Comparative performance analysis of 3-phase IPMSM rotor configurations with dampers for integrated charging application in EVs

Abstract

Integrated charging (IC) technology in electric vehicles (EVs) employing conventional power electronics and motor drivetrain components facilitates level 3 fast charging capabilities with reduction in overall weight and cost of the vehicle. However, when the winding inductances of 3-phase interior permanent magnet synchronous machines (IPMSMs) are realized as line inductors for battery charging, due to machine saliency, the magnetic fields produced by the sinusoidal AC supply results in 1) asymmetrical voltages in the air-gap as a function of rotor position and 2) relatively high magnitudes of oscillating torques causing harmful noise and vibrations. This can lead to significant AC losses with risk of permanent magnet demagnetization in the machine. Since the same motor is employed for traction application as well, it is of significance to optimally design the machine for IC operation. Thus, this paper exclusively investigates three IPMSM rotor configurations to be employed for IC operation in EV. This paper firstly presents a conventional dq-axis circuit model based damper design approach implemented for mitigating the saliency effect during IC. Then, a comparative performance analysis of the rotor configurations with damper bars during IC operation on machine saliency; asymmetrical voltage waveforms; oscillating electromagnetic torque; permanent magnet operating point and magnet losses is performed using finite-element analysis (FEA). Results obtained are analyzed and discussed.