Powertrain EV synchronous reluctance motor design with redundant topology with novel control

Abstract

A doubly three-phase fed synchronous reluctance machine (SynRM) is designed for electrical vehicle powertrain application. SynRM aims to deliver instant power and high power density, high torque at low speeds and high power at high speeds, wide speed range, high efficiency throughout its range of operation, ruggedness, high safety at a reasonable cost. Under these requirements, a 60 kW, 9000 rpm and 400 Nm SynRM has been designed. The main objective is to demonstrate the SynRM powertrain operation behaviour and determinate the operation points electrically and thermally. To reach the proposed SynRM goal, a new direct torque control algorithm based on output regulation subspace theory control is presented. The winding motor topology is galvanic isolated, so it is possible to operate with the six phases directly to the load and because of that, the combination with a back-to-back (B2B) converter becomes so profitable. To validate the system, two B2B fullconverters and two motors (SynRM and induction machine) were used in a real test bench. Finally, a simulated and real efficiency map is obtained covering different drive cycles range. Some remarks about normal and failure mode of operation are presented.

Comprehensive Overview of Modern Controllers for Synchronous Reluctance Motor

“…As a result, the fux produced by the stator fows into the rotor with the lowest magnetic resistance. As a result, if the rotor is not aligned with the fux, the reluctance torque will cause the rotor to revolve in the direction with the least magnetic resistance [22,36,[39][40][41][42][43][44]. In this sense, the magnetomotive force (MMF) is caused by the saliency ratio, and the reluctance torque spins the rotor.…”

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“…During charging the cells are having different voltages due to internal resistance being different in each case. The nominal capacity of the cell is 4.1v and during charging [4] the voltage of each cell keeps on increasing till their nominal value after which the current is stopped in that series connection of the cell. The role of BMS is to ensure that each cell in the series connection is charged at uniform rate thereby actively balancing the current to be sent to each cell.…”

A Review of Synchronous Reluctance Motor-Drive Advancements

“…In this sense, SynRM offers the high performance of PMSM, while it can be as cheap, simple, and service-friendly as IM. Therefore, the attention paid for these motors in high-speed applications has experienced continuous growth in the literature, which has convinced the electric vehicles (EVs) and hybrid electric vehicles (HEVs) manufacturers to apply SynRMs as an alternative for PMSM [38][39][40]. Having said this, the possibility of the drive with the same VSDs for IM and PMSM in various recently designed VSDs has provided a viable development base for SynRM [41].…”