Abstract
A 48 V Belt-Driven Starter Generator (BSG) System is featured with high output current, high starting torque, and highly efficient thermal management. This paper firstly elaborates hardware design considerations of a high power density three-phase BSG inverter to address the challenges of even current distribution among paralleled MOSFETs, small drain-source voltage spike and good thermal dissipation. In order to satisfy the high-current requirement, a careful selection of MOSFET device with high-current rating and low on-resistance has been presented. In order to suppress circulating current among paralleled devices, individual gate resistors have been placed in the gate loop of each MOSFET. In order to provide good thermal dissipation, an Insulated Metal Substrate (IMS) board and single-layer layout technique have been implemented. Multiple low-profile electrolytic capacitors are used to increase the power density of the prototype. Moreover, the use of automotive gate driver IC TLE9180 and microcontroller TC1782 makes the prototype more readily accepted by industry. An improved Interior Permanent Magnet (IPM) motor control strategy and a pump-back system based on a virtual machine concept have been implemented to facilitate the validation of the prototype under rated condition without using a real motor. The control algorithm automatically adjusts the onset of field-weakening by using an additional inverter voltage loop and takes into account the nonlinearity of the stator flux linkage by using curve fitting technique, which makes the motor drive adaptive to machine parameter changes as well as DC bus voltage fluctuation. A three-phase BSG inverter prototype with a peak power of 12 kW has been built and tested. The prototype power density has reached 20.3 kW/L. Both PLECS simulations and hardware experiments show a continuous and stable operation with up to 200 A phase current and up to 600 Hz output frequency.
Highlights
A 48 V Belt-Driven Starter Generator (BSG) System is featured with high output current, high starting torque, and highly efficient thermal management
In order to test the BSG inverter hardware, a simple and robust Interior Permanent Magnet (IPM) control strategy should be implemented in the controller
The nonlinear effect can be accommodated by inserting look-up tables [19] and by using curve fitting equations based on Finite Element Analysis (FEA) results of a physical IPM machine [20] – [23]
Summary
THE 48 V Belt-Driven Starter Generator (BSG) system has been developed for cost-efficient mass hybridization. This paper elaborates the hardware design considerations of a low-voltage high-current high power density three-phase 48V BSG inverter to address the challenges of even current distribution among paralleled MOSFETs, small drain-source voltage spike and good thermal dissipation. A detailed hardware design procedure for a 48 V BSG inverter is firstly presented in Section II including device selection, device paralleling, DC link capacitor selection, IMS board and heatsink selection, and an introduction to automotive standard gate driver ICs and microcontrollers for this application. PLECS simulations and hardware experiments are presented in Section VI and VII, respectively, to show the continuous operation of the prototype and the robustness of the improved control technique under machine parameter changes and DC bus voltage variation
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