HEDSPM, and FSPM machines. From the structures and the PM flux distributions shown in Fig.7, features of these machines can be readily summarized in contrast to the conventional PM machines in the following: (a) Concentrated winding – The edge connection of stator winding is shorter than distributed ones, which means less copper loss with the same amplitude of stator current. (b) Strong thermal dissipation capability – As the PMs are inserted in the stator, they can have greater cross sectional area and are less likely to suffer the demagnetization problem. The winding current density can reach 7-8 A/mm2 or even larger. In continuous operation, the stator temperature can be maintained well below 125oC, which is in the range of Hgrade insulation by water cooling. (a). DSPM machine with 12/8 (stator/rotor) poles. (b). HEDSPM machine with 12/8 poles. (c) The mutual inductances are nonlinear functions of the rotor position and stator currents, which causes difficulty to the advanced performance control. (d) With the PMs inserted in the stator, the fabrication of the stator iron core is more complicated than that of traditional PM machines. Fortunately, special considerations in practical design will be taken to optimize the performance by enhancing the effects of merits and mitigating the effects of demerits. To find the most suitable electric machine(s) for the PHEV propulsion, an exercise of design optimization was conducted for four different electric machines, namely DSPM machine with 12/8 stator /rotor poles, HEDSPM machine with 12/8 stator/rotor poles, FSPM machine with 6/7 stator/rotor poles, and FSPM machine with 12/10 stator/rotor poles, without rotor skewing, for optimal torque and efficiency as expressed by the following objective function: Max f (c). FSPM machine with 6/7 poles. (d). FSPM machine with 12/10 poles. Fig.7 Flux distribution of four machines with stator PMs. (c) Strong structure robustness – Similar to SRMs, the rotor has no PMs or brushes, and therefore is suitable for high speed operation, e.g. above 20,000 rpm. For a given power rating, as the rated speed increases, the machine volume can be reduced. (d) High power or torque density – Same as the traditional PM machines, PMs are employed to generate the major air gap flux in the DSPM, HEDSPM, and FSPM machines, and the merit of high power or torque density is retained. (e) Great flux weakening ability – It is one of the most important indices for PHEV propulsion. In general, the flux weakening ability (ratio of the maximum and base speeds) of conventional PM machines does not exceed 3. However, some recent studies [7-9] show that the flux weakening ability of DSPM machine may reach 3, HEDSPM machine 4, and FSPM machine 4, which is closely related to their structures. (f) Good redundancy capability – The stator mounted PM machines with concentrated windings possess the feature of independent electric and magnetic circuits among phases such that the control of each phase is independent of other phases. When one phase is out of order due to open-circuit fault, the current of the other two phases could be controlled to maintain almost the same MMF before the fault [7]. This fault tolerance provides a favorable redundancy in extreme embarrassments. (g) Feasible control schemes – The back-EMF of stator mounted PM machines could be optimized to be close to sine waves by skewing the rotor, and the advanced control schemes for traditional machines, such as the vector control and direct torque control can be readily applied to achieve excellent steady and dynamic state performances. The demerits of the stator mounted PM machines include: (a)There exist partial saturation phenomena in the stator and rotor components, such as the stator teeth, and rotor poles. (b)The back-EMF waves contain harmonics, resulting in extra copper loss. = a1 η − ηw T − Tw + a2 Tb − Tw ηb − η w (6) where T is the optimal torque, Tw the worst or minimum acceptable torque, Tb the best or most desired torque, the optimal efficiency, w the worst or minimum acceptable efficiency, b the best or most desired efficiency; a1 and a2 are the weighting factors. As the optimization variables are normalized such that the objective function is dimensionless, the designer’s preference can be implemented through the choice of a1, a2, Tw, Tb, w, and b. In this paper, these parameters, as tabulated in Table II, were determined through the PHEV simulation by PSAT in the stage of specification. For a fair comparison, the main dimensions, such as the stator outer diameter, air gap length, the axial length, and the rotor diameters, and ratings, such as the terminal voltage, stator winding current density, and the rated speed, of the four machines are chosen to be the same. Table III lists the main dimensions of the four machines. The flux linkage and torque curves of the four machines are illustrated in Figs.8-11, respectively. TABLE II INDEXES OF OBJECTIVE FUNCTION Items FSPM (6/7) FSPM (12/10) DSPM HEDSPM a1 0.6 0.6 0.6 0.6 a2 0.4 0.4 0.4 0.4 Tw (Nm) 230 200 110 100 Tb (Nm) 280 220 190 180 T (Nm) 272 215 153.5 137.6 w 0.85 0.84 0.85 0.84 b 0.97 0.97 0.97 0.96 0.971 0.968 0.962 0.952 IV. PERFORMANCE COMPARISON Four key indices including the power density, torque density, flux weakening ability, and efficiency, of the four electric machines are compared in order to find the most suitable one for the PHEV propulsion. TABLE III MAIN DIMENSIONS OF FOUR MACHINES (length unit: mm) FSPM FSPM Items DSPM HEDSPM (6/7) (12/10) 101.5 101.5 101.5 101.5 Outer radius Stator York height 23 17.5 23.5 23.5 Number of pole 6 12 12 12 Pole width 46.8 23.4 16 16 Pole height 20.4 20.8 17.5 17.5 Number of turns per 13 9 8 8 pole winding PM Width 12 8 12 12 Height 36.3 18.1 40 34 0.5 0.5 0.5 0.5 Air gap length Rotor Pole width 24 12 17 24 Pole height 24.6 24.2 14 14 York 17.5 17.5 25 25 Number of poles 7 10 8 8 21 21 21 21 Radius of shaft 211 211 211 211 Effective axial length PhaseB 200 PhaseC 180 0.2 160 140 Torque (Nm) Flux linkage (Wb) PhaseA 0.25 0.15 0.1 120 80 60 40 0 20 0 90 180 270 0 360 90 180 270 360 Rotor position (electrical degree) Rotor position (electrical degree) (a) Flux distribution. (b) Torque (average: 153.5 Nm). Fig.8. DSPM machine with 12/8 poles. -1400Aturns 1400Aturns 200 0Aturns 180 0.3 160 140 Toruqe (Nm) Flux linkage (Wb) 0.25 0.2 0.15 0.1 120 100 80 60 40 0.05 20 0 0 0 90 180 270 360 0 90 Rotor position (electrical degree) 180 270 360 Rotor position (electrical degree) (b) Torque (average: 137.6 Nm). (a) Flux distribution (Phase A). Fig.9. HEDSPM machine with 12/8 poles. PhaseA(Wb) PhaseB(Wb) Flux linkage (Wb) 0.05 180 270 360 -0.1 -0.15 -0.2 B. Flux Weakening Ability According to the definitions of flux weakening ability for DSPM machine [8] and FSPM machine [9], the flux weakening abilities of the four machines are calculated as shown in Table V. TABLE V FLUX-WEAKENING ABILITY OF FOUR MACHINES FSPM FSPM DSPM HEDSPM Machine (6/7 poles) (12/10) Flux weakening ability 4.24 5.01 3.01 4.17 As shown, the flux weakening ability of the FSPM machines is stronger than that of the DSPM and HEDSPM machines because of the greater d-axis inductances. In the FSPM machines, the ability of the one with 12/10 poles is larger than that of the one with 6/7 poles mainly because the one with more poles has smaller PM linkage. Compared with the DSPM machine, the HEDSPM machine has better flux weakening ability by using the DC excitation. This, however, reduces the efficiency because of the extra copper loss produced by the DC current. C. Torque Torque is one of most important performance indices of electric machines for PHEV propulsion. In the starting and acceleration stages, the drive machine with a higher torque could reach the desired speed in a shorter time. In the four machines, the torque is closely related to the structure and size of PMs. By optimizing the dimensions of the stator slot, stator pole, PM width and length, rotor pole, and number of turns of stator windings in series, etc., the optimal rated torque is obtained for the four machines as summarized in Table VI, where the torque ripples are calculated by the definition in [9]. 0.1 90 The power densities of the DSPM and HEDSPM machines are significantly lower than those of the FSPM machines. This is mainly because less PM material is used in these machines in order to achieve acceptable flux weakening ability. PhaseC(Wb) 0.2 0.15 0 -0.05 0 TABLE IV POWER DENSITY ESTIMATION OF DRIVE MACHINES (unit: kW/kg) Toyota FSPM FSPM Prius DSPM HEDSPM Machine (6/7) (12/10) (IPM) Power density 1.69 1.93 1.60 1.07 0.9 100 0.05 0 of Toyota Prius, followed by the FSPM machine with 12/10 poles of 1.60 kW/kg. The main reason for the difference in power density between the two FSPM machines is that the one with more poles has higher leakage inductance. Rotor position(electrical degree) Torque (Nm) (b) Torque (average: 272 Nm). (a) Flux distribution (Phase A). Fig.10. FSPM machine with 6/7 poles. 260 240 220 200 180 160 140 120 100 80 60 40 20 0 0 90 180 270 360 Rotor position (electrical degree) (b) Torque (average: 215 Nm). (a) Flux distribution (Phase A). Fig.11. FSPM machine with 12/10 poles. A. Power Density Table IV tabulates the power densities at the rated speed of the four machines and the IPM of Toyota Prius [10]. As shown, the FSPM machine with 6/7 poles has the highest power density of 1.93 kW/kg, which is a little higher than that TABLE VI TORQUE DENSITY OF FOUR MACHINES FSPM FSPM DSPM Items (6/7) (12/10) Average torque (Nm) 272 215 153.5 Torque ripple (%) 2.52 2.93 11.91 HEDSPM 137.7 17.17 As shown, the FSPM machine with 6/7 poles has the highest average torque and lowest torque ripple, followed by the FSPM machine with 12/10 poles. While the DSPM and HEDSPM machines have small rated torque, and their torque ripples are much higher than those of the FSPM machines. D. Efficiency Table VII tabulates the calculated rated efficiency of the four machines. In the calculation, it is assumed that the total of the frictional, windage, and stray losses is up to 1.5 % of the output power. The core loss is calculated by summing up the core losses in each finite element, which is obtained by interpolating the silicon steel core loss curves according to the flux density in each element and the frequency. As shown in the table, the FSPM machine with 6/7 poles has the highest efficiency, while the HEDSPM machine with 12/8 poles has the lowest efficiency because of the extra copper loss produced by the DC excitation current. TABLE VII EFFICIENCY OF FOUR MACHINES FSPM FSPM DSPM HEDSPM Machine (6/7) (12/10) Efficiency 97.1 96.77 96.2 95.18 V. CONCLUSIONS The PHEV technology can significantly improve the energy efficiency, and greatly reduce the greenhouse gas emission through regenerative braking, e-CVT to improve ICE efficiency, and electricity produced from clean energy sources. Using one electrical machine and super-capacitors, the proposed PHEV can have lower weight, better regenerative braking, and dynamic performance. Through a qualitative comparison, it is identified that the stator mounted PM machines have much more robust rotor structure while retaining the merits of high power or torque density and high efficiency of the conventional PM machines. 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