electrified vehicle traction machine design with ... electrified vehicle traction machine design...

Download ELECTRIFIED VEHICLE TRACTION MACHINE DESIGN WITH ... ELECTRIFIED VEHICLE TRACTION MACHINE DESIGN WITH

Post on 24-Mar-2020

12 views

Category:

Documents

1 download

Embed Size (px)

TRANSCRIPT

  • ELECTRIFIED VEHICLE TRACTION MACHINE DESIGN WITH

    MANUFACTURING CONSIDERATIONS

  • ELECTRIFIED VEHICLE TRACTION MACHINE DESIGN WITH

    MANUFACTURING CONSIDERATIONS

    by

    Rong Yang, B.Sc., M.Sc.

    A Thesis Submitted to the School of Graduate Studies in Partial Fulfilment of the

    Requirements for the Degree of Doctor of Philosophy

    McMaster University

    October 2016

  • ii

    McMaster University (Mechanical Engineering), Hamilton, Ontario, 2016.

    TITLE: Electrified Vehicle Traction Machine Design With

    Manufacturing Considerations

    AUTHOR: Rong Yang

    B.Sc. (Xi’an Jiaotong University)

    M.Sc. (Xi’an Jiaotong University)

    SUPERVISORS: Dr. Ali Emadi, Dr. Stephen Veldhuis

    NUMBER OF PAGES: xxiii, 177

  • iii

    谨以此献给我的父亲母亲

    To My Parents

  • iv

    Abstract

    This thesis studies the brushless permanent magnet synchronous (BLPM) machine design

    for electric vehicle (EV) and hybrid electric vehicle (HEV) application. Different rotor

    topologies design, winding design, and multiphase designs are investigated and discussed.

    The Nissan Leaf interior permanent magnet (IPM) traction machine has been widely

    analyzed and there is much public domain data available for the machine. Hence, this

    machine is chosen as a representative benchmark design. First, the Nissan Leaf machine

    is analyzed via finite element analysis (FEA) and the results confirmed via published

    experimental test data. The procedure is then applied to all the following machine designs

    and results compared. Then the Nissan Leaf machine rotor is redesigned to satisfy the

    performance specification with sinusoidal phase current in the full range for the same

    performance specification and permanent magnet material. Afterword, a comparative

    study assessing the design and performance attributes of the Nissan Leaf IPM machine,

    when compared to a surface permanent magnet (SPM) machine designed within the main

    Nissan Leaf machine dimensional constraints. The study illustrates and concludes that

    both the IPM and SPM topologies have very similar capabilities with only subtle

    differences between the design options. The results highlight interesting manufacturing

    options and materials usage.

    The grain boundary diffusion processed (GBDP) magnets are proposed to reduce the rare

    earth material content in the permanent magnet machines, especially subject to high load

    and high temperature operating scenarios by preventing or reducing the onset of

    demagnetization. The design and analysis procedure of BLPM machine with GBDP

    magnets are put forward. In the end, the Nissan Leaf IPM machine is taken as an example

    to verify the analysis procedure. and the results illustrates that IPM machines with GBDP

    magnets can realize torque and maintain efficiency at high loads while being less prone to

    demagnetization.

  • v

    A new multi-phase synchronous reluctance machine (SRM) with good torque

    performance and conventional voltage source inverter is introduced for traction machine

    applications. Although the torque density is low compared with BLPM machine, the SRM

    machine gets rid of permanent magnets and achieve low torque ripple compared with

    switched reluctance machine when the asymmetric inverter is replaced with conventional

    voltage source inverter.

    The concentrated windings are designed and studied with both IPM and SPM rotor

    according to the Nissan Leaf machine requirements of performance and dimension to

    investigate how the concentrated windings affect the machine performance and

    manufacturability and cost. 9-, 12-, 15- slot concentrated windings’ stator share the same

    slot area with the Nissan Leaf machine distributed winding and the performance are

    evaluated and compared.

    Multi-phase concentrated windings machines with IPM and SPM rotor are designed and

    analyzed based on the Nissan Leaf machine specification and dimension constraints. The

    performance of 23-phase, 5-phase, 9-phase machine at low speed and top speed are

    studied and the advantages and disadvantages are compared in terms of torque quality,

    efficiency, and power electronic requirements.

  • vi

    Acknowledgments

    First and foremost, I would like to thank my supervisor, Dr. Ali Emadi, for his support,

    guidance, and patience on me and my research work. It has been a great honor to be one

    of his Ph.D. students. I am proud of being part of the Canada Excellence Research Chair

    in Hybrid Powertrain Program and appreciate all the knowledge and experience gained

    through several projects. It is the best thing ever happened to my life to join Dr. Emadi’s

    group and work with him.

    I would also like to thank Dr. Stephen Veldhuis. He gave me lots of precious suggestions

    and instruction on my research, especially on manufacturing parts. Dr. Veldhuis sees the

    best in people, encourages them, supports them, and guides them to what they want to

    achieve. I am grateful for working with him and being involved MMRI research group.

    I would also like to express my special thanks to Dr. Nigel Schofield. This thesis would

    have been more difficult without his help and guidance. Dr. Schofield is warm-hearted,

    very knowledgeable, critical thinking, and ready to assist when I have unanswered

    questions. I learned a lot from his insightful comments and careful thinking. I would also

    like to thank Dr. Fengjun Yan, for his stimulating discussions throughout my Ph.D.

    program.

    I am grateful to my colleagues in the Canada Excellence Research Chair in Hybrid

    Powertrain Program. Special thanks to Dr. Berker Bilgin, Dr. Yinye Yang, Dr. James

    (Weisheng) Jiang for their support and sharing expertise and assisting with the projects I

    am working on. Special thanks go to Jianning Dong, Hao Ge, Sandra Castano, Miachael

    Kasprzak, Trevor Hadden, Hannah Koke, Fei Peng, Yu Miao, and everyone in the Lab for

    being working and spending great times together.

    I am also grateful to all my friends at McMaster University. It is you who make my life in

    Canada so wonderful. Special thanks to Linyan Liu for her encouragement and support

    over the years. I will all my friends every luck in their life and career.

  • vii

    My deepest gratitude goes to my parents for their continuous love and unwavering

    support. My very special thank you goes to my brother for supporting me and helping me

    look after my parents. It is to them that I would like to dedicate this thesis.

    This research was undertaken, in part, thanks to funding from the Canada Excellence

    Research Chairs Program and the Natural Sciences and Engineering Research Council of

    Canada Discovery Grant Program.

  • viii

    Table of Contents

    Abstract ................................................................................................................................ iv

    Acknowledgments............................................................................................................... vi

    Table of Contents ............................................................................................................. viii

    List of Figures .................................................................................................................... xii

    List of Tables ...................................................................................................................... xvii

    Nomenclature ....................................................................................................................... xx

    Declaration ............................................................................................................................ i

    Chapter 1 Electrified Vehicle Powertrains ......................................................................... 1

    1.1 Introduction ................................................................................................................ 1

    1.2 Literature Review ....................................................................................................... 7

    Interior versus Surface-mounted Permanent Magnets Machines .................. 7 1.2.1

    Grain Boundary Diffusion Processed Magnet ............................................... 8 1.2.2

    Distributed Windings versus Concentrated Windings ................................. 10 1.2.3

    Multiphase Machines ................................................................................... 14 1.2.4

    1.3 Research Contributions ............................................................................................ 16

    1.4 Thesis Outline .......................................................................................................... 17

    Chapter 2 Electrified Vehicle Traction Machines ............................................................ 19

    2.1 Introduction ..................................................................

View more >