Module 3: DC and AC Machines & Drives in EV & HV

Module 3
DC and AC Machines & Drives in EV & HV
List the various types of motors used in the EV and HV:
1. Induction motor
2. Permanent magnet motor
3. Brushed DC motor
4. Brushless DC motor
5. switched reluctance motor
6. Interior Permanent Magnet motor drive (IPM) motor drive

Selection and size of motors:

Here's a general guide on how to select and size motors for EVs:

1. Define Vehicle Requirements :

Determine the weight of the vehicle, including passengers and

cargo.
 Specify the desired performance metrics such as acceleration, top
speed, and range.
 Consider any additional features or requirements such as towing
capacity or
off-road capabilities.
2. Calculate Required Torque and Power :
 Use vehicle dynamics equations to calculate the torque and power
required to meet the defined performance criteria.
 Consider factors such as rolling resistance, aerodynamic drag,
and grade resistance.
 Account for losses in the drivetrain, such as transmission
efficiency.
3. Select Motor Type:
Choose the appropriate type of motor based on the vehicle
requirements and application.
 Consider factors such as torque density, efficiency, and cost.
 Common motor types for EVs include Permanent Magnet
Synchronous Motors (PMSM), Induction Motors, and Switched
Reluctance Motors.
4. Size the Motor :
 Once the required torque and power are determined, select a
motor with sufficient torque and power output to meet the vehicle's
needs.
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 Consider the motor's continuous and peak power ratings, as well as
its torque- speed characteristics.
 Ensure that the motor operates within its thermal limits to prevent
overheating.
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5. Consider Cooling and Thermal Management :

 Evaluate the cooling requirements of the motor to maintain optimal
operating temperatures.
 Implement appropriate thermal management techniques such as
liquid or air
cooling systems to dissipate heat efficiently.
6. Integration with Power Electronics :
 Ensure compatibility between the selected motor and the
associated power electronics, such as inverters and motor
controllers.
 Size the power electronics to match the motor's voltage
and current
requirements.
7. Validation and Testing :
 Conduct simulations and testing to validate the motor selection and
sizing.
 Verify that the motor meets the specified performance criteria
under various operating conditions.
8. Iterate and Optimize :
 Iterate the motor selection and sizing process as necessary to
optimize performance, efficiency, and cost.
 Consider trade-offs between different motor characteristics
and vehicle
requirements to find the best balance.

An AC (Alternating Current) motor is an electric motor that operates on alternating

current (AC) power. AC motors are widely used in various applications, from
household appliances to industrial machinery, due to their simplicity, reliability, and
efficiency. Here's an overview of how an AC motor works:

1. Basic Components of an AC Motor

AC motors generally consist of the following key components:

 Stator: The stationary part of the motor that generates a rotating

magnetic field. It consists of a core made of laminated iron and windings
(coils of wire) that are connected to an AC power supply.
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 Rotor: The rotating part inside the stator. It is typically made of

conductive bars (in the case of a squirrel-cage rotor) or windings. The
rotor turns in response to the magnetic field created by the stator.
 Shaft: Connected to the rotor and transmits mechanical power to the load
(e.g., a fan or conveyor belt)

Types of AC Motors

There are mainly two types of AC motors:

a. Induction Motor (Asynchronous Motor)

 The most common type of AC motor.

 The rotor does not have any external electrical connection.
 It operates on the principle of electromagnetic induction.
 The rotor always rotates slower than the magnetic field (hence
"asynchronous").
 Common in fans, pumps, and industrial machinery.

b. Synchronous Motor

 The rotor spins at the same speed as the rotating magnetic field
(synchronous speed).
 Requires a separate DC power supply for the rotor (to create a magnetic
field).
 More efficient and used in situations where precise speed is crucial (e.g.,
clocks, timing devices, high-precision equipment).
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Induction Motors:

o An induction motor is an AC electric motor where torque is

generated through electromagnetic induction from the stator’s
rotating magnetic field to the rotor.

o It works on Principle of Electromagnetic Induction

o Electromagnetic induction is the phenomenon in which the

electromotive force induces across the electrical conductor when it
is placed in a rotating magnetic field

Construction:
It mainly Consists of two Parts
 Stator
 Rotor
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Working OF Induction Motor

 Rotating Magnetic Field: The motor has two main components – the
stationary part called the stator and the rotating part called the rotor.
When AC (alternating current) electricity flows through the stator
windings, it creates a rotating magnetic field around the stator.
 Induced Current in Rotor: As the rotating magnetic field cuts across
the rotor, it induces a flow of electric current in the rotor’s conductors
(wires). This is similar to how a moving magnet can induce current in a
coil of wire.
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 Interaction of Magnetic Fields: The induced current in the rotor creates

its own magnetic field. This induced magnetic field interacts with the
rotating magnetic field of the stator.
 Torque and Rotation: The interaction between the stator’s rotating
magnetic field and the rotor’s induced magnetic field results in a force,
known as torque. This torque causes the rotor to start rotating and follow
the rotation of the stator’s magnetic field.
 Continuous Rotation: As long as the stator is supplied with AC power,
the rotating magnetic field will persist, continually inducing currents in
the rotor and keeping the motor rotating.

Here are the key characteristics of induction motor drives and their control

1. Speed Control:
 Voltage Control: Induction motors can be controlled by varying
the voltage supplied to the motor. By adjusting the voltage
frequency, the motor's speed can be controlled within a certain
range. This method is commonly known as Volts-per-Hertz
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control.
 Variable Frequency Drives (VFD): VFDs use power
electronics to vary the frequency and voltage supplied to the
motor, enabling precise control of motor speed over a wide
range.
2. Torque Control:
 Induction motor torque is directly proportional to the square of
the voltage and inversely proportional to the frequency.
Therefore, torque control can be achieved by adjusting the
voltage and frequency supplied to the motor.
 Torque can also be controlled by controlling the slip frequency,
which is the difference between the synchronous speed of the
motor and the actual speed.
3. Starting Characteristics:
 Direct-on-Line (DOL) Starting: In DOL starting, the motor is
connected directly to the power supply without any intermediate
control. This method provides full voltage and frequency to the
motor during starting, resulting in high starting torque but also
high inrush current.
 Soft Starting: Soft starters gradually ramp up the voltage and
frequency supplied to the motor during starting, reducing inrush
current and mechanical stress on the motor.
4. Efficiency and Energy Savings:
 Induction motors exhibit good efficiency under normal operating
conditions. However, efficiency can be further improved by
using control techniques such as flux optimization, vector
control, and sensorless control.
 Variable speed operation using induction motor drives allows for
energy savings by matching motor speed to the load
requirements.
5. Regenerative Braking:
 Induction motor drives can be used for regenerative braking,
where the motor operates as a generator to convert kinetic
energy into electrical energy during deceleration. This energy
can be stored or returned to the power supply, improving overall
system efficiency.
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6. Sensorless :
Control
 Sensorless control techniques eliminate the need for speed and
position sensors by using algorithms to estimate motor parameters
based on measurements such as voltage and current. This reduces
cost and complexity
while maintaining accurate control.
7. Fault Detection and :
Diagnostics
 Advanced control algorithms can detect faults in the motor or drive
system and take corrective actions to prevent damage or
shutdowns. Diagnostic features such as current and temperature
monitoring help identify potential issues before they lead to
failures.

Construction and Working Principle of DC Motors:

A DC motor is an electromechanical energy conversion device, which converts
electrical energy input into the mechanical energy output.
The operation of the DC motor is based on the principle that when a current
carrying conductor is placed in a magnetic field, a mechanical force acts on the
conductor. The magnitude of the force is given by,
F= BIL Newton
F- Force, B- Magnetic Field, I- Current, & L- Length of conductor
The direction of this is given by the Fleming’s left hand rule.
FLEMING’S LEFT-HAND RULE:
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If you stretch the index finger, middle finger, and thumb of the left hand
mutually perpendicular to each other. If the index finger indicates the direction
of the magnetic field, the middle finger indicates the direction of current
through the conductor, and then the thumb will indicate the direction of force
acting on the conductor.

Construction of a Brushed DC Motor

A brushed DC motor consists of the following components:

1. Stator:

 The stationary part of the motor.

 Contains either permanent magnets or field windings to generate a
magnetic field.

2. Rotor (Armature):

 The rotating part of the motor.

 Made of a laminated iron core with slots to house the armature
winding (coils of wire).
 The armature winding is connected to a commutator.

3. Commutator:

 A mechanical switch made of copper segments insulated from each

other.
 Attached to the rotor shaft, it reverses the current direction in the
armature windings to maintain continuous rotation.

4. Brushes:

 Made of carbon or graphite.

 Pressed against the commutator to provide an electrical connection
between the external power supply and the rotating armature.

5. Shaft:

 Transfers the rotational motion from the rotor to the external

mechanical load.

6. Bearings:

 Support the rotor, allowing it to rotate smoothly within the stator.

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Working Principle of a Brushed DC Motor

The brushed DC motor works on the principle of Lorentz Force, where a

current-carrying conductor placed in a magnetic field experiences a force.

1. Initial Current Flow:

 When a DC voltage is applied across the brushes, current flows

through the commutator into the armature windings.

2. Magnetic Interaction:

 The current in the armature windings generates a magnetic field

around the conductor.
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 This field interacts with the magnetic field of the stator (from
permanent magnets or field windings), creating a force on the
armature conductors.

3. Torque Generation:

 The forces acting on the armature conductors are in opposite

directions on either side of the armature, producing a torque that
causes the rotor to rotate.

4. Commutation:

 As the rotor rotates, the commutator ensures that the direction of

current in the armature windings is reversed periodically.
 This reversal maintains continuous torque in the same direction,
keeping the motor running.

Construction of a Brushless DC (BLDC) Motor

A Brushless DC motor has the following main components:

1. Stator:

 The stationary part of the motor.

 Contains laminated steel cores with slots to hold the stator
windings (copper wire).
 The windings are connected in a specific sequence to create a
rotating magnetic field when energized.

2. Rotor:

 The rotating part of the motor.

 Made of permanent magnets (usually ferrite or rare earth materials
like Neodymium).
 The number of poles in the rotor determines the motor's
performance characteristics.

3. Hall effect Sensor or Electronic controller:

The Hall effect Sensor is the brain of the motor. It is responsible for
controlling the flow of current to the motor windings. The controller also
senses the position of the rotor and adjusts the current accordingly to
ensure smooth and efficient operation.
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4. Shaft:
 Connects the rotor to the load, transmitting the mechanical power.

Working Principle of a Brushless DC Motor

The BLDC motor operates based on the interaction between the stator's rotating
magnetic field and the rotor's magnetic field.

1. Current Flow in Stator Windings:

 When DC voltage is supplied, the controller energizes specific

stator windings in a sequence, creating a rotating magnetic field.

2. Magnetic Interaction:

 The rotor’s permanent magnets are attracted to the stator's rotating

magnetic field, causing the rotor to align with the field.
 As the stator field rotates, the rotor follows, generating continuous
motion.

3. Electronic Commutation:

 The controller switches the current between the stator windings in

synchronization with the rotor’s position.
 The absence of brushes eliminates mechanical wear and tear,
making the motor more reliable and efficient.

4. Feedback for Position and Speed:

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 Hall-effect sensors detect the rotor's position.

 The controller adjusts the timing and magnitude of the stator's
magnetic field for precise speed and torque control.

Characteristics of Brushed DC Motors

a. Speed-Torque Characteristics
 Speed decreases linearly as torque increases (under load conditions).
 At no load, the motor runs at maximum speed, and at stall torque, the
speed drops to zero.

b. Efficiency
 Efficiency is lower than brushless motors due to friction losses in brushes
and commutator, as well as resistive losses in the windings.

c. Torque Ripple

 Minimal torque ripple due to continuous mechanical commutation.

d. Maintenance Requirements
 Brushes and commutator wear out over time, requiring periodic
maintenance or replacement.

e. Noise and Vibration

 Mechanical commutation introduces noise and vibration, making these
motors less suitable for noise-sensitive applications.

f. Speed Control
 Speed is easily controlled by varying the applied voltage, making these
motors simple to integrate into basic control systems.

g. Reliability
 The reliability is moderate, limited by the wear of brushes and
commutator.

h. Thermal Performance

 Heat is generated in both the rotor and stator, which can lead to uneven
cooling and increased thermal stress.

Switched Reluctance Motors (SRMs)

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Switched reluctance motors (SRMs) are a type of electric motor that operate based on the
principle of reluctance, which refers to the opposition to the flow of magnetic flux in a
magnetic circuit. They are known for their robust structure, high efficiency, and simplicity in
design.

Construction and Working of Switched Reluctance Motors (SRMs)

Construction of SRM

Switched reluctance motors have a simple yet robust structure consisting of the
following key components:

1. Stator:
o Structure: The stator is made of laminated ferromagnetic material
and has salient poles (projected poles).
o Windings: Coils are wound around the stator poles in pairs to form
a specific number of phases.
o For example:
 A 3-phase SRM might have six stator poles (two per phase).

2. Rotor:
o Structure: The rotor is also made of laminated ferromagnetic
material, but it has no windings, magnets, or electrical components.
It is purely a passive component.
o Salient Poles: The rotor poles align with stator poles when
energized.

3. Air Gap:
o The air gap between the stator and rotor is not uniform but
designed to maximize the magnetic force when the rotor aligns
with the stator poles.

4. Power Electronics:
o Inverter Circuit: Manages the switching of currents to the stator
windings.
o Controller: Controls timing and sequencing of the excitation based
on rotor position.

5. Position Sensor:
o A sensor (such as an encoder or resolver) is used to detect rotor
position. This information is crucial for synchronized switching of
stator windings.
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Working Principle of SRM

Switched reluctance motors operate on the principle of variable reluctance,

which means the rotor tends to move to a position of minimum reluctance
(maximum inductance) with respect to the stator magnetic field.

1. Energizing the Stator Windings:

 When a stator winding (phase) is energized with current, it generates a

magnetic field.
 The magnetic field creates a force that pulls the nearest rotor pole into
alignment with the energized stator pole.

2. Sequential Excitation:

 Once the rotor aligns with the energized stator pole, that phase is
switched off, and the next stator winding (in sequence) is energized.
 This sequential switching creates a rotating magnetic field that pulls the
rotor continuously in one direction.

3. Rotor Movement:

 The rotor moves to reduce reluctance, following the path of least

magnetic resistance.
 The timing of phase excitation must synchronize with rotor position to
maintain smooth rotation.
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