UNIT 3

ELECTRIC PROPULSION UNIT

Syllabus
Introduction to electric components used in hybrid and electric vehicles, Configuration and control of DC
Motor drives, Configuration and control of Induction Motor drives, configuration and control of Permanent
Magnet Motor drives, Configuration and control of Switch Reluctance Motor drives, drive system
efficiency. Sizing the propulsion motor, sizing the power electronics.

INTRODUCTION TO ELECTRIC COMPONENTS USED IN HYBRID AND ELECTRIC

VEHICLES

Hybrid and electric vehicles use a variety of electric components to power their propulsion systems,
manage energy storage, and control various vehicle functions. Some of the key electric components used
in these vehicles are:

 Electric motor: The electric motor is the main power source for the vehicle's propulsion system.
It converts electrical energy from the battery into mechanical energy to drive the wheels.

 Battery: The battery is the primary energy storage device in hybrid and electric vehicles. It stores
electrical energy that is used to power the electric motor and other vehicle systems.

 Power electronics: Power electronics are used to control the flow of electricity between the
battery, electric motor, and other vehicle systems. They include components such as inverters,
converters, and controllers.

 Charging system: The charging system is used to recharge the vehicle's battery. It includes
components such as charging ports, cables, and charging controllers.

 Energy management system: The energy management system is responsible for optimizing the
use of energy in the vehicle. It monitors the battery state-of-charge, manages the flow of energy to
the electric motor and other systems, and controls regenerative braking.

 DC/DC converter: The DC/DC converter is used to convert high-voltage DC power from the
battery to the lower-voltage DC power needed to power the vehicle's auxiliary systems, such as
lighting, air conditioning, and audio systems.

 Regenerative braking system: Regenerative braking is a technology that recovers energy from
the vehicle's braking system and converts it into electrical energy that can be stored in the battery.

Overall, these electric components work together to provide efficient and sustainable propulsion for hybrid
and electric vehicles.
CONFIGURATION AND CONTROL OF DC MOTOR DRIVES

DC motor drives are used in a wide range of industrial applications where precise control of motor speed
and torque is required. These drives typically consist of a power electronics converter that converts AC
power from the grid into DC power, which is then used to power the motor. The speed and torque of the
motor can be controlled by varying the voltage and current supplied to the motor.

There are different types of DC motor drives, including:

 Chopper-controlled drives: These drives use a chopper circuit to control the average voltage
applied to the motor. The chopper circuit switches the DC voltage on and off at a high frequency,
creating a series of pulses. By varying the duty cycle of the pulses, the average voltage applied to
the motor can be controlled, which in turn controls the motor speed.

 Pulse-width modulation (PWM) drives: PWM drives also use a chopper circuit, but the
switching frequency is much higher. Instead of varying the duty cycle of the pulses, PWM drives
vary the width of the pulses. This creates a smooth and continuous waveform, which provides
better motor control.

 Four-quadrant drives: Four-quadrant drives are capable of controlling the direction of motor
rotation as well as the speed and torque. These drives use a four-quadrant converter, which can
supply both positive and negative voltage and current to the motor. This allows the motor to be
operated in both forward and reverse directions, and enables regenerative braking.
The control of DC motor drives can be achieved through various techniques, including:

 Open-loop control: Open-loop control is a basic control technique that does not provide feedback
from the motor. In this method, the motor speed and torque are controlled based on the input
voltage and current supplied to the motor.

 Closed-loop control: Closed-loop control is a more advanced control technique that uses feedback
from the motor to adjust the control inputs. In this method, a sensor is used to measure the motor
speed or torque, and this information is fed back to the control system to adjust the voltage and
current supplied to the motor.

 Field-oriented control: Field-oriented control is a sophisticated control technique that provides

precise control of the motor speed and torque. This method uses mathematical models to control
the current and voltage supplied to the motor, based on the motor's magnetic field orientation.

Overall, the configuration and control of DC motor drives are critical to achieving efficient and reliable
operation of industrial systems that rely on these drives. Careful selection of the appropriate drive type and
control technique can help ensure optimal performance and longevity of the system.

CONFIGURATION AND CONTROL OF INDUCTION MOTOR DRIVES

Induction motor drives are widely used in various industrial applications because of their robustness and
reliability. These drives typically consist of a power electronics converter that converts AC power from
the grid into a variable-frequency AC voltage that is applied to the induction motor. The speed and torque
of the motor can be controlled by varying the frequency and magnitude of the applied voltage.

There are different types of induction motor drives, including:

  Variable frequency drives (VFDs): VFDs are the most commonly used induction motor drives.
They use a power electronics converter to vary the frequency and voltage of the AC power supplied
to the motor, allowing for precise control of motor speed and torque.

 Direct torque control (DTC) drives: DTC drives use a sophisticated control algorithm to directly
control the motor's torque and flux. This method provides faster and more accurate control of the
motor compared to VFDs.

The control of induction motor drives can be achieved through various techniques, including:

 Open-loop control: Open-loop control is a basic control technique that does not provide feedback
from the motor. In this method, the motor speed and torque are controlled based on the input
voltage and current supplied to the motor.

 Closed-loop control: Closed-loop control is a more advanced control technique that uses feedback
from the motor to adjust the control inputs. In this method, a sensor is used to measure the motor
speed or torque, and this information is fed back to the control system to adjust the voltage and
frequency supplied to the motor.

 Field-oriented control: Field-oriented control is a sophisticated control technique that provides

precise control of the motor speed and torque. This method uses mathematical models to control
the current and voltage supplied to the motor, based on the motor's magnetic field orientation.

Overall, the configuration and control of induction motor drives are critical to achieving efficient and
reliable operation of industrial systems that rely on these drives. Careful selection of the appropriate drive
type and control technique can help ensure optimal performance and longevity of the system.

CONFIGURATION AND CONTROL OF PERMANENT MAGNET MOTOR DRIVES

Permanent magnet (PM) motor drives are becoming increasingly popular in industrial applications due to
their high efficiency, power density, and reliability. These drives use a permanent magnet rotor instead of
an induction rotor, which eliminates the need for a separate rotor excitation circuit and reduces the losses
associated with rotor current.

The configuration of PM motor drives typically includes a power electronics converter that converts AC
power from the grid into a variable-frequency AC voltage that is applied to the PM motor. The speed and
torque of the motor can be controlled by varying the frequency and magnitude of the applied voltage.

The control of PM motor drives can be achieved through various techniques, including:

 Scalar control: Scalar control is a basic control technique that does not provide precise control of
the motor's magnetic field. In this method, the motor speed and torque are controlled based on the
input voltage and current supplied to the motor.

 Field-oriented control (FOC): FOC is a sophisticated control technique that provides precise
control of the motor's magnetic field. This method uses mathematical models to control the current
and voltage supplied to the motor, based on the motor's magnetic field orientation. The FOC
method can achieve very high levels of efficiency and accuracy.

 Direct torque control (DTC): DTC is another advanced control technique that provides very fast
and accurate control of the motor's torque and speed. This method uses a sophisticated control
algorithm that directly controls the motor's torque and flux.
Overall, the configuration and control of PM motor drives are critical to achieving efficient and reliable
operation of industrial systems that rely on these drives. Careful selection of the appropriate drive type and
control technique can help ensure optimal performance and longevity of the system.

CONFIGURATION AND CONTROL OF SWITCH RELUCTANCE MOTOR DRIVES

Switched reluctance (SR) motors are a type of electric motor that uses the magnetic reluctance of the rotor
to produce torque. SR motors are simpler and less expensive than other types of motors, and they can
operate at high speeds with good efficiency. However, the control of SR motors can be more challenging
due to their nonlinear behaviour and the complexity of the control algorithms.

The configuration of SR motor drives typically includes a power electronics converter that converts AC
power from the grid into a variable-frequency AC voltage that is applied to the SR motor. The speed and
torque of the motor can be controlled by varying the frequency and magnitude of the applied voltage.

The control of SR motor drives can be achieved through various techniques, including:

 Current control: Current control is a basic control technique that regulates the current supplied to
the motor. This method can provide reasonable control of the motor speed and torque, but it may
not be sufficient for high-performance applications.

 Sensor less control: Sensor less control is a more advanced control technique that uses
mathematical models to estimate the motor's position and speed, based on the voltage and current
signals. This method eliminates the need for position sensors, which can reduce the cost and
complexity of the motor drive system.

 Model predictive control (MPC): MPC is a sophisticated control technique that uses a
mathematical model of the motor and the load to predict the future behavior of the system. This
method can provide very precise control of the motor speed and torque, but it requires significant
computational resources.

Overall, the configuration and control of SR motor drives are critical to achieving efficient and reliable
operation of industrial systems that rely on these drives. Careful selection of the appropriate drive type and
control technique can help ensure optimal performance and longevity of the system.

DRIVE SYSTEM EFFICIENCY

Electric drive system efficiency refers to the ratio of the output mechanical power of the electric motor to
the input electrical power from the power source. The efficiency of an electric drive system is an important
factor in determining its performance and energy consumption.

The efficiency of an electric drive system depends on various factors, including:

 Motor efficiency: The efficiency of the electric motor itself is a key factor in determining the
overall efficiency of the drive system. The motor efficiency depends on factors such as the design
of the motor, the materials used in the motor, and the operating conditions.

 Power electronics efficiency: The power electronics converter used to control the motor can also
affect the overall efficiency of the drive system. The efficiency of the converter depends on factors
such as the design of the converter, the switching frequency, and the load characteristics.
  System losses: The electric drive system can also experience losses due to factors such as friction,
windage, and thermal losses. These losses can reduce the overall efficiency of the system.

Improving the efficiency of an electric drive system can be achieved through various techniques, including:

 Motor design optimization: Designing the motor to minimize losses, such as copper and iron
losses, can improve its overall efficiency.

 Power electronics optimization: The efficiency of the power electronics converter can be
improved by using high-performance components and optimizing the control algorithm.

 System optimization: Optimizing the system design and operating conditions can help minimize
losses and improve overall efficiency.

 Energy recovery: Regenerative braking systems can capture some of the kinetic energy of the
system and convert it back into electrical energy, improving overall system efficiency.

Overall, improving the efficiency of an electric drive system is essential for reducing energy consumption,
increasing system performance, and reducing operating costs.

SIZING THE PROPULSION MOTOR

Sizing the propulsion motor for an electric vehicle (EV) or hybrid electric vehicle (HEV) is a crucial step
in designing the powertrain system. The propulsion motor size is primarily determined by the vehicle's
weight, desired acceleration performance, and operating conditions. The following steps can be followed
to size the propulsion motor:

 Determine the vehicle weight: The weight of the vehicle, including the passengers, cargo, and
other components, should be determined. This information can be used to calculate the required
torque and power of the motor.

 Determine the required torque: The required torque is a function of the vehicle weight, desired
acceleration performance, and the vehicle's rolling resistance and aerodynamic drag. The torque
can be calculated using the following formula:

Torque = (Rolling Resistance + Aerodynamic Drag) × Vehicle Speed + (Vehicle Weight × Acceleration)

 Determine the required power: The required power is the product of the torque and the motor
speed. The maximum motor speed is typically limited by the battery voltage and the motor's
mechanical design.

 Select the motor: Based on the torque and power requirements, a suitable motor can be selected.
The motor should be able to provide the required torque and power while operating within its safe
operating limits.

 Verify the motor selection: The selected motor should be tested under the desired operating
conditions to ensure that it can meet the performance requirements.

It's worth noting that the sizing process is not a one-time activity, and it may need to be revisited as the
design of the vehicle evolves. Additionally, the selection of the motor should also consider other factors
such as the motor's efficiency, weight, cost, and reliability.
SIZING THE POWER ELECTRONICS

Sizing the power electronics for an electric vehicle (EV) or hybrid electric vehicle (HEV) involves
selecting the appropriate motor controller, DC-DC converter, and other power electronic components
based on the motor's power and voltage requirements. The following steps can be followed to size the
power electronics:

 Determine the motor voltage and current requirements: The voltage and current requirements
of the motor should be determined to select a suitable power electronics configuration. The voltage
and current ratings of the motor can be obtained from the motor manufacturer or calculated from
the motor's power rating and speed.

 Determine the switching frequency: The switching frequency of the power electronics affects
the efficiency and size of the components. Higher switching frequencies result in smaller and
lighter components, but they may also reduce efficiency and increase losses. The switching
frequency should be selected based on the motor's speed and the desired efficiency.

 Select the motor controller: The motor controller is responsible for regulating the voltage and
current supplied to the motor. A suitable motor controller should be selected based on the motor's
voltage and current requirements, the desired switching frequency, and the control algorithm used.

 Select the DC-DC converter: The DC-DC converter is responsible for converting the high-voltage
battery power to the low-voltage power required by the auxiliary systems, such as the lights, air
conditioning, and other electronics. A suitable DC-DC converter should be selected based on the
voltage and power requirements of the auxiliary systems.

 Verify the power electronics selection: The selected power electronics configuration should be
tested under the desired operating conditions to ensure that it can meet the performance
requirements and operate reliably.

It's worth noting that the sizing process is not a one-time activity, and it may need to be revisited as the
design of the vehicle evolves. Additionally, the selection of the power electronics should also consider
other factors such as the power electronics' efficiency, weight, cost, and reliability.