Benchmarking of electric and hybrid vehicle electric machines, power electronics, and batteries

Sarlioglu, Bulent; Morris, Casey T.; Han, Di; Li, Silong

doi:10.1109/optim.2015.7426993

Cited by 32 publications

(22 citation statements)

References 6 publications

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“…Nevertheless, in general, it is practical for rated nominal power (the highest measured continuous working point) of the inverter unit to subsist the peak power of the electric motor (also referred to as maximum power, i.e., a temporary thermal overload of the motor) (Nordelöf and Alatalo 2017). Such matching of power capability between the inverter unit and the electric motor has been confirmed in vehicle benchmarking literature (Burress et al 2011;Burress and Campbell 2013;Sarlioglu et al 2015).…”

Section: Design Variability and Application Areassupporting

confidence: 54%

“…Presumably, the model will remain relevant a number of years ahead, as long as IGBTs and plastic film capacitors are the preferred choice for the power stage. While other transistor technologies are developing fast in terms of performance improvements, silicon-based IGBTs have matured to become an enabling technology for the electrification of vehicles, largely based on improvements in production leading to decreased component cost and high reliability (Guerra 2011;Sarlioglu et al 2015).…”

Section: Results and Evaluationmentioning

confidence: 99%

“…Today, the IGBT is the dominating power transistor type in automotive inverter unit applications, especially when power ratings are higher than 20 kW (Emadi 2005 Krah et al 2013;Albanna et al 2016). Other transistor technologies are subject to faster progress in terms of power module design (Guerra 2011;Davis 2009;Sarlioglu et al 2015), whereas the IGBT power modules often align to a standard concept, which has remained much the same since the 1990s (Tan et al 2010;Volke and Hornkamp 2012).…”

Section: Design Variability and Application Areasmentioning

confidence: 99%

“…Progress in casing design has been a key factor for improved power density (i.e., rated kilowatts per liter) of inverter units for a number of years (Burress et al 2011;Kang 2012;Sarlioglu et al 2015). For example, the inverter mass is about the same in the 2007 Toyota Camry as in the 2008 Lexus LS600H, but the latter handles 40 kW higher power (Burress et al 2011;Sarlioglu et al 2015). Recalculated, the specific power (i.e., rated kilowatts per kilogram) is 35% lower for the Camry.…”

Section: Design Variability and Application Areasmentioning

confidence: 99%

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A scalable life cycle inventory of an automotive power electronic inverter unit—part I: design and composition

Lundmark

Alatalo

Söderman

2018

Int J Life Cycle Assess

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Purpose A scalable life cycle inventory (LCI) model, which provides mass composition and manufacturing data for a power electronic inverter unit intended for controlling electric vehicle propulsion motors, was developed. The purpose is to fill existing data gaps for life cycle assessment (LCA) of electric vehicles. The model comprises new and easy-to-use data with sufficient level of detail to enable proper component scaling and more in-depth analysis of inverter units. It represents a stand-alone three-phase inverter with insulated gate bipolar transistors (IGBTs), typical in electric vehicles. This article (part I) explains the modeling of the inverter design including the principles for scaling, exemplifies results, and evaluates the models' mass estimations. Methods Data for the design of power electronic inverter units was compiled from material content declarations, textbooks, technology benchmarking literature, experts in industry, and product descriptions. Detailed technical documentation for two electrically and electronically complete inverter units were used as a baseline and were supplemented with data for casings, connectors, and bus bars suitable for automotive applications. Data, theory, and design rules were combined to establish a complete model, which calculates the mass of all subparts from an input of nominal power and DC system voltage. The validity of the mass estimates was evaluated through comparison with data for real automotive inverter units. Results and discussion The results of the LCI model exemplifies how the composition of the inverter unit varies within the model range of 20-200 kW and 250-700 V, from small passenger car applications up to distribution trucks or city buses. The models' mass estimations deviate up to 14% from the specified mass for ten examples of real inverter units. Despite the many challenges of creating a generic model of a vehicle powertrain part, including expected variability in design, all results of the model validation fall within the targeted goal for accuracy. Preamble This is the first article in a series of two presenting a new scalable life cycle inventory (LCI) data model of a power electronic inverter unit for control of electrical machines in vehicles, available to download. In part I, it is described how the LCI model was established, how it is structured, and the type of results it provides, including a validating comparison with real-world inverter units. It also covers design data and the principles for scaling of the main active parts-the power module and the DC link capacitor. Part II presents how new production datasets were compiled from literature and factory data to cover the manufacturing chain of all parts, including the power module fabrication, mounting of printed circuit boards, and the complete assembly. Part II also explains the data collection methods, system boundaries, and how to link the gate-to-gate inventory to the Ecoinvent database in order to establish a complete cradle-to-gate LCI.

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Section: Design Variability and Application Areassupporting

confidence: 54%

Section: Results and Evaluationmentioning

confidence: 99%

Section: Design Variability and Application Areasmentioning

confidence: 99%

Section: Design Variability and Application Areasmentioning

confidence: 99%

See 2 more Smart Citations

A scalable life cycle inventory of an automotive power electronic inverter unit—part I: design and composition

Lundmark

Alatalo

Söderman

2018

Int J Life Cycle Assess

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show abstract

“…Due to this strongly non-linear relationship, the mechanical stress on the rotor iron requires special consideration. The introduction of so-called pockets for the permanent magnets has the consequence of weakening the material, which further increases the mechanical stresses [7]. For fast rotating electric machines, it is common to reinforce the rotor with a so-called bandage or sleeve.…”

Section: Surface Pm Typementioning

confidence: 99%

On the Impact of Maximum Speed on the Power Density of Electromechanical Powertrains

et al. 2020

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In order to achieve the European Commission’s ambitious climate targets by 2030, BEVs (Battery Electric Vehicles) manufacturers are faced with the challenge of producing more efficient and ecological products. The electromechanical powertrain plays a key role in the efficiency of BEVs, which is why the design parameters in the development phase of electromechanical powertrains must be chosen carefully. One of the central design parameters is the maximum speed of the electric machines and the gear ratio of the connected transmissions. Due to the relationship between speed and torque, it is possible to design more compact and lighter electric machines by increasing the speed at constant power. However, with higher speed of the electric machines, a higher gear ratio is required, which results in a larger and heavier transmission. This study therefore examines the influence of maximum speed on the power density of electromechanical powertrains. Electric machines and transmissions with different maximum speeds are designed with the state-of-the-art for a selected reference vehicle. The designs are then examined with regard to the power density of the overall powertrain system. Compared to the reference vehicle, the results of the study show a considerable potential for increasing the power density of electromechanical powertrains by increasing the maximum speed of the electric machines.

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A performance study of a high-torque induction motor designed for light electric vehicles applications

Camargos

Caetano

2021

Electr Eng

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Benchmarking of electric and hybrid vehicle electric machines, power electronics, and batteries

Cited by 32 publications

References 6 publications

A scalable life cycle inventory of an automotive power electronic inverter unit—part I: design and composition

A scalable life cycle inventory of an automotive power electronic inverter unit—part I: design and composition

On the Impact of Maximum Speed on the Power Density of Electromechanical Powertrains

A performance study of a high-torque induction motor designed for light electric vehicles applications

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