electric motor research paper

Power and Energy Optimization in EV with Sensorless Externally Excited Synchronous Motor

• Research Paper
• Published: 19 March 2024

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• T. Paulraj 1 &
• Yeddula Pedda Obulesu 1  

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This paper presents a comprehensive analysis of an Externally Excited Synchronous Motor (EESM) integrated with sensorless Field-Oriented Control (FOC) using the stator and rotor mutual inductance method focusing on its impact on electric vehicle (EV) performance, energy efficiency, and optimization considerations. The investigation on the performance analysis of the EV shows that there is an improvement in the performance of the EV in terms of the efficiency of the three-phase Voltage Source Inverter (VSI) as 95.23, 95.07, and 94.51% across IHDC, WLTP, and NEDC drive cycles respectively. The efficiency of the traction motor, EESM, is 89.61, 89.92, and 88.46% for the same cycles, highlighting the efficacy of sensorless FOC in optimizing power and energy consumption. The research analysis reveals that the energy consumption rates of 280, 190, and 140 W/km for IHDC, WLTP, and NEDC cycles, with corresponding running costs of 1.19, 0.81, and 0.59 INR/km respectively. The analysis also uncovers driving ranges, with IHDC offering a maximum of 197 km, while WLTP and NEDC provide 290 and 400 km respectively. Additionally, the research study evaluates greenhouse gas emissions, with EESM-based EVs demonstrating substantial emission reductions. Specifically, IHDC records emissions of 198.8 g/km, WLTP at 134.9 g/km, and NEDC at 99.4 g/km, compared to 158.7 g/km for petrol cars and 145.25 g/km for diesel cars respectively. This research highlights the potential of EESM-based EVs with sensorless FOC control to enhance efficiency, reduced energy consumption and reduce emissions, making them a promising choice for sustainable transportation. The proposed research work carried out using Matlab/Simulink and results are presented to validate the proposed work.

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Abbreviations

Electrically or externally excited synchronous motor

Greenhouse gas

Field-oriented control

Electric vehicle

Voltage source inverter

Indian highway drive cycle

Worldwide harmonized light vehicles test procedure

New european driving cycle

Permanent magnet synchronous motor

High-frequency signal injection

Electromagnetic interference

Extended kalman filter

Real-world driving cycle

Internal combustion engine vehicle

Machine learning

Space vector pulse width modulation

Indian rupees

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From the above Eqs. ( 15 – 25 ), a program was developed using python to calculate the energy consumption, cost/km and range of the EV as given below.

Python Program to Analyse Energy Consumption.

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Paulraj, T., Obulesu, Y.P. Power and Energy Optimization in EV with Sensorless Externally Excited Synchronous Motor. Iran J Sci Technol Trans Electr Eng (2024). https://doi.org/10.1007/s40998-024-00714-0

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Received : 08 November 2023

Accepted : 25 February 2024

Published : 19 March 2024

DOI : https://doi.org/10.1007/s40998-024-00714-0

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The Vehicle Technologies Office (VTO) is supporting research and development (R&D) to improve  motors in hybrid and plug-in electric vehicles, with a particular focus on reducing the use of rare earth materials currently used for permanent magnet-based motors.

In an electric drive system, an electric motor converts the stored electrical energy in a battery to mechanical energy. Electric motors consist of a rotor (the moving part of the motor) and a stator (the stationary part of the motor). A permanent magnet motor includes a rotor containing a series of magnets and a current-carrying stator (typically taking the form of an iron ring), separated by an air gap. There are three types of electric motors that can be used in hybrid or plug-in electric vehicle traction drive systems.

• Internal permanent magnet (IPM) motors have high power density and maintain high efficiency over a high percentage of their operating range. Almost all hybrid and plug-in electric vehicles use rare earth permanent magnets in their traction motors. Because of the high costs of magnets and rotor fabrication, these motors are relatively expensive. Other challenges to using IPM motors include the limited availability and high cost of rare earth magnetic materials. Despite the challenges, the automotive industry anticipates continuing to use IPM motors in the majority of electric drive vehicles over the next decade.
• Induction motors have high starting torque and offer high reliability. However, their power density and overall efficiency are lower than that of IPM motors. They are widely available and common in various industries today, including some production vehicles. Because this motor technology is mature, it is unlikely research could achieve additional improvements in efficiency, cost, weight, and volume for competitive future electric vehicles.
• Switched reluctance motors offer a lower cost option that can be easy to manufacture. They also have a rugged structure that can tolerate high temperatures and speeds. However, they produce more noise and vibration than comparable motor designs, which is a major challenge for use in vehicles. Also, switched reluctance motors are less efficient than other motor types, and require additional sensors and complex motor controllers that increase the overall cost of the electric drive system.

VTO Electric Motor R&D

VTO's primary goal is to decrease electric motors' cost, volume, and weight while maintaining or increasing performance, efficiency, and reliability. To meet 2022 cost targets, research must reduce the cost of the motor by 50%.

To achieve these goals, VTO and its partners are examining many research avenues:

• The Beyond Rare Earth Magnets (BREM) R&D project led by Ames Laboratory is investigating lower-cost permanent magnets and magnetic materials. This effort is closely coordinated with the Critical Materials Institute also led by Ames Laboratory .
• Oak Ridge National Laboratory and industry projects are pursuing reduced rare-earth magnet motors, non-permanent magnet motor designs, and innovative motor materials and designs.
• The National Renewable Energy Laboratory is focusing research on improving electric motor thermal management, performance and reliability.