Three different motor drives for electric traction are compared, in terms of output power and efficiency at the same stack dimensions and inverter size. Induction motor (IM), surface-mounted permanent-magnet (PM) (SPM), and interior PM (IPM) synchronous motor drives are investigated, with reference to a common vehicle specification. The IM is penalized by the cage loss, but it is less expensive and inherently safe in case of inverter unwilled turnoff due to natural de-excitation. The SPM motor has a simple construction and shorter end connections, but it is penalized by eddy-current loss at high speed, has a very limited transient overload power, and has a high uncontrolled generator voltage. The IPM motor shows the better performance compromise, but it might be more complicated to be manufactured. Analytical relationships are first introduced and then validated on three example designs and finite element calculated, accounting for core saturation, harmonic losses, the effects of skewing, and operating temperature. The merits and limitations of the three solutions are quantified comprehensively and summarized by the calculation of the energy consumption over the standard New European Driving Cycle.

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Comparison of Induction and PM Synchronous Motor Drives for EV Application Including Design Examples

Superconducting technology applications in electric machines have long been pursued due to their significant advantages of higher efficiency and power density over conventional technology. However, in spite of many successful technology demonstrations, commercial adoption has been slow, presumably because the threshold for value versus cost and technology risk has not yet been crossed. One likely path for disruptive superconducting technology in commercial products could be in applications where its advantages become key enablers for systems which are not practical with conventional technology. To help systems engineers assess the viability of such future solutions, we present a technology roadmap for superconducting machines. The timeline considered was ten years to attain a Technology Readiness Level of 6+, with systems demonstrated in a relevant environment. Future projections, by definition, are based on the judgment of specialists, and can be subjective. Attempts have been made to obtain input from a broad set of organizations for an inclusive opinion. This document was generated Superconductor Science and Technology Supercond. Sci. Technol. 30 (2017) 123002 (41pp) https://doi.org/10.1088/1361-6668/aa833e Original content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI. 0953-2048/17/123002+41$33.00 © 2017 IOP Publishing Ltd Printed in the UK 1 through a series of teleconferences and in-person meetings, including meetings at the 2015 IEEE PES General meeting in Denver, CO, the 2015 ECCE in Montreal, Canada, and a final workshop in April 2016 at the University of Illinois, Urbana-Champaign that brought together a broad group of technical experts spanning the industry, government and academia.

https://iopscience.iop.org/article/10.1088/1361-6668/aa833e/pdf

High power density superconducting rotating machines—development status and technology roadmap

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the ground transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. This paper will provide details of the design, analysis, and testing of two permanent magnet (PM) machines that were developed to meet the FreedomCar 2020 specifications. The first machine is an interior PM (IPM) machine and the second machine is a surface PM (SPM) machine. Both machines are equipped with fractional-slot concentrated windings (FSCW). The goal of this paper is to provide a quantitative assessment of how achievable this set of specifications is, as well as a comparison with the state of the art. This paper will also quantitatively highlight the tradeoffs between IPM and SPM FSCW machines especially in the context of traction applications.

Comparison of Interior and Surface PM Machines Equipped With Fractional-Slot Concentrated Windings for Hybrid Traction Applications

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the ground transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. This paper will provide details of the design, analysis, and testing of an advanced interior permanent magnet (PM) machine that was developed to meet the FreedomCAR 2020 specifications. The 12-slot/10-pole machine has segmented stator structure equipped with fractional-slot nonoverlapping concentrated windings. The rotor has a novel spoke structure/assembly. Several prototypes with different thermal management schemes have been built and tested. This paper will cover the test results for all these prototypes and highlight the tradeoffs between the various schemes. Due to the high machine frequency (~1.2 kHz at the top speed), detailed analysis of various loss components and ways to reduce them will be presented. In addition, due to the high coolant inlet temperature and the fact that the machine is designed to continuously operate at 180 °C, detailed PM demagnetization analysis will be presented. The key novelty in this paper is the advanced rotor structure and the thermal management schemes.

Advanced High-Power-Density Interior Permanent Magnet Motor for Traction Applications

https://eprints.ncl.ac.uk/file_store/production/211554/03D342FA-4EE9-4E58-A553-55632B07B13A.pdf

Electric vehicle traction motors without rare earth magnets

Interior permanent magnet (PM) machines are considered the state of the art for traction motors, particularly in light-duty hybrid and electrical vehicles. These motors usually use neodymium–iron–boron (NdFeB) PMs. These magnets include both light rare-earth materials such as neodymium (Nd) as well as heavy rare-earth materials such as dysprosium (Dy). The main purpose of Dy is to enhance the magnet coercivity to avoid demagnetization under both high temperatures as well as flux weakening. One of the key risks in terms of using these rare-earth magnets is the significant fluctuation/increase in their prices over the past few years. Applications that use large quantities of these magnets, such as traction motors and wind generators, are the most affected by these fluctuations. There has been an ongoing global effort to try to reduce or eliminate the use of rare-earth materials (particularly Dy which is the most expensive) without sacrificing too much performance. This paper will focus on advanced spoke designs targeting traction applications. The goal of this paper is to come up with new spoke designs using various grades of Dy-free magnets as well as ferrites targeting the same set of specifications. This paper will provide a detailed comparison between the various designs highlighting the key tradeoffs in terms of power density, efficiency, flux-weakening capability, and magnet susceptibility to demagnetization. Also, a prototype using ferrites has been built and tested, and the experimental results will be presented.

Effect of Magnet Types on Performance of High-Speed Spoke Interior-Permanent-Magnet Machines Designed for Traction Applications

General Electric, under contract with the Air Force Research Labs (AFRL), has successfully developed and tested a high speed, multimegawatt superconducting generator. The generator was built to demonstrate high temperature superconducting (HTS) generator technology for application in a high power density Multimegawatt Electric Power System (MEPS) for the Air Force. The demonstration tested the generator under load conditions up to 1.3 MW at over 10,000 rpm. The new MEPS generator achieved 97% efficiency including cryocooler losses. All test results indicate that the generator has a significant margin over the test points and that its performance is consistent with program specifications. This demonstration is the first successful full-load test of a superconducting generator for the Air Force. In this paper we describe the development of the generator and present some key test results used to validate the design. Extrapolation to a higher power density generator is also discussed.

Development of a High Speed HTS Generator for Airborne Applications

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the ground transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. This paper will provide details of the design, analysis and testing of an advanced interior permanent magnet (IPM) machine that was developed to meet the FreedomCar 2020 specifications. The 12 slot/10 pole machine has segmented stator structure equipped with fractional-slot concentrated-windings (FSCW). The rotor has a novel spoke structure. Several prototypes with different thermal management schemes have been built and tested. The paper will cover the test results for all these prototypes and highlight the tradeoffs between the various schemes.

Advanced high power-density interior permanent magnet motor for traction applications

There has been growing interest in electrical machines that reduce or eliminate rare-earth material content. Traction applications are among the key applications where reducing cost and, hence, reduction of rare-earth materials are key requirements. This paper will assess the potential of different variants of flux-switching machines (FSMs) that either reduce or eliminate rare-earth materials in the context of traction applications. Two designs use different grades of dysprosium-free permanent magnets (PMs), and the third design is a wound-field variant that does not include PMs at all. A detailed analysis of all three designs in comparison to the required set of specifications will be presented. The key opportunities and challenges will be highlighted. The impact of the high pole-count/frequency of the FSMs will also be evaluated. Experimental results for one of the designs with dysprosium-free PMs will also be presented.

James Pellegrino Alexander

Papers

Advanced High-Power-Density Interior Permanent Magnet Motor for Traction Applications

Effect of Magnet Types on Performance of High-Speed Spoke Interior-Permanent-Magnet Machines Designed for Traction Applications

Development of a High Speed HTS Generator for Airborne Applications

Advanced high power-density interior permanent magnet motor for traction applications

Reduced Rare-Earth Flux-Switching Machines for Traction Applications