Status Review of Advances in Hybrid Electric Vehicles

1 Status Review of Advances in Hybrid Electric VehiclesProfessor M. A. RahmanMemorial University of Newfoundland and St. John s, NL, Canada A1B 3X5E-mail: 2014St. John s (MUN)Reasons for Electric and Hybrid vehiclesYaskawaIPM MotorPresentation OutlineIntroductionIPM motor technologyDesignStartingOperationApplica tionsChallengesCreate variation of d-q axis inductances without varying air gapVary and Control of excitation of permanently excited rotor of IPMO ptimum variation of PM torque and reluctance torque in IPM for specific applicationsReduction of cost, weight, size of IPM for specific applicationsIntelligent power converter and inverter for IPM motor drivesContentsRequirements for Hybrid Electric vehiclesHistory of high efficiency permanent magnet motor technology using non-rare earth(ferrites) and rare earth (NdBFe) permanent magnet materialsExample #1 for uses of IPM Technology in compressors for air conditionersExample #2 for uses of IPM Technology in motors/generators for HEVsHistory of Permanent Magnet MaterialsGasoline prices Energy DiversificationEnvironmental and echo logical concernsEV/HEV GrowthRare earth material cost has increased.

2 In last 8 years, Nd and Dy prices are 17 and 36 times the price in $10/kg $50/kg2010 April$40/kg$270/kg2011 July$500/kg$3000/kg2012 May$170/kg$1800/kglast 8 years 17 36 Rare earth problempeak0 100 200 300 400 500 600 700 IPMSM@2012costIPMSM@2005costWire(US$)Iro n(US$)PM(US$)Estimated Prius 09 motor material costHEV09PM756gPM occupies 64% and 81% in the total material cost in 2005 and $it emUS$/ ( ) cost is $250/kg and $625/kg in 2005 and 2012, of NEDO projects Rare-Earth-Free Electric motorsare strongly demanded for mass production HEVs and EVs. NEDO has started rare-earth-free or half-rare earth motor projects since 2008. The rare-earth-free motors must power no rare-earth permanent magnetwith respect to the rare-earth(NdFeB) IPM motors employed in HEVs and EVs. Thus, the targets are very challenging. Rare-earth-free motors are a new generation motorof post NeFeBIPM of target specific NEDO projects for rare-earth-free reluctance motor (TUS&TIT)target: 2ndgeneration PM axial gap motor with segmented rotor( Hokkaido Univ.)

3 Target: 2ndgeneration magnet assisted synchronous reluctance motor with stepped gaptarget: 2ndgeneration Prius 1/10 field winding and soft magnetic composite core motortarget: Lexus 400hModelPrius 03 flux density analysis SPEEDPC-BDC+FEA1200r/min, 400 NmSerious magnetic saturationMax. currentVdcis the inverter VA. Target IPM motor analysis3000r/min 50kW half of the rated current for 50kW field weakening =65deg Magnetic saturation is not ironRotor ironRare earth PMsCrosssectionof2ndHEVIPM motorTorque 400 NmPower 50kWOuter Dia. 269mmAxial length 154mmHigh power and torque for has thick axial length. About 1kg of NdFeB PM is used. $ 625. Iron and cupper are only $ TechnologyReduced Environment Impact : CO2 Footprint of the AGVE nergy Optimzation : Recovering Braking EnergyTractionElectric Sub-StationBraking EnergyFeedingDissipationBrakingRAILWAY TRACTION MOTORTGV : a 25 years historyTGVP aris-Sud estTGVA tlantique53553511301130 DCSynchronousWound rotorEurostar10201020 InductionAGVAGVHigh speed EMU720 SynchronousRotor magnets1981198919942004 Equipower kW156015601525152512601260720 Weight KgTypeType2,92,91,351,351,231,231,001,00 Ratio Kg/KWRatio Kg/KWThe AGV TrainFrom the TGVan Articulated train with ConcentratedMotorisationto the AGVan Articulated train withdistributedMotorisationTraction motors specificities Embedded device : Severe mechanical environment Low volume & mass High power density Pollution Severe thermal environment High torque at very low speed Voltage & current waveforms with high harmonic level (inverters 12 to 20 h/day service Guarantied life duration.)

4 30 or 40 years Safety requirements PM Machines TypesRequirements for Hybrid Electric Vehicles Largetorqueandhigherpowerdensity Hightorqueat lowspeedsforstartinganduphillclimb Highpowerat highcruisingspeeds Maximumefficiencyoverwidespeedandtorquer anges Widespeedrangewithconstantpowermode,exce eding2- 5 timesthebasespeed Optimumcompromisebetweenmotorpeaktorquea ndinvertervolt-ampereratingsRequirements for Hybrid Electric Vehicles -2 Shorttermoverloadcapability,typicallytwi cetheratedtorqueovershortduration Lowcoggingtorque,lowrippleandlowacoustic noise Distributed,short- pitchedandconcentricstatorwindings. OptimumstatorwindingdesignwithlowestTHDf actors Rotordesignwithmagnetsorientationforopti mumd-qreactancesforbestreluctanceandmagn ettorques Reductionofmagneticsaturationduetocross- couplinglimitsto opencircuitvoltageandtotalharmonicconten tsRequirements for Hybrid Electric Vehicles -3 Lowstatorcopperandlowironlossesathighspe ed Highreliabilityforalloperatingconditions Minimumweightandsmallestsize Lowfuelconsumptionrate(litre/km) NewICEenginetechnologywithhybridgasoline /diesel Homogenouscharge-compressionignition(HCC I)

5 Clean,ecologicallybenignandenvironmental lyfriendly Minimumvibration,quiet,smoothandcomforta blerideRequirements for Hybrid Electric Vehicles -4 Aestheticallyacceptableto customers,aerodynamicdesignforlowestdrag at cruisingspeed Betterbatterypower,andself-charging Smartsensorsandinterfaces Leastmagnetfluxleakageandmaximumairgapfl uxes Magnetdemagnetizationwithstandtoarmature reaction Temperatureandsurfacecorrosionconstraint sofmagnets EffectsofshearstressonpermeabilityofPMma terials MinimumgearandmoredirectdriveRequirement s for Hybrid Electric Vehicles -5 Regenerativebrakingandshortchargingcycle ofbatteries Impulsechargingof batteries Plug-induringoffpeakperiodsofdailyloadin gcycles Noplug-in andhybridtransmission Quickplug-inchargingandminimumgasgenerat ion PVsolarpanelbodyforself-chargingof on-boardbatteryforairconditionersandauto mobilesmartpowersystem. Seamlesstransferbetweenengineandelectric tractionRequirements for Hybrid Electric Vehicles -6 Minimummaintenance,highestreliabilityand highefficiency LowestCo2gasemissionandminimumclimatecha nge.

6 Rare-earth-freerotordesign(switchedreluc tancemotor)fornicheapplicationsconsideri ngsecurityofsupplyandhighpriceofrareeart hpermanentmagnets,etc. Taxesanddutiesofsmartvehiclesataffordabl eprices induction motorLine-start interior permanent magnet synchronous motor Rotors for IM and IPM MotorsStarting Torque of Squirrel Cage Induction MotorDeveloped Power and Torque in IPM motor XX)X(XV XEVqdqdpdp2sin23sin3P20d +=}i)iL(Li{ pTqddqqmd +=2 MotortypesIPMM otorInductionMotorInputvoltage:Vi(V)1302 00 Inputcurrent:Ii(A) :Wi(W)687818 Rotorspeed:n (rpm)at 50Hz15001434To r q u e:T (Nm) : (%) :pf (%) :Po(W)600600 Eff . pf product(%) : Pmax(W)9601240 Performance Comparisons of IPM and Induction MotorsChallenges for IPM Designs An IPM motor is a Hybrid motor with no saliency. Create airgap saliency variation of d-q axis reluctances without varying physical air gap of the IPM motor . Varying and control of permanent magnetic (PM) excitation of rotor of IPM motor . Optimum variation of PM torque and reluctance torque components for specific applications.

7 Availability and security of PM materials, weight, size, and overall cost of IPM motor . Smart ac-dc converter and dc-ac inverter for IPM traction motor drive and IPM generator for charging IPM PatentRotors of Hysteresis, Reluctance, Squirrel Cage and IPM MotorsRotors of Squirrel Cage and IPM MotorsExperimental IPM motor (1982, MUN)Cross Section of IPM MotorRotor Configurations for IPMIPM Rotor for Air ConditionersOldNewIPM Rotor for CompressorIPM motor Twin compressor Split Window Air ConditionersIndoor Multi-Unit Air ConditionersAir Quality FeatureAnnual Power Consumption Change for Air Conditioners in Japan1990 1994 1995 2000 2005 Refrigeration Year ( )IPM motor and Generator for Toyota HybridsFront IPM MotorIPM GeneratorGear2012 Toyota Prius VRatio of reluctance and magnet torques/total torqueConclusionBrief introduction to the emergence of high efficiency interior permanent magnet (IPM) synchronous motors. A short survey of significant as well as some incremental contributions in chronological order of appearance over the past 50 years.

8 Rotor design features for specific applications Successful simulation and experimental resultsHighlights of IPM motor drives include applications in Japanese air P. Steinmetz (1917), Theory and Calculations of Electrical Apparatus, McGraw-Hill, N. Y. Teare, Theory of Hysteresis motor Torque, , PhD Thesis, Yale University, : Miyairi and T. Kataoka "A Basic Equivalent Circuit of the Hysteresis motor ", Journal , Japan, vol. 85, , 1965 Wakui, K. Kurihara, and T. Kubota, Radial flux type hysteresis motor with reaction torque--Numerical analysis of hysteresis motor using finite element method, Magnetics, IEEE Transactions on, vol. 23 , no. 5, 1987. Nitao, Scharlemann, and Kirkendall, Equivalent Circuit Modeling of Hysteresis Motors, Lawrence Livermore National Laboratory, LLNL-TR-416493.