System‐level optimal design process of inverter‐fed BLAC motor used for 12–48 V integrated electric brake system

Abstract

In this study, to maximise the performance and efficiency of 48 V integrated electric brake (IEB) system, a system-level optimal design process is proposed for inverter-driven brushless AC (BLAC) motor, taking into account the available input voltage that varies depending on the motor operating conditions. To get available input voltages, the voltage drops of battery wiring and inverter are reversely calculated from the motor output power. In the optimal design process, the resistance components in the inverter are separated into DC and AC parts, and these are analysed by including the dq equivalent circuit for motor analysis. The battery currents are obtained using the calculated maximum output performance and the loss between the battery and inverter. The proposed design process is applied to the optimal design of the 48 V motor for IEB systems. Also, to reduce the development cost of the 48 V motor, the manufacturing tools of the previously developed 12 V motor are shared. As an optimal design results, it is confirmed that there is an efficiency improvement effect of ∼5% compared to the conventional design of 12–48 V BLAC motor.