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    CSIRO EV Research PDF

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    schlemihl69
    This document provides a summary of CSIRO's research into electric vehicles (EVs). It discusses several prototype in-wheel motors that have been developed, including for bicycles, solar cars, and a small 4-wheel drive EV. Characteristics like power levels, efficiency, size and weight are provided for different motor designs, such as axial and radial flux motors using surface magnets or Halbach arrays. The document concludes with a discussion of potential motor types for further research.

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    CSIRO EV Research PDF

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    schlemihl69
    180 views27 pages
    This document provides a summary of CSIRO's research into electric vehicles (EVs). It discusses several prototype in-wheel motors that have been developed, including for bicycles, solar cars, and a small 4-wheel drive EV. Characteristics like power levels, efficiency, size and weight are provided for different motor designs, such as axial and radial flux motors using surface magnets or Halbach arrays. The document concludes with a discussion of potential motor types for further research.

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    This document provides a summary of CSIRO's research into electric vehicles (EVs). It discusses several prototype in-wheel motors that have been developed, including for bicycles, solar cars, and a small 4-wheel drive EV. Characteristics like power levels, efficiency, size and weight are provided for different motor designs, such as axial and radial flux motors using surface magnets or Halbach arrays. The document concludes with a discussion of potential motor types for further research.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    180 views27 pages

    CSIRO EV Research PDF

    Uploaded by

    schlemihl69
    This document provides a summary of CSIRO's research into electric vehicles (EVs). It discusses several prototype in-wheel motors that have been developed, including for bicycles, solar cars, and a small 4-wheel drive EV. Characteristics like power levels, efficiency, size and weight are provided for different motor designs, such as axial and radial flux motors using surface magnets or Halbach arrays. The document concludes with a discussion of potential motor types for further research.

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    Review of CSIRO Research in EVs


    Dr. Howard C. Lova- | Team Leader Electrical Machines (Some slides from Dr. Peter A Wa-erson)
    Plug In for Power 2012, Swinburne Hawthorn Campus, Melbourne, Australia
    CSIRO MATERIALS SCIENCE AND ENGINEERING

    Talk Overview
    AutoCRC
    A SpecicaMon for a Small 4 Wheel Drive Electric Vehicle (EV)
    Bicycle In-Wheel Motors
    Direct-Drive, In-Wheel Motors
    Solar Car In-Wheel Motors
    Prototype In-Wheel EV Motors
    Interior Permanent Magnet (IPM) Motors?
    Transverse Flux (TF) Machine?
    Switched Reluctance (SR) Motor?

    Conclusions

    2 | CSIRO EV Research | Dr. Howard C. Lova-

    AutoCRC

    EducaMon & Training


    Supplier Improvement

    3 | CSIRO EV Research | Dr. Howard C. Lova-

    A SpecicaBon for a Small 4 Wheel Drive EV


    Assume 4 wheel motors, peak total power 48 kW constant over
    30 km/h - 120 km/h, 175/65 R14 tyres
    High peak torque - 420 Nm up to 273 rpm
    Low mass - e.g. 15 kg ! 28 Nm/kg
    Small volume - e.g. OD 340 mm, length 75 mm ! 62 kNm/m3
    High eciency - e.g. 90%, ideally enabling air cooling
    Robust to vibraMons
    Low cost minimum NdFeB use
    Flux weakening e.g. 4:1, but safe in the event of a fault

    4 | CSIRO EV Research | Dr. Howard C. Lova-

    Bicycle In-Wheel Motors


    Direct Drive

    Geared

    www.value-e-bikes.com.au
    5 | CSIRO EV Research | Dr. Howard C. Lova-

    In-Wheel Hybrid e-CVT


    Planetary gear e-CVT like a Prius
    A design for a bicycle:
    ConMnuous rider power 200 W
    ConMnuous electric power 200 W
    110 270 rpm
    Hub OD 190 mm
    Hub axial length 75 mm

    Details:
    Wa-erson P.A., 11th InternaMonal
    Conference on Electrical Machines
    and Systems, ICEMS 2008, Wuhan

    NexxtDrive patents similar


    6 | CSIRO EV Research | Dr. Howard C. Lova-

    Solar Car In-Wheel Motors


    Aurora Solar Car

    Direct Drive In-Wheel Motor


    In conjuncMon with University of Technology Sydney, Newcastle University (UK),
    and Aurora
    7 | CSIRO EV Research | Dr. Howard C. Lova-

    Marand/CSIRO - Halbach Magnet Motor


    Tyre

    Magnet
    Blocks

    Copper
    Winding

    Winding
    Magnet
    Ring

    Axial ux

    Axle

    !
    z

    8 | CSIRO EV Research | Dr. Howard C. Lova-

    Marand/CSIRO - Halbach Magnet Motor


    Axial ux
    Halbach magnet array
    40 pole
    ConMnuous power 5 kW
    Eciency 98%
    Motor OD 360 mm
    Motor axial length 43 mm
    Motor mass 6 kg
    Used by Aurora in World Solar
    Challenges, including 1st in 1999

    9 | CSIRO EV Research | Dr. Howard C. Lova-

    Marand/CSIRO Surface Magnet Motor


    Axial ux
    Magnets on surface of steel
    plate
    40 pole
    ConMnuous power 4 kW
    Eciency 97%
    Motor OD 355 mm
    Motor axial length 45 mm
    Motor mass 10 kg
    Used by 2nd, 3rd, and 4th cars in
    World Solar Challenge 2009

    10 | CSIRO EV Research | Dr. Howard C. Lova-

    h-p://innovaMon2012.com.au/wp-content/
    uploads/2012/04/Marcel-Kamp.pdf

    Mitsuba In-Wheel Motor


    Radial ux
    Surface magnet
    32 pole
    ConMnuous power 5 kW
    Eciency 97%
    Motor OD 260 mm
    Motor axial length 60 mm
    Used by Tokai University, in
    winning World Solar
    Challenge 2009, 2011

    11 | CSIRO EV Research | Dr. Howard C. Lova-

    Prototype In-Wheel EV Motors


    General Motors
    axial ux, two-sided
    surface magnets
    500 Nm peak

    Rahman et al., IEEE Trans. Industry


    Applica3ons 42, 1185-1192, 2006;
    and US Patent 7,262,536

    12 | CSIRO EV Research | Dr. Howard C. Lova-

    Mitsubishi MIEV
    radial ux, external rotor,
    embedded magnets,
    600 Nm peak

    Wikipedia

    13 | CSIRO EV Research | Dr. Howard C. Lova-

    TM4
    radial ux, external rotor,
    surface magnets,
    670 Nm peak, 40 kg

    Protean Electric Protean Drive PD18


    Radial ux, surface magnets
    Peak torque 800 Nm
    ConMnuous torque 500 Nm,
    liquid cooled
    Motor OD 420 mm
    Motor axial length 115 mm
    Hence peak 50 kNm/m3
    Total motor mass 31 kg
    (including inverter?)
    Tests suggest unsprung mass
    not so criMcal
    ProducMon 2014, Liyang, China

    14 | CSIRO EV Research | Dr. Howard C. Lova-

    Surface PM Motor
    Pros (parMcularly Halbach,
    Iron-less)
    Smallest
    Lightest
    Most ecient

    15 | CSIRO EV Research | Dr. Howard C. Lova-

    Cons
    Motor cost (lots of magnets)
    Electronics cost (no eld
    weakening)

    ogging torque
    t
    amplitu
    ude.

    [W]

    (5)

    ND MMF
    F HARMONICSS

    Interior Permanent Magnet (IPM) Motors

    Where
    W
    arre the wavefoorms in fig. 1 and fig. 2. Due
    D to
    stator coils
    c
    is geneerally
    the possibility off operation inn excess of ten
    t times the base
    by the stator (Bs) liinked
    speeed in the field
    d weakening region, there will be harm
    monic
    ) with reeluctance (Rair).
    com
    mponents preseent at frequenccies of severall kilohertz.
    Comparison of Concentrated
    VericaMon
    V Experimental
    V.
    METHOD
    DS AND
    RESULLTSof Open Circuit
    (4
    4) Windings in
    [A
    A] Distributed
    and
    Parameters
    f an IPM fi
    M
    achine
    with (FE)
    I this paper,, time-stepped
    d, otransient
    inite
    element
    an IPM Machine for Field In
    Concentrated Windings
    ncluding
    g airgap length
    h and
    anal
    Weakening
    ApplicaMons
    lysis is used to determinee the machinne parameterss and
    Chong, D[1
    u-a,
    iao, two
    Rahman
    (UNSW),
    and
    perfformance charracteristics
    8]. XThe
    models
    comp
    pared
    ant. Th
    herefore
    the Qonly
    Chong,
    Du-a,
    uang Dai,
    double-laye
    heree areThis
    84-slo
    er, modeled
    distributed
    dd windings
    and
    d 18Lova-
    (CSIRO)
    flux open
    airgap isd the
    woss
    thethe
    modeled
    measured
    sectiont, will
    show
    the
    and
    measured open
    Rahman and
    (UNSW),
    and slot,, double-layer
    r, concentrated
    d windings
    as
    s shown
    in fiig. 3a
    of an 800W,
    reacti
    ion. 18-s
    Integral
    00W,
    14-pole,
    slot, l-slot
    double-layer circuit parameters
    14-pole, 18-s
    slot,
    double-layer
    Lova- (CSIRO)
    and 3b
    respectivel
    ly. (fig. 2).
    p. wavefo
    forms containiing a
    CW-IPM
    machine
    eakage harm
    ow le
    monic

    us it is a common praactice
    mpletely sinusoidal.

    F
    Fundamental
    term
    m
    Fig. 4. Measured peak cogging torque pointts and FE estimated waveform of
    the CW-IPM prototype machine

    Fig. 4. Meas
    the CW-IPM

    In a comparison made with two other UNSW IPM

    In a c

    (a)
    (b)(b)
    (b)
    (a)
    machines
    roduced
    by
    the(a) CW-IPM
    machines
    [13],
    cogging
    torque
    pr
    m
    machine
    FE model,
    2. 800W,
    14-pole,
    layer CW-IPM
    machine (a) FE model,
    double layer CW-IPM m
    Fig. Fig.
    ution18-slot
    of a)double
    84--slot,
    distributed
    d windings
    b) 18-slot
    1
    3. Flux
    distribu
    machines
    a much
    lower cogging torque
    t
    as a percentage of machines
    (b)
    Manufactured
    prototype.
    25
    5
    50

    CSIRO produced
    EV Research | Dfro
    r. om
    Howard
    16 | um
    ic spectru
    anC. Lova-

    conceentrated windingss

    rated torque produced (1.54%(peakk


    A. Electromotive Force

    to peak)

    as compared to

    a
    rated torqu

    Interior PM Motors
    Pros
    Field weakening
    Reduced magnet volume

    17 | CSIRO EV Research | Dr. Howard C. Lova-

    Cons
    SMll uses considerable magnet
    material
    Weight
    Volume

    Transverse Flux (TF) Motor?


    Genesis:

    Current
    MoMon

    18 | CSIRO EV Research | Dr. Howard C. Lova-

    Other TFM Patents


    Bosch, WO 90/09697

    19 | CSIRO EV Research | Dr. Howard C. Lova-

    Rolls Royce, US 5,886,449

    Daimler-Chrysler Rail
    Systems, US 6,236,131

    20 | CSIRO EV Research | Dr. Howard C. Lova-

    Nissan/Renault,
    US 2007/0164628

    Servax TFM TorqueChampion


    Up to 75 Nm peak

    www.servax.com

    21 | CSIRO EV Research | Dr. Howard C. Lova-

    TFM Example

    Weh H., May H., & Shalaby M.,


    InternaMonal Conf. on Electrical
    Machines, Cambridge USA, 13-15
    Aug 1990, 1040-1045

    CSIRO EV Research | Dr. Howard C. Lova-

    22 | In-Wheel Motors | Peter A. Wa-erson

    Parameter

    Value

    Wanted

    continuous torque
    (Nm)

    400

    210

    peak torque (Nm)

    600

    420

    active mass (kg)

    14

    15

    active OD (mm)

    270

    340

    active length (mm)

    125

    75

    peak volume torque 84,


    density (kNm/m3)
    active
    parts

    62,
    over all
    volume

    peak mass torque


    density (Nm/kg)

    43,
    active
    parts

    28,
    over all
    mass

    speed, power
    factor, inductance

    not
    stated

    TFM
    Advantages Disadvantages
    High torque density
    Many poles and many parts
    proporMonal to pole number
    Low magnet mass, hence low
    material cost
    Simple, cheap winding just
    one coil per phase
    High inductance enabling
    ux weakening for constant
    power range

    23 | CSIRO EV Research | Dr. Howard C. Lova-

    to assemble
    Less robust to vibraMon
    Low rigidity may imply
    higher noise
    Inductance can be too high
    Low eciency

    Switched Reluctance (SR) Motor?


    Advantages:
    Low cost no magnets
    Robust
    High temperature
    Good eld weakening

    Disadvantages:
    Lower torque density

    A typical SR motor

    24 | CSIRO EV Research | Dr. Howard C. Lova-

    An SR In-Wheel Motor

    CSIRO/Latrobe/Swinburne/VPAC/AutoCRC
    Axial ux, two airgaps
    Goal peak torque 425 Nm
    Goal motor mass 25 kg
    Under development

    Details
    Lova- H.C. et al., 37th Annual
    Conf. of the IEEE Industrial
    Electronics Society, 7-10 Nov.
    2011, Melbourne, Australia

    25 | CSIRO EV Research | Dr. Howard C. Lova-

    (not nal dimensions)

    Conclusions
    CollaboraMon PossibiliMes (AutoCRC, ARC, Tax IncenMves,
    Grants)
    Direct-Drive, In-Wheel Motors
    Surface PM Motor (cost++)
    Interior PM Motor (cost and mass)
    Transverse Flux Machine (research)
    Switched Reluctance Motor (mass)

    26 | CSIRO EV Research | Dr. Howard C. Lova-

    Thank you
    CSIRO Materials Science and Engineering
    Dr. Howard C. Lova-
    Team Leader Electrical Machines
    t +61 2 9413 7412
    m +61 419 971 263
    e [email protected]
    w www.csiro.au/science/ElectricMachines.html

    CSIRO MATERIALS SCIENCE AND ENGINEERING

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