Interior Permanent Magnet Research Articles

Traction Drive Motor for Small EVs Using Mass Producible Amorphous Laminated Cores

ABSTRACTThis study presents the development of a small electric vehicle (EV) traction drive motor using Fe‐based amorphous laminated cores that can be mass produced. The following innovative technologies are developed to realize the amorphous laminated core: (1) production technology for thicker amorphous alloy foils to reduce the number of machining operations and (2) punching press technology for amorphous alloy foils that improves the usability of the tool life and maintains quality. The interior permanent magnet synchronous motor (IPMSM) using the amorphous laminated core is designed to be compatible with a 4.5‐kW‐class small EV traction drive with high efficiency while satisfying the required torque characteristics. A prototype of the designed IPMSM was manufactured and evaluated. The test machine achieves a maximum efficiency of 98.7% and a wide range of efficiencies exceeding 97%. Additionally, the prototype motor exhibit improved efficiency in all operating points compared with a prototype manufactured using an electrical steel sheet.

Enhanced Maximum Torque per Ampere Control With Predictable Core Loss for the Interior Permanent Magnet Synchronous Motor

Enhanced Maximum Torque per Ampere Control With Predictable Core Loss for the Interior Permanent Magnet Synchronous Motor

Design and real-time implementation of a sliding mode observer utilizing voltage signal injection and PLL for sensorless control of IPMSMs

In this study, a sliding mode observer (SMO) based on high-frequency (HF) voltage signal injection and a phase-locked loop (PLL) is proposed for estimating the extended electromotive force (EEMF), rotor position, and rotor velocity of an interior permanent magnet synchronous machine (IPMSM).This approach addresses real-time estimation challenges associated with standard SMO and PLL at very low speeds and standstill. A reliable and accurate sensorless speed control system for IPMSM is then developed and implemented in real time using the proposed SMO and PLL, covering a wide range of speeds, including low-speed and standstill conditions. The SMO effectively estimates the EEMF, while the PLL extracts the rotor velocity and position based on these estimates. Compared to conventional SMO and PLL methods, real-time results from an 8-pole, 0.4 kW IPMSM demonstrate the superior efficiency of the proposed system.

Research on the Mechanism of Thermal Power Enhancement in an Interior Permanent Magnet Eddy Current Heater Driven by Wind

This article uses numerical simulation methods to study the comprehensive influences of the stator structure and materials on the thermal power of an interior permanent magnet eddy current heater (IPMECH). By analyzing the air-gap magnetic flux density (MFD), stator MFD, thermal power, and torque at different rotational speeds, the mechanism of thermal power enhancement has been revealed in depth. The results indicate that the armature magnetic field (MF) generated by the eddy current produces a magnetization effect on the side of its rotation direction, but the MF in the stator will be weakened in general, and this effect becomes more significant with the increase in the rotational speed. The stator material of the IPMECH has higher permeability, which has higher thermal power and torque, and a lower proportion of high-order harmonics, which is beneficial for reducing the radial vibration of the IPMECH. A permanent magnet with high remanence can increase the thermal power and torque of the IPMECH. Reducing the length of the air gap is beneficial for improving the thermal power, but it also increases the harmonic MFD. The rotational speed is 200 rpm, the air gap is 0.1 mm and 2 mm, and the thermal power is 1.12 kW and 0.35 kW, respectively. The fundamental amplitudes of the 0.1 mm and 2 mm air-gap lengths are 0.94 T and 0.64 T, respectively, and the 3rd harmonic Bi* values are 0.24 and 0.18, respectively. At rotational speeds of 200 rpm, 800 rpm, and 1600 rpm, the δPmax values are 17 mm, 11 mm, and 8 mm, respectively. When designing a heater, the higher the rotational speed, the smaller the stator wall thickness should be.

Active Disturbance Rejection Control for Flux Weakening in Interior Permanent Magnet Synchronous Motor Based on Full Speed Range

To address the impact of load disturbances on the full-speed-range control of an interior permanent magnet synchronous motor (PMSM), an active disturbance rejection control (ADRC) method is proposed. The speed loop employs phased field-weakening control (FW) based on ADRC, while the current loop utilizes proportional-integral-derivative (PID) control. Starting from the motor parameters, the Lagrange multiplier method was used to derive the critical speeds for the maximum torque per ampere (MTPA) and maximum torque per voltage (MTPV) ratios, and the timing for the field-weakening control was analyzed. A full-speed-range control model of the motor was established, and an ADRC-based speed loop controller was designed to achieve smooth transitions between high speeds and anti-disturbance solid capabilities. Based on the proposed control strategy, a 21 kW PMSM was used as the research object, and a full-speed-range control simulation model was developed in MATLAB/SIMULINK to verify the strategy. Compared to the traditional PID control, the simulation results demonstrate that the proposed strategy effectively observes and compensates for load disturbances, significantly reducing initial torque oscillations under three different operating conditions. After a sudden load increase, torque oscillations were reduced by 16%, with the stator current reaching steady state 0.03 s faster, response speed improving by 0.02 s, smooth transitions between speed ranges, and enhanced anti-disturbance performance.

Discrete‐time full‐order sensorless control of high‐speed interior permanent magnet synchronous motor in electric vehicle traction system

AbstractA discrete‐time full‐order sensorless control strategy for high‐speed interior permanent magnet synchronous motor (IPMSM) used in electric vehicle (EV) traction system is designed in this paper. While most speed and position observer (SPO) methods are developed in the continuous‐time domain, the presence of a unit‐time‐delay block existed in feedback loop and discretisation of the algorithm can lead to performance degradation during digital implementation. In this work, speed and angle are observed using the discrete‐time four‐order IPMSM model. A quadrature phase‐locked loop model with compensation is introduced, and its stability condition is established for the first time. Furthermore, to address the potential for sudden speed changes in vehicle applications, the parameter range is further refined to keep the estimation error within a specified range. The sliding mode observer is discretised and its stability is analysed using discrete Lyapunov theory. Additionally, the time sequence of interactive signals between SPO and field‐oriented control is thoroughly examined to ensure accurate time cycle. Finally, the proposed control strategy is validated and demonstrated through bench tests and real EV (LS6 of IM Motors) tests with a 190 kW IPMSM, which can improve the accuracy by 0.3 radians at 8000 rpm compared to traditional methods, and achieve stable control at 15,000 rpm on the test bench and at 120 kph with the EV.

Electromagnetic-thermal-mechanical performance of novel interior permanent magnet motor

To mitigate the challenges of magnetic leakage and iron loss in the rotor of interior permanent magnet (IPM) motors, this article proposes a novel rotor structure that eliminates the bilateral bridge, relying solely on a central bridge to maintain rotor strength. This design reduces the overall bridge width of the rotor, thereby decreasing magnetic leakage and improving torque. The novel rotor features a distinctive design that combines high silicon steel sheets and low silicon steel sheets. High silicon steel sheets are used on the rotor's surface to minimize iron loss, while low silicon steel sheets are used internally to ensure rotor strength. This design takes advantage of the high silicon steel's low iron loss while mitigating its brittleness and saturation issues. The article describes the method for producing this combined rotor. Mechanical and electromagnetic property tests are conducted on both high and low silicon steel sheets, resulting in stress-strain curves, B-H curves, and iron loss characteristics. Finally, the rotor stress is calculated. The analysis indicates that this novel motor can reduce magnetic leakage, increase torque by 7.5 %, improve efficiency by 0.18 %, decrease rotor iron loss by 36.2 %, and lower rotor temperature by 3.9 % compared to the original motor.

Research on Performance of Interior Permanent Magnet Synchronous Motor with Fractional Slot Concentrated Winding for Electric Vehicles Applications

The fractional-slot, concentrated-winding, interior permanent magnet synchronous motor (FSCW IPMSM) has advantages, such as reducing motor copper consumption, improving flux-weakening capability, and motor fault tolerance, and has certain development potential in application fields such as electric vehicles. However, fractional-slot concentrated-winding motors often contain rich harmonic components due to their winding characteristics, leading to increased motor losses and back electromotive force harmonics, thereby affecting the efficiency and constant power speed regulation range of the motor. Based on this, this article first uses the winding function method to explore the inductance and saliency ratio of the interior permanent magnet synchronous motor with different slot pole combinations in the fractional-slot concentrated- winding of electric vehicles. Secondly, this article will establish a 2D finite element parameterized model to analyze and compare the performance of fractional-slot concentrated-winding motors with different slot pole combinations, including air gap magnetic density, back electromotive force distortion rate, overload multiple, and torque. The structural parameters of the motor were optimized with the objective of minimizing the torque ripple under the constraint of minimizing the average torque reduction. The motor slot width, permanent magnet angle, and permanent magnet pole arc angle were analyzed and optimized. The simulation results showed that 12 slots and 8 poles were the optimal design schemes, providing a theoretical basis for the selection of slot pole coordination in the fractional-slot concentrated-winding interior permanent magnet synchronous motor for electric vehicles.

Optimal powertrain system design and V2V and V2I based hierarchical control strategy of FRIDEV under vehicle-following scenarios

In this paper, the front- and rear-independent-drive electric vehicle (FRIDEV) is selected as the target vehicle for its good dynamic and economy performance. Based on the analysis of the cost, efficiency, and loss characteristics of different motors, the interior permanent magnet synchronous motor (IPMSM) and induction motor (IM) are applied in the target powertrain system. Then, the proposed powertrain system is optimized based on the analysis of driving cycles. The optimal control strategy for the target powertrain system is developed, which consists of the driving mode switching algorithm and the driving torque distribution based on adaptive particle swarm optimization (APSO). Furthermore, in order to achieve the efficient autonomous driving of the target vehicle under the vehicle-following scenarios, a hierarchical control strategy is proposed with the combination of upper-level control of the speed planning strategy and the lower-level control of powertrain system control strategy. The upper-level control of speed planning strategy is designed, which can determine and track the target vehicle speed based on the information from vehicle-to-vehicle (V2V) and vehicle-to-infrastructure (V2I) communications. Finally, simulation analysis in MATLAB/Simulink and virtual driving experiments are conducted to verify the superiority of the proposed powertrain system and hierarchical control strategy.

평균 토크 향상을 위한 단절권 매입형 영구자석 동기전동기의 회전자 배리어 형상 최적 설계

평균 토크 향상을 위한 단절권 매입형 영구자석 동기전동기의 회전자 배리어 형상 최적 설계

Auxiliary Notching Rotor Design to Minimize Torque Ripple for Interior Permanent Magnet Machines

Auxiliary Notching Rotor Design to Minimize Torque Ripple for Interior Permanent Magnet Machines

Magnetic Field Calculation of the U-Shaped Interior Permanent-Magnet Synchronous Machine Considering the Parallel Magnetization and Bridge Saturation

Magnetic Field Calculation of the U-Shaped Interior Permanent-Magnet Synchronous Machine Considering the Parallel Magnetization and Bridge Saturation

Multi-physics Analysis of Interior Permanent Magnet Synchronous Motor with Torque Ripple Reduction Using Voltage Control Method

Multi-physics Analysis of Interior Permanent Magnet Synchronous Motor with Torque Ripple Reduction Using Voltage Control Method

Adaptive Current Angle Compensation Control Based on the Difference in Inductance for the Interior PMSM of Vehicles

Achieving good performance in terms of a fast and accurate maximum torque per ampere (MTPA) control method depends on both accurate parameter estimation and a sophisticated control strategy. However, it often requires a complex and long computational process. This paper proposes an efficient control method using the relationship of torque and current angle for maximum torque per ampere control of the interior permanent magnet synchronous motor (IPMSM) for vehicle application. It was found that it is not necessary for the control method to determine the inductance in the d-q axes; the identification of the difference between each axis is enough. Furthermore, this paper presents a simple and effective procedure to estimate the difference in inductance online, where the linear iron loss calculation method is also designed to support the above process. The proposed control method was experimentally validated on a 5 kW prototype by a TMS320F28335 microcontroller and DSPACE synchronized with a personal computer. The results show that the control process has faster and more accurate performance than the conventional method.

Active flux based adaptive and non-adaptive observer for sensorless interior permanent magnet synchronous machine drive

The use of the interior permanent magnet synchronous machine (IPMSM) drive has profoundly increased in a large number of applications due to numerous advantages. Owing to the disadvantages of mechanical sensors, sensorless control techniques are employed to enhance the performance of the IPMSM drive by removing the effect of noise and gain drift due to the sensor, increasing reliability, cost saving, and reducing overall size. This article presents the comparative analysis between the adaptive observer and non-adaptive extended electromotive force (EEMF) observer based on the active flux concept in a stationary reference frame (α–β). Moreover, the effect of slot harmonics and non-sinusoidal distribution of rotor flux is present in the three-phase IPMSM, this problem is considered as the control system disturbances in this article. Due to the non-sinusoidal distribution of flux and slot harmonics, the observer structure in the rotating reference frame (d–q) fails to estimate at the low-speed operation range. Comparative analysis between adaptive and non-adaptive observer structures is provided for a wide speed range. The effectiveness of the observer structures is examined using the classical field-oriented control scheme. In the end, simulation and experimental results are demonstrated to validate the performance of the sensorless control scheme using the adaptive and non-adaptive observer structures for the three-phase IPMSM drive setup.

Sensorless control in full speed domain of interior permanent magnet synchronous motor based on hybrid observer

Aiming at the problem that an Interior Permanent Magnet Synchronous Motor (IPMSM) cannot be smoothly started in zero-low speed range and smoothly transitioned to medium-high speed range by a single observer. This paper proposes a full-speed range control algorithm based on the fusion of pulsating high-frequency injection and back electromotive force (EMF) position error information. In the low-speed range or at start-up, a square-wave high-frequency signal is injected, and the obtained high-frequency current signal is processed to obtain the rotor position error information. The phase shift due to the introduction of a filter is reduced, which improves the control bandwidth and reduces the noise. To ensure smooth switching of the observer, the observer uses a dual second-order generalized integrator module to output the angular frequency in the low-speed range. A higher-order sliding mode observer based on an inverse EMF model obtains rotor position error information at high speeds. During switching, the rotor position information is processed by a fusion strategy, and the obtained hybrid information is fed into the system to improve the stability of the motor operation. A 0.2 kW IPMSM position sensorless vector control system verifies the algorithm’s accuracy.

A dead-time compensation method for motor drive inverters based on nonlinear observer

Silicon carbide (SiC) inverters and interior permanent magnet synchronous motors (IPMSMs) are widely employed in electric vehicles (EVs) due to their superior efficiency and high power density. However, the harmonics generated by the high switching frequency and the dead-time effect in SiC inverters present a significant challenge. The time-varying nature of on–off delays and conduction voltage drops in power devices makes it difficult to establish a precise nonlinear model for inverters, thus limiting the effectiveness of traditional dead-time compensation methods. This paper introduces a dead-time compensation approach for voltage source inverters (VSIs) that leverages a nonlinear observer, thereby circumventing the need for a complex inverter model while enhancing compensation accuracy. The method determines the three-phase stator current polarity of the IPMSM by deriving the relationship between the current vector angle and the rotor position angle. Along with duty cycle variations computed by the PI controller, the inverter’s nonlinearity is adaptively compensated. Simulation and experimental results indicate that the proposed method outperforms the traditional method based on the error voltage model, effectively reducing the total harmonic distortion (THD) of the phase current.

Analytical Investigation of Electromagnetic Vibration in Interior Permanent Magnet Synchronous Motors With Dynamic Eccentricity Fault

Analytical Investigation of Electromagnetic Vibration in Interior Permanent Magnet Synchronous Motors With Dynamic Eccentricity Fault

Torsional Vibration Analysis and Suppression of Interior Permanent Magnet Synchronous Motor With Staggered Segmented Rotor for Electric Vehicles

Torsional Vibration Analysis and Suppression of Interior Permanent Magnet Synchronous Motor With Staggered Segmented Rotor for Electric Vehicles

Voltage Angle-Based Torque Control of Dual Three-Phase Interior Permanent Magnet Synchronous Motor Considering Mismatch in Winding Parameters

Voltage Angle-Based Torque Control of Dual Three-Phase Interior Permanent Magnet Synchronous Motor Considering Mismatch in Winding Parameters