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Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
ELECTRIC VEHICLES: TECHNOLOGY,
RESEARCH AND DEVELOPMENT
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Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
ELECTRIC VEHICLES: TECHNOLOGY,
RESEARCH AND DEVELOPMENT
GERALD B. RAINES
EDITOR
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
Copyright © 2009 by Nova Science Publishers, Inc.
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Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
CONTENTS
Preface vii
Chapter 1 Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 1
K. T. Chau
Chapter 2 Environmental Friendly Inter-City Aircraft (ENFICA-FC)
and Preliminary Analysis for 2-seat Aircraft Conversion
into Fuel Cells Powered Innovative System 41
G. Romeo, G. Frulla, E. Cestino and F. Borello
Chapter 3 Clarifying the Debate on Electric Two-Wheelers in China 67
Christopher Cherry
Chapter 4 Examination of State Estimators for Electrochemical Energy
Storage Devices by Means of a Hardware-in-the-Loop System 87
Mark Verbrugge, Damon Frisch, Trudy Weber,
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
vi Contents
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
PREFACE
With ever increasing concern on environmental protection and energy conservation, there
is a fast growing interest in electric vehicles (EVs) from automakers, governments and
customers. As electric propulsion is the core of EVs, there is a pressing need for researchers
to develop advanced electric motor drives for various classes of EVs, including the battery,
hybrid and fuel cell vehicles. Such issues are addressed in this book.
The development and use of a fuel cell based power system for propulsion of electric
aircrafts is discussed. A study done on the flight mechanics of the new aircraft, to verify the
new flight performance, is also examined.
Electric powered two-wheelers have risen in popularity in China over the past several
years. This book investigates the growth of these electric two-wheelers in China and
compares their environmental and safety impacts to those of alternative modes of
transportation.
Futhermore, the design and implementation of a hardware-in-the-loop system for the
development, verification, and validation of algorithms used to construct state estimators for
batteries and supercapacitors is addressed.
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
There are several different kinds of devices that can be used to achieve electrochemical
energy conversion. Some of these conversion technologies are reviewed, as well as their
impact on the environment.
The method used to control a power-train of a hybrid electric vehicle is discussed as well
as how both the engine and the electric machine may achieve respective higher efficiencies
after using this method.
The regulated and unregulated emissions of diesel engines operating on different sulfur
content fuels are also looked at.
Energy efficiency issues include research and development priorities, funding for
climate-related efficiency programs, implementation of equipment efficiency standards,
regulation of vehicle fuel efficiency, and electricity industry ratemaking for energy efficiency
profitability. Such issues are addressed in this book.
Chapter 1 - With ever increasing concern on environmental protection and energy
conservation, there is a fast growing interest in electric vehicles (EVs) from automakers,
governments and customers. As electric propulsion is the core of EVs, it is a pressing need for
researchers to develop advanced electric motor drives for various classes of EVs, including
the battery, hybrid and fuel cell vehicles. This chapter firstly reviews various electric motor
drives, including DC, induction, switched reluctance and permanent magnet (PM) brushless
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
viii Gerald B. Raines
types, for application to EVs. As the development of PM brushless motor drives is being
actively engaged, their motor configurations and operating principles are delineated.
Secondly, two emerging PM brushless motor drives, namely the double-stator PM brushless
motor drive and the hybrid-PM brushless motor drive, are discussed. Their motor
configurations, design equations, analysis approaches, converter topologies and control
strategies are described when necessary. Then, their operating characteristics are evaluated.
Finally, the concept of integrated PM motor drive systems is revealed. It takes the definite
advantages of high efficiency, good controllability, compact size and lightweight, which are
particularly essential for future vehicles. Hence, three latest integrated PM brushless motor
drive systems, namely the magnetic-geared PM brushless motor drive system, the memory-
PM brushless integrated-starter-generator system and the PM brushless electric variable
transmission system, are discussed. Future research directions of these integrated systems are
particularly identified.
Chapter 2 - The main objective of the ENFICA-FC project (ENvironmentally Friendly
Inter City Aircraft powered by Fuel Cells), funded by European Commission, is to develop
and validate the use of a fuel cell based power system for propulsion of more/all electric
aircraft. The following items shall be pursued: a) A fuel cell system shall be designed, built
and tested in laboratory ready to be installed on board for flying; b) A high efficiency
brushless electric motors and power electronics apparatus for their control shall be designed
and manufactured ready to be installed on board for flying; c) high efficiency would be
obtained by an optimised aerodynamic propeller design; d) A study of the flight mechanics of
the new aircraft will be carried to verify the new flight performance; e) Validation of the
overall high performance of an all electric aircraft by means of flight test. The fuel cell
system will be installed in a light sport aircraft which will be flight and performance tested as
a proof of functionality and future applicability for inter city aircraft. A selection of most
suitable aircraft for conversion is presented and the light sport aircraft Rapid 200 chosen. The
high efficiency two-seat existing aircraft Rapid 200, manufactured by Jihlavan Aircraft, has
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
been selected over more than 100 light sport aircrafts after the preliminary reported
evaluation based on merit index as indicated. The aircraft will be used for the conversion
from internal combustion engine to an electric one. Analysis about the COTS equipments for
electric propulsion system has been performed and presented. Design indication of an optimal
propeller complete the identification phase that continue with the analysis of some parameters
influencing the general configuration of the converted aircraft and the mission items.
Preliminary consideration about the definition of storage configuration are presented and
some safety issues are considered for H2-gas management. Design indications and conversion
limitations conclude the reported activity.
Chapter 3 - Electric two-wheelers have entered the ever-expanding transportation market
in China, fully penetrating the market in most cities and rural areas. Over the past five years,
more than 50 million electric two-wheelers have been sold in China. Electric two-wheelers
have surpassed bicycle ridership in many cities, moving this mode beyond filling small niches
that electric vehicles have historically filled in developed nations. Electric two-wheelers are
used for many types of transportation, from commuting to goods delivery to law enforcement.
This chapter outlines the recent historic growth of electric two-wheelers and scooters in
China, discussing several of the controversial issues surrounding them, including safety,
congestion, environmental performance, and competition with public transit. Electric two-
wheelers provide high levels of personal mobility, matching that of the automobile. They do
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
Preface ix
so with much fewer of the environmental, congestion, and safety externalities associated with
personal cars. Currently, though, most electric two-wheeler users would otherwise ride a
traditional bicycle or bus, obscuring the relative impact of electric two-wheelers on China’s
urban transportation systems. When balancing electric two-wheelers’ effect on mobility and
access, environment, safety, and congestion in the entire transportation system, they
debatably provide net benefits. This chapter clarifies those debates and frames the challenges
in ways that can be quantified.
Chapter 4 - We have designed and implemented a hardware-in-the-loop system for the
development, verification, and validation of algorithms used to construct state estimators for
batteries and supercapacitors. The intent of the work is to allow algorithm developers to test
their algorithms rapidly and in the context of the actual application. Promising results are
shown for a carbon based electric double layer capacitor (a supercapacitor); the modeled
vehicle configuration corresponds to the General Motors Saturn Vue Green Line 36V HEV,
with the NiMH battery replaced by a supercapacitor pack. While the work is pragmatic in
terms of addressing vehicle applications, the theoretical underpinnings and mathematical
methods are relatively new, evolving, and comprise substantial complexity.
Chapter 5 - The treatise presents an extensive simulation and analytical analysis of the
energy conversion phenomena in parallel and series hybrid-electric powertrains. Parameters
of both hybrid powertrains are evaluated and compared to parameters of the conventional-
internal combustion engine powertrain. Simulation approach is based on an accurate and fast
forward-facing simulation model that is capable of capturing dynamics of the powertrain
components. Moreover, the treatise offers an analytical approach based on the energy balance
equations in order to analyze and predict energy conversion efficiency in both hybrid
powertrains. The analysis covers broad range of parallel and series hybrid powertrain
configurations. Very good agreement between simulation and analytical results gives
confidence in the accuracy of the performed analysis and confirms the validity of the
analytical framework. Combined simulation and analytical analysis enables deep insight into
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
x Gerald B. Raines
AEI and cut earmarks. The Senate Appropriations Committee has also approved AEI funding
and would cut earmarks even further than the House.
Energy efficiency programs have long been justified for the ability to reduce petroleum
use and curb environmental impacts such as air pollution. This made it economically and
administratively convenient to have them also serve as part of a low cost “no regrets” policy
to reduce greenhouse gas (especially CO2) emissions.
In addition to DOE funding, H.R. 5386 would provide about $100 million for the
Environmental Protection Agency’s energy efficiency program, and the Senate
Appropriations Committee’s version of H.R. 5522 would provide about $200 million for
energy efficiency-related programs in developing countries.
DOE’s implementation of equipment efficiency standards has been a subject of some
congressional criticism. The Energy Policy Act of 2005 (EPACT, P.L. 109-58) directed DOE
to report to Congress on actions taken to address the concern. In response, DOE issued a
schedule for rulemakings on 30 products. EPACT also raised the goals for energy efficiency
in federal agencies and provided modest tax incentives for efficiency in certain vehicles and
buildings.
Automobile fuel efficiency regulation has been one of the most controversial aspects of
energy efficiency policy. The Corporate Average Fuel Economy (CAFE) program for new
cars and light trucks achieved significant energy savings through 1985 but has remained
relatively flat since then. Critics say that recent CAFE increases for light trucks are too small,
given concerns about high gasoline prices, air emissions. Proponents counter that larger
CAFE increases would pollution, and CO2 compromise safety and cause hardship for
manufacturers.
The National Action Plan for Energy Efficiency aims to defer the need for 20,000
megawatts of new electric power plant capacity. Its success will depend mainly on the ability
of state regulators to make energy efficiency profitable for electricity companies, by
addressing the link between profits and sales.
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Chapter 7 - FreedomCAR and the Hydrogen Fuel Initiative are two complementary
government-industry research and development (R&D) policy initiatives that promote the
development of hydrogen fuel and fuel cell vehicles. Coordinated by the Department of Energy
(DOE), these initiatives aim to make mass-market fuel cell and hydrogen combustion
vehicles available at an affordable cost within 10 to 15 years from the launch of the
initiatives. However, questions have been raised about the design and goals of the initiatives.
This report discusses the organization, funding, and goals of the FreedomCAR and Fuel
partnerships, and issues for Congress.
Chapter 8 - Pursuant to section 801(a)(2)(A) of title 5, United States Code, this is our
report on a major rule promulgated by the Department of Transportation, National Highway
Traffic Safety Administration, entitled “Federal Motor Vehicle Safety Standards; Occupant
Protection in Interior Impact; Side Impact Protection; Fuel System Integrity; Electric-
Powered Vehicles: Electrolyte Spillage and Electrical Shock Protection; Side Impact Phase-In
Reporting Requirements” (RIN: 2127-AJ10). We received the rule on September 14, 2007. It
was published in the Federal Register as a final rule on September 11, 2007. 72 Fed. Reg.
51,908.
The final rule upgrades the Federal Motor Vehicle Safety Standard (FMVSS) No. 214, “Side
impact protection.” The final rule does so by incorporating a dynamic pole test into FMVSS
No. 214 requiring manufacturers to improve head and thorax protection to occupants of
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
Preface xi
vehicles that crash into poles and trees, or that are laterally struck by a higher-riding vehicle,
and to reduce fatalities and injuries caused by partial ejections through side windows.
Additionally, the final rule enhances the moving deformable barrier test by adding a second
dummy to better represent the at-risk population in vehicle-to-vehicle side crashes.
Enclosed is our assessment of the NHTSA’s compliance with the procedural steps required by
section 801(a)(1)(B)(i) through (iv) of title 5 with respect to the rule. Our review indicates that
NHTSA complied with the applicable requirements.
Chapter 9 - In this study, electric-drive vehicles with series powertrains were
configured to utilize a lithium- ion battery of very high power and achieve sport-sedan
performance and excellent fuel economy. The battery electrode materials are LiMn2O4 and
Li4Ti5O12, which provide a cell area-specific impedance of about 40% of that of the commonly
available lithium-ion batteries. Data provided by EnerDel Corp. for this system
demonstrate this low impedance and also a long cycle life at 55oC. The batteries for these
vehicles were designed to deliver 100 kW of power at 90% open- circuit voltage to provide
high battery efficiency (97-98%) during vehicle operation. This results in battery heating
of only 1.6oC per hour of travel on the urban dynamometer driving schedule (UDDS) cycle,
which essentially eliminates the need for battery cooling. Three vehicles were designed, each
with series powertrains and simulation test weights between 1575 and 1633 kg: a hybrid electric
vehicle (HEV) with a 45-kg battery, a plug-in HEV with a 10-mile electric range (PHEV10) with
a 60-kg battery, and a PHEV20 with a 100-kg battery. Vehicle simulation tests on the
Argonne National Laboratory’s simulation software, the Powertrain System Analysis
Toolkit (PSAT), which was developed with MATLAB/Simulink, showed that these
vehicles could accelerate to 60 mph in 6.2 to 6.3 seconds and achieve fuel economies of
50 to 54 mpg on the UDDS and highway fuel economy test (HWFET) cycles. This type of
vehicle shows promise of having a moderate cost if it is mass produced, because there is no
transmission, the engine and generator may be less expensive since they are designed to
operate at only one speed, and the battery electrode materials are inexpensive.
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Chapter 10 - The Energy Independence and Security Act (P.L. 110-140, H.R. 6) is an
omnibus energy policy law that consists mainly of provisions designed to increase energy
efficiency and the availability of renewable energy. This report describes the key
provisions of the enacted law, summarizes the legislative action on H.R. 6, and provides a
summary of the provisions under each of the titles in the law. The highlights of key provisions
enacted into law are as follows:
Corporate Average Fuel Economy (CAFE). The law sets a target of35 miles per gallon for
the combined fleet of cars and light trucks by model year 2020.
Renewable Fuels Standard (RFS). The law sets a modified standard that starts at 9.0
billion gallons in 2008 and rises to 36 billion gallons by 2022.
Energy Efficiency Equipment Standards. The adopted bill includes a variety of new
standards for lighting and for residential and commercial appliance equipment. The
equipment includes residential refrigerators, freezers, refrigerator-freezers, metal halide
lamps, and commercial walk-in coolers and freezers.
Repeal of Oil and Gas Tax Incentives. The enacted law includes repeal of two tax
subsidies in order to offset the estimated cost to implement the CAFE provision.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
xii Gerald B. Raines
The two most controversial provisions of H.R. 6 that were not included in the enacted law
were the proposed Renewable Energy Portfolio Standard (RPS) and most of the proposed tax
provisions, which included repeal of tax subsidies for oil and gas and new incentives for energy
efficiency and renewable energy.
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
In: Electric Vehicles: Technology, Research and Development ISBN 978-1-60741-142-0
Editor: Gerald B. Raines © 2009 Nova Science Publishers, Inc.
Chapter 1
K. T. Chau*
International Research Center for Electric Vehicles, Department of Electrical
and Electronic Engineering, The University of Hong Kong, Hong Kong, China
ABSTRACT
With ever increasing concern on environmental protection and energy conservation,
there is a fast growing interest in electric vehicles (EVs) from automakers, governments
and customers. As electric propulsion is the core of EVs, it is a pressing need for
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
researchers to develop advanced electric motor drives for various classes of EVs,
including the battery, hybrid and fuel cell vehicles. This chapter firstly reviews various
electric motor drives, including DC, induction, switched reluctance and permanent
magnet (PM) brushless types, for application to EVs. As the development of PM
brushless motor drives is being actively engaged, their motor configurations and
operating principles are delineated. Secondly, two emerging PM brushless motor drives,
namely the double-stator PM brushless motor drive and the hybrid-PM brushless motor
drive, are discussed. Their motor configurations, design equations, analysis approaches,
converter topologies and control strategies are described when necessary. Then, their
operating characteristics are evaluated. Finally, the concept of integrated PM motor drive
systems is revealed. It takes the definite advantages of high efficiency, good
controllability, compact size and lightweight, which are particularly essential for future
vehicles. Hence, three latest integrated PM brushless motor drive systems, namely the
magnetic-geared PM brushless motor drive system, the memory-PM brushless integrated-
starter-generator system and the PM brushless electric variable transmission system, are
discussed. Future research directions of these integrated systems are particularly
identified.
*
Professor. Department of Electrical and Electronic Engineering, The University of Hong Kong, Pokfulam Road,
Hong Kong. Phone: 852-2859-2704; Fax: 852-2559-8738; Email: [email protected]
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
2 K. T. Chau
1. INTRODUCTION
Vehicles equipped with an internal combustion engine have been in existence since 1885.
Although engine vehicles are continually improved by modern automotive electronics, they
need a major change to improve the fuel economy and to reduce the exhaust emission.
Electric vehicles (EVs), including battery, hybrid and fuel cell vehicles, have been
identified to be the most viable solution to fundamentally solve the problems associated
with engine vehicles (Chan and Chau, 2001; Ehsani et al., 2005).
Electric motor drives are the core technology for EVs. The basic requirements of an
electric motor drive for EVs are summarized below (Chau and Chan, 2007; Ehsani et al.,
1997; Zhu and Howe, 2007):
The purpose of this chapter is to give an overview of electric motor drives for EVs.
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Firstly, a review of traditional electric motor drives, namely the DC, induction, switched
reluctance (SR) and permanent magnet (PM) brushless ones, will be conducted. Secondly,
two emerging PM brushless motor drives, namely the double-stator PM brushless motor drive
and the hybrid-PM brushless motor drive, will be presented. Thirdly, the latest integrated PM
motor drive systems, namely the magnetic-geared PM brushless motor drive system, the
memory-PM brushless integrated-starter-generator system and the PM brushless electric
variable transmission system, will be discussed. Finally, a conclusion will be drawn.
2. REVIEW
Among different types of electric motor drives, there are four types that are viable for
EVs, namely the DC, induction, SR, and PM brushless motor drives. They possess
fundamentally different motor topologies as illustrated in Figure 1. Basically, they are
classified into two main groups, namely the brushed and brushless groups, and each group
can be further classified into different subgroups as illustrated in Figure 2. It should be noted
that the branches that are not viable for EVs have been pruned. Table 1 also lists the previous
or latest applications of those viable motor drives to flagship EVs.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 3
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
4 K. T. Chau
DC motor drives used to be widely accepted for EVs. Based on the location of field
excitation, they can be grouped as the self-excited DC and separately excited DC types. Based
on the source of field excitation, they can also be grouped as the wound-field DC and PM DC
types. As determined by the mutual interconnection between the field winding and the
armature winding or the use of PM excitation, the whole family consists of the separately
excited DC, series DC, shunt DC and PM DC types. Because of their technological maturity
and control simplicity, various DC motor drives have ever been applied to different EVs as
listed in Table 1.
For the separately excited DC motor drive, the field and armature voltages can be
controlled independent of each other. The torque-speed characteristic is linearly related that
speed decreases as torque increases and speed regulation depends on the armature circuit
resistance. For the series DC motor drive, the field current is the same as the armature current.
An increase in torque is accompanied by an increase in the armature current and hence an
increase in flux. The speed must drop to maintain the balance between the supply and induced
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
voltages. The torque-speed characteristic has an inverse relationship. For the shunt dc motor
drive, the field and armature are connected to a common voltage source. The corresponding
characteristic is similar to that of the separately excited DC motor drive. For the PM DC
motor drive, it has relatively higher power density and higher efficiency because of the space-
saving benefit by PMs and the absence of field losses. Owing to the low permeability of PMs,
similar to that of air, armature reaction is usually reduced and commutation is improved.
However, since the field excitation in the PM DC motor drive is uncontrollable, it cannot
readily attain the operating characteristics similar to that of other wound-field DC motor
drives.
In general, speed control of DC motor drives can be accomplished by two methods,
namely armature control and field control. When the armature voltage is reduced, the
armature current and hence the motor torque decrease, causing the motor speed to decrease.
In contrast, when the armature voltage is increased, the motor torque increases, causing the
motor speed to increase. Since the maximum allowable armature current remains constant and
the field is fixed, this armature voltage control has the advantage of retaining the maximum
torque capability at all speeds. However, since the armature voltage cannot be further
increased beyond the rated value, this control is used only when the DC motor drive operates
below its base speed. On the other hand, when the field voltage of the DC motor is weakened
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 5
while the armature voltage is fixed, the motor induced EMF decreases. Because of low
armature resistance, the armature current will increase by an amount much larger than the
decrease in the field. Thus, the motor torque is increased, causing the motor speed to increase.
Since the maximum allowable armature current is constant, the induced EMF remains
constant for all speeds when the armature voltage is fixed. Hence, the maximum allowable
motor power becomes constant so that the maximum allowable torque varies inversely with
the motor speed. Therefore, in order to achieve wide-range speed control of DC motor drives
for EVs, armature control has to be combined with field control. By maintaining the field
constant at the rated value, armature control is employed for speeds from standstill to the base
speed. Then, by keeping the armature voltage at the rated value, field control is used for
speeds beyond the base speed.
All DC motor drives suffer from the same problem due to the use of commutators and
brushes. Commutators cause torque ripples and limit the motor speed, while brushes are
responsible for friction and radio-frequency interference. Moreover, due to the wear and tear,
periodic maintenance of commutators and brushes is always required. These drawbacks make
them less reliable and unsuitable for maintenance-free operation, and limit them to be widely
applied for modern EV propulsion.
At present, induction motor drives are the most mature technology among various
brushless motor drives. There are two types of induction motors, namely the wound-rotor and
squirrel-cage. Because of high cost, need of maintenance and lack of sturdiness, wound-rotor
induction motors are less attractive than squirrel-cage counterparts for electric propulsion in
EVs. Hence, squirrel-cage induction motors are loosely named as induction motors. Apart
from those advantages of brushless motor drives, induction motor drives possess the definite
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
induction motors is transformed from the stationary reference frame (d-q frame) to the
general synchronously rotating frame (x-y frame). When the x-axis is purposely selected to be
coincident with the rotor flux linkage vector, the reference frame (α-β frame) becomes
rotating synchronously with the rotor flux. Hence, the motor torque T can be obtained as:
3 M2
T= p i s α is β
2 Lr
where p is the number of pole pairs, M is the mutual inductance per phase, Lr is the rotor
inductance per phase, and isα and isβ are the α-axis component and β-axis component of
stator current, respectively. This torque equation is very similar to that of separately excited
DC motor drives. Therefore, by means of this FOC, the motor torque can be effectively
controlled by adjusting the torque component isβ as long as the field component isα remains
constant. Hence, induction motor drives can offer the desired fast transient response similar to
that of separately excited DC motor drives.
It is well known that a change of the number of pole pairs of induction motor drives can
adjust the rotating-field synchronous speed. The squirrel-cage type takes a definite advantage
over the wound-rotor type that it is able to automatically adapt the pole number of the rotor to
that of the stator. In early time, this pole-changing control was implemented by using
mechanical contactors, and only two or three discrete speeds were achieved. With the
advancement of power electronics and control technologies, the pole-changing control can be
implemented electronically. Hence, the high-speed constant-power capability can be
remarkably extended, which is particularly desirable for EV cruising.
Recently, new design approaches have been developed to improve the power density of
EV induction motor drives by up to 30% (Wang, et al., 2005). Interdisciplinary design
considerations on mechanical vibration and acoustic noise of induction motor drives have also
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been analyzed for EVs (Lo et al., 2000). Also, electronically pole-changing schemes have
been developed for EV induction motor drives, which can significantly extend the constant-
power operating region to over four times the base speed (Jiang et al., 2003).
SR motor drives have been recognized to have considerable potential for EVs. They have
the definite advantages of simple construction, low manufacturing cost and outstanding
torque-speed characteristics. The operating principle of SR motor drives is based on the
‘minimum reluctance’ rule. According to the co-energy principle, the reluctance torque
produced by one phase at any rotor position is given by:
1 dL
T (θ , i ) = i 2
2 dθ
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 7
where θ is the rotor position angle, i is the phase current and L is the phase inductance. They
have two significant features. One is that the direction of torque is independent of the polarity
of the phase current. Another is that the motoring torque can be produced only in the direction
of rising inductance ( dL / dθ > 0 ); otherwise, a negative torque (or braking torque) is
produced. So, each phase can produce a positive torque only in half a rotor pole-pitch, hence
creating the torque ripple. Also, because of the heavy saturation of pole tips and the fringing
effect of poles and slots, they usually exhibit acoustic noise problems.
The SR motor drives have basically two operating modes. When the speed is below the
base speed, the current can be limited by chopping, so-called current chopping control (CCC).
In the CCC mode, the torque and thus the constant-torque characteristic can be controlled by
changing the current limits. During high speed operation, however, the peak current is limited
by the EMF of the phase winding. The corresponding characteristic is essentially controlled
by phasing of switching instants relative to the rotor position, so-called angular position
control (APC). In the APC mode, the constant-power characteristic can be achieved.
In short, SR motor drives have two fundamental problems hindering their application to
EVs – acoustic noise and control nonlinearity. Over the years, fuzzy sliding mode control has
been developed for SR motor drives in EVs (Zhan et al., 1999). This control approach
incorporates both fuzzy logic and sliding mode control in such a way that the former
functions to handle the motor nonlinearities while the latter is used to reduce the control
chattering. Also, the corresponding constant-power region has been extended to 3−7 times the
base speed through phase advancing excitation (Rahman et al., 2000; Inderka et al., 2002).
On the other hand, an active vibration cancellation technique for SR motor drives has been
proposed, which induces an anti-phase vibration to cancel a specified vibration mode and
hence reduces the acoustic noise (Long et al., 2005).
PM brushless motor drives are becoming more and more attractive for EVs, since they
inherently offer high efficiency, high power density and high reliability. The key problems
are their relatively high PM material cost and uncontrollable PM flux. In recent years,
research and development of EV motor drives has been focused on PM brushless motor
drives, aiming to fully utilize their PM material and to control the resultant air-gap flux.
Various viable motor topologies have been proposed. Based on the location of PMs, they can
be classified as the rotor-PM and stator-PM classes. According to the operating current and
no-load EMF waveforms, they can also be classified as the PM brushless AC (BLAC) and
PM brushless DC (BLDC) types (Chan et al., 1996).
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8 K. T. Chau
The generated torque of these rotor-PM brushless motors consists of two components,
namely the PM torque and reluctance torque, which are given by:
T=
3
2
[
p ψ m I q − (Lq − Ld )I d I q ]
where p is the number of pole-pairs, ψ m is the stator winding flux linkage due to the PMs,
Ld , Lq are respectively the d-axis and q-axis stator winding inductances, and I d , I q are
respectively the d-axis and q-axis currents.
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For the surface-mounted PM brushless motor topology, the PMs are simply mounted on
the rotor surface by using epoxy adhesives. Since the permeability of PMs is near to that of
air, the effective air-gap is the sum of the actual air-gap length and the radial thickness of the
PMs. Hence, the corresponding armature reaction field is small and the stator winding
inductance is low. Also, since the d-axis and q-axis stator winding inductances are nearly the
same, its reluctance torque is almost zero.
For the surface-inset PM brushless motor topology, the PMs are inset or buried in the
rotor surface. Thus, the q-axis inductance becomes higher than the d-axis inductance, hence
producing the additional reluctance torque. Also, since the PMs are inside the rotor, it can
withstand the centrifugal force at high-speed operation, hence offering good mechanical
integrity.
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Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 9
For the interior-radial PM brushless motor topology, the PMs are radially magnetized and
buried inside the rotor. Similar to the surface-inset one, the PMs are mechanically protected,
hence allowing for high-speed operation. Also, because of its d-q saliency, an additional
reluctance torque is generated. Different from the surface-inset one, this interior-radial
topology adopts linear PMs which are easier for insertion and can be easily machinable.
For the interior-circumferential PM brushless motor topology, the PMs are
circumferentially magnetized and buried inside the rotor. It takes the definite advantage that
the air-gap flux density can be higher than the PM remanent flux density, so-called the flux
focusing. Also, it holds the merits of good mechanical integrity and additional reluctance
torque. However, because of significant flux leakage at the inner ends of PMs, a nonmagnetic
shaft or collar is generally required.
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10 K. T. Chau
al., 1997; Zhu and Howe, 2007). Each stator tooth has a pair of PMs of different polarities
mounted onto the surface. Hence, the flux linkage variation is bipolar so that the torque
density is higher than that of the conventional DSPM motor. However, since the PMs are on
the surface of stator teeth, they are more prone to partial demagnetization. Also, significant
eddy current loss in the PMs may be resulted.
The tooth-interior-magnet motor topology is commonly termed as the flux-switching PM
motor (Zhu et al., 2005; Zhu and Howe, 2007). In this topology, each stator tooth consists of
two adjacent laminated segments and a PM, and each of these segments is sandwiched by two
circumferentially magnetized PMs. Hence, it enables flux focusing. Compared with the rotor-
PM topologies, this flux-switching motor has less armature reaction, hence offering higher
electric loading. Since its back EMF waveform is essentially sinusoidal, this machine is more
suitable for the BLAC operation.
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Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 11
flux so that they need high-resolution position signal for closed-loop control, hence desiring a
costly position encoder or resolver. In contrast, for the PM BLDC motor drives, they operate
with rectangular current and trapezoidal air-gap flux so that they just need a low-cost sensor
for phase-current commutation. Nevertheless, the PM BLAC motor drives allow for open-
loop operation, whereas the position feedback is mandatory for the PM BLDC motor drives.
Ld I r
=1
ψm
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
where ψ m is the PM flux linkage, Ld is the d-axis winding inductance and I r is the rated
current. In general, the ratio of Ld I r /ψ m is less than unity. So, the higher the ratio, the higher
will be the flux-weakening capability. The flux-weakening control has been comprehensively
studied in various PM BLAC motor drives (Zhu et al., 2000; Uddin and Rahman, 2007). For
the PM BLDC motor drives, constant-power operation is more complex. Since the operating
waveforms are no longer sinusoidal, d-q transformation and hence flux-weakening control are
ill-suited. Nevertheless, the corresponding constant-power operation can be offered by using
advanced conduction angle control (Chan et al., 1995; Kim et al., 1997).
Figure 6 shows the torque-speed characteristics of the PM brushless motor drives without
control and with control (either flux-weakening control for the BLAC or advanced conduction
angle control for the BLDC). It illustrates that the speed range of constant-power operation
can be significantly extended. On the other hand, Figure 6 gives a comparison of the torque-
speed characteristics of the PM BLAC motor drive and the PM BLDC motor drive. It can be
seen that the BLAC motor drive offers higher torque and power capabilities than the BLDC
motor drive employing the 2-phase 120° conduction. Nevertheless, the BLDC motor drive
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12 K. T. Chau
employing the 3-phase 180° conduction can offer better high-speed power capability, but with
the sacrifice of low-speed torque capability (Zhu and Howe, 2007). Moreover, for the PM
BLDC motor drive with multiphase polygonal windings (Wang et al., 2002), the
corresponding back EMF, rather than the air-gap flux, can be directly varied to enable
constant-power operation. Similarly, the split-winding DSPM motor drive (Cheng et al.,
2003) can perform constant-power operation by varying the effective number of armature
winding turns.
• The use of double stators can significantly increase the torque density, and can
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
provide versatile connection modes for generation over a wide speed range.
• The cup-shape rotor can effectively shorten the magnetic circuit length, thus
improving the torque density.
• Since the permeability of PMs is similar to that of air, the mutual inductance between
the inner stator and the outer stator is negligible, thus improving the controllability.
• Since the coil span of both stator windings is one slot pitch, the flux path of each
phase is independent so that the mutual inductance between phase windings is
negligible, thus further improving the controllability.
• Since the motor adopts a fractional number of slots per pole per phase, namely the
slot pitch is 11/12 pole pitch, the cogging torque can be significantly reduced.
• The mutipole structure can shorten the magnetic circuit length while the one-slot-
pitch coil-span winding arrangement can shorten end-windings, thus improving the
utilization of both iron and copper materials, and hence the torque density.
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Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 13
In order to achieve high starting torque, the double-stator windings can be arranged in
such a way that the same phases are connected in series. On the other hand, in order to
achieve constant generated output voltage over a wide range of speeds, the double-stator
windings can adopt versatile connection modes. When there is a spatial angle of 20° between
the two stators, it yields six possible ways to connect the two sets of three-phase windings.
As shown in Figure 8, different composite vectors can be generated by using different
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
winding connections. When the rotor speed ω is below its base speed ωb , the same phases
(for instance, E A and Ea ) are connected in series to form E1 , so-called the Mode 1 of
operation. Between ωb and 1.2ωb , the adjacent anti-phases are connected in series to form
E2 , so-called the Mode 2. Similarly, between 1.2ωb and 1.5ωb , E3 is formed under the
Mode 3 of operation. Then, between 1.5ωb and 2ωb , the adjacent phases are connected in
series to form E4 under the Mode 4 of operation. Similarly, between 2ωb and 3ωb , E5 is
formed under the Mode 5 of operation. Finally, between 3ωb and 6ωb , the same anti-phases
are connected in series to form E6 under the Mode 6 of operation.
Based on the corresponding vector diagrams, it can be deduced that E1 ≈ 6 E6 ,
E2 ≈ 5E6 , E3 ≈ 4E6 , E4 ≈ 3E6 and E5 ≈ 2E6 , indicating that the generated EMF can be
discretely tuned in terms of E6 . For further fine tuning or with speed beyond 6ωb , the
conventional flux-weakening control can be employed to adjust the output voltage.
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14 K. T. Chau
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
• By varying the polarity and magnitude of the DC field winding current, the air-gap
flux density becomes easily controllable.
• By realizing flux strengthening, the motor can offer the exceptionally high-torque
feature, which is very essential for cold cranking engines, or providing temporary
power for vehicular overtaking and hill climbing.
• By realizing flux weakening, the motor can offer the exceptionally wide-speed
constant-power feature, which is very essential for vehicular cruising.
• By online tuning the air-gap flux density, the motor can maintain constant voltage
output under generation or regeneration over a very wide speed range, which is very
essential for battery charging.
• By online tuning the air-gap flux density, the motor can also offer efficiency-
optimizing control, which is highly desirable for EVs.
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16 K. T. Chau
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
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Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 17
• By adopting the claw-type rotor structure, the leakage flux can be minimized and the
construction becomes compact. Moreover, by locating the field winding in the inner
stator, the motor axial length can be shortened and the material consumption can be
reduced.
• Due to the existence of both PMs and the field winding, the motor can be designed to
achieve higher air-gap flux density and hence higher power density. Increasingly, the
mounting of PMs adopts the flux-focusing arrangement, which allows the air-gap
flux density even higher than the operating flux density of individual PMs.
• By controlling the direction and magnitude of the DC field current, the air-gap flux
can be flexibly adjusted, hence the torque-speed characteristics can be easily shaped
to meet the special requirements for EV propulsion. Particularly, by using field
current control to weaken the air-gap flux produced by PMs, the speed range for
constant-power operation can be significantly extended.
• By properly controlling the applied voltage and DC field current, the efficiency of
the motor drive can be optimized throughout the whole operating range. Thus, the
efficiency at those operating regions for EV propulsion, such as high-torque low-
speed hill-climbing and low-torque high-speed cruising, can be improved.
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Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
18 K. T. Chau
Although this hybrid-PM brushless motor drive possesses the above advantages, it does
have some shortcomings. Particularly, the structure is quite complicated, which desires artful
integration. Also, its motor design and optimization desire three-dimensional electromagnetic
field analysis, which is lengthy and tedious.
The three-phase armature winding operates like that for a DSPM motor, whereas the DC
field winding not only works as an electromagnet but also as a tool for flux weakening and
efficiency optimization. Notice that flux-weakening operation is necessary for high-speed EV
cruising, whereas efficiency-optimizing control is essential for long EV driving range. Also,
there is an extra air bridge in shunt with each PM. If the field winding MMF reinforces the
PM MMF, this extra flux path will assist the effect of flux strengthening. On the other hand,
if the field winding MMF opposes the PM MMF, this extra flux path will favor the PM flux
leakage, hence amplifying the effect of flux weakening. As a result, with a proper design of
the air-bridge width, a wide flux-regulating range can be obtained by using a small DC field
excitation.
Under the assumptions that the fringing effect is negligible and the permeability of the
iron core is infinite, a linear variation of flux linkage is resulted, where the maximum value
occurs at the alignment between the rotor pole and the stator pole, whereas the minimum
value occurs at their nonalignment. When the flux linkage is increasing, an armature current
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Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 19
with a positive value is applied to the phase winding, hence producing a positive torque.
Similarly, when the flux linkage is decreasing, a negative current is applied to the winding so
that a positive torque is also produced. Thus, two possible torque producing zones are fully
utilized.
Although this topology takes the definite advantages of high mechanical integrity and
flexible air-gap flux control which are highly desirable for EVs, its stator is relatively bulky
and the corresponding leakage flux is also significant.
• The outer-rotor topology can enable full utilization of the space of inner stator (the
part beneath the armature windings) to accommodate both the PMs and DC field
windings, hence improving the power density. Also, since both the PMs and DC field
windings are embraced by the rotor, the problem of flux leakage can be minimized.
• Since the rotor does not involve any windings or PMs, it can provide high
mechanical integrity which is essential to handle the high starting torque and to
withstand high-speed operation.
Electric Vehicles: Technology, Research and Development, Nova Science Publishers, Incorporated, 2009. ProQuest Ebook Central,
20 K. T. Chau
• The DC field windings can provide flexible flux control, including both flux
strengthening and flux weakening. When operating as a starter motor, the DC field
windings are excited to produce additional flux in the same direction as the PM flux,
hence strengthening the air-gap flux linkage to achieve very high starting torque. On
the other hand, when operating as a generator, the air-gap flux linkage is regulated by
varying the DC field current in such a way that the PM flux is weakened or
strengthened by the DC field, hence realizing the desired constant output voltage
over a wide speed range.
• The air bridges can bypass the PM flux when the two field excitations are opposite,
hence amplifying the effect of flux weakening.
• Since the stator adopts fractional-slot concentrated windings, it can effectively
reduce the cogging torque which usually occurs in PM BLDC motors. Also, it can
shorten the length of end-windings, hence saving the copper material and improving
the power density.
Copyright © 2009. Nova Science Publishers, Incorporated. All rights reserved.
To illustrate the ability and the range of controllable flux, an equivalent magnetic circuit
of the motor at no load is shown in Figure 14, where RPM is the PM reluctance, Rb is the air-
bridge reluctance, Rg is the air-gap reluctance, FDC is the DC field winding MMF, and FPM
is the PM MMF. Hence, it yields two design equations:
FDC + ⎛⎜ Φ g + ⎞ ⎛ R PM ⎞
= − 1⎟ ⎜⎜ + 1⎟⎟
FPM ⎜Φ g0 ⎟
⎝ ⎠ ⎝ Rb ⎠
FDC − ⎛⎜ Φ g − ⎞
⎟
⎛ R PM ⎞
= 1− ⎜⎜ + 1⎟⎟
FPM ⎜ Φ g0 ⎟
⎝ ⎠ ⎝ Rb ⎠
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Electric Motor Drives for Battery, Hybrid and Fuel Cell Vehicles 21
where Φ g 0 is the air-gap flux at FDC = 0 , FDC − and Φ g − are under flux weakening, and
FDC + and Φ g + are under flux strengthening. Given the air-gap flux ranges of (Φ g + Φ g 0 ) = 3
and (Φ g − Φ g 0 ) = 1 / 3 , the relationship between ( RPM Rb ) , ( FDC − FPM ) and ( FDC + FPM )
can be obtained as listed in Table 3. When selecting ( RPM Rb ) = 7 , it results
( FDC − = FPM 12) and ( FDC + = FPM 4) , indicating that the DC field winding excitation
needs only 8.3% of PM excitation for flux weakening and 25% of PM excitation for flux
strengthening to achieve 9 times change of air-gap flux.
The operating principle of this motor drive is similar with that of a DSPM motor drive,
except that the flux is controllable. Figure 15 shows the magnetic flux density distributions
with flux weakening (–350 A-turns), with no flux control and with flux strengthening (+1000
A-turns). It can be seen that the air-gap flux can be effectively controlled. Consequently, the
developed torque waveforms with and without flux strengthening are shown in Figure 16. It
depicts that the developed torque under flux strengthening can be boosted up by about 3
times, which is very essential to offer high starting torque. On the other hand, the no-load
rectified output voltage characteristics with and without flux control are shown in Figure 17.
It depicts that the output voltage can maintain constant over the whole speed range, which is
very essential for battery charging.
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Figure 15. Magnetic flux density distributions with and without flux control.
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