Electric Vehicle Motor Insights
Electric Vehicle Motor Insights
PAPER
ABSTRACT | This paper reviews the relative merits of induction,                        •    Wide speed range, with a constant power operating
switched reluctance, and permanent-magnet (PM) brushless                                    range of around 3–4 times the base speed being a
machines and drives for application in electric, hybrid, and fuel                           good compromise between the peak torque
cell vehicles, with particular emphasis on PM brushless machines.                           requirement of the machine and the volt-ampere
The basic operational characteristics and design requirements,                              rating of the inverter.
viz. a high torque/power density, high efficiency over a wide                           • High efficiency over wide speed and torque ranges,
operating range, and a high maximum speed capability, as well as                            including low torque operation.
the latest developments, are described. Permanent-magnet                                • Intermittent overload capability, typically twice
brushless dc and ac machines and drives are compared in terms                               the rated torque for short durations.
of their constant torque and constant power capabilities, and                           • High reliability and robustness appropriate to the
various PM machine topologies and their performance are                                     vehicle environment.
reviewed. Finally, methods for enhancing the PM excitation                              • Acceptable cost.
torque and reluctance torque components and, thereby, improv-                           In addition, low acoustic noise and low torque ripple
ing the torque and power capability, are described.                                 are important design considerations. On an urban driving
                                                                                    cycle, a traction machine operates most frequently at light
KEYWORDS          |   Brushless drives; electric vehicles; electrical               loads around the base speed. Therefore, in general, it
machines; hybrid vehicles; induction machines; permanent-                           should be designed to operate at maximum efficiency and
magnet machines; switched reluctance machines                                       minimum acoustic noise in this region.
                                                                                        Typical torque/power-speed characteristics required
                                                                                    for traction machines are illustrated in Fig. 1. Induction
I. INTRODUCTION                                                                     machines (IM), switched reluctance machines (SRMs),
Electrical machines and drives are a key enabling                                   and permanent-magnet (PM) brushless machines (Fig. 2)
technology for electric, hybrid, and fuel cell vehicles.                            have all been employed in traction applications, and can be
The basic characteristics which are required of an                                  designed to exhibit torque/power-speed characteristics
electrical machine for traction applications include the                            having the form shown in Fig. 3. In the constant torque
following [1]–[3].                                                                  region I, the maximum torque capability is determined by
    • High torque density and power density.                                        the current rating of the inverter, while in the constant
    • High torque for starting, at low speeds and hill                              power region II, flux-weakening or commutation phase
        climbing, and high power for high-speed cruising.                           advance has to be employed due to the inverter voltage and
                                                                                    current limits. In region III, the torque and power reduce
                                                                                    due to the increasing influence of the back-electromotive
Manuscript received June 10, 2006; revised November 11, 2006.                       force (back-EMF). However, the power capability and the
The authors are with the Department of Electronic and Electrical Engineering,
University of Sheffield, S1 3JD Sheffield, U.K. (e-mail: Z.Q.Zhu@sheffield.ac.uk;
                                                                                    maximum speed can be enhanced without sacrificing the
D.Howe@sheffield.ac.uk).                                                            low-speed torque capability by employing a dc–dc voltage
Digital Object Identifier: 10.1109/JPROC.2006.892482                                booster [4], a technique which is employed in the Toyota
746      Proceedings of the IEEE | Vol. 95, No. 4, April 2007                                                  0018-9219/$25.00  2007 IEEE
                                Zhu and Howe: Electrical Machines and Drives for Electric, Hybrid, and Fuel Cell Vehicles
                                                                                                       Vs2   2
                                                                                         Tmax /            / s           (2)
                                                                                                      fs Xk Lk
                                                                                                      mpVs2 Rr0
                                                                                  Tst ¼          h           2    i    (3)
                                                                                          2fs        Rs þ Rr0 þXk2
C. Optimal Flux, Maximum Efficiency, and                      usually has to be determined experimentally, since no
Minimum Acoustic Noise                                        general and simple analytical method is available [11].
    High-efficiency operation is a very important issue for
traction drives. The optimal flux level for maximum
efficiency varies directly with the torque and inversely      III . SWITCHED RELUCTANCE
with the speed [11]. Thus, at low torque it is advantageous   MACHINES (SRMs)
to reduce the flux in an optimal manner in order to
reduce the iron loss and maximize the efficiency.             A. Features of SRMs
However, as the torque level is increased the flux must           The design and operational features of SRMs are
be simultaneously increased until the rated flux level is     well-documented [15], [16], and may be summarized
attained; otherwise, the copper loss will increase exces-     as follows.
sively due to the low torque per ampere. If optimal flux          • Simple, robust rotor structure, without magnets or
control is employed, a significant efficiency improvement             windings, which is desirable for high-temperature
is achieved at all loads in both constant torque and                  environment and high-speed operation. However,
constant power modes [11]–[13]. Above base speed, in the              it can have a significant rotor iron loss.
constant power mode, the flux naturally reduces since it          • Potentially low cost, although relatively high man-
is inversely proportional to the speed due to the limited             ufacturing tolerances are required due to the need
inverter voltage.                                                     for a small air gap.
    Optimal flux control for maximum efficiency also              • Modest short-duration, peak torque capability as
results in lower acoustic noise [14], which, in general,              the magnetic circuit tends to be relatively highly
increases with both the load and the flux. By way of                  saturated.
example, Fig. 6 shows the variation of the sound pressure         • Smooth operation at low rotational speeds requires
level with flux and load, for a constant stator fundamental           relatively complex profiling of phase current
frequency. It will be observed that:                                  waveforms and accurate measurement of rotor
                                                                      position.
   1)   under the same flux level, the sound pressure level
                                                                  • Unipolar operation requires nonstandard power
        increases with load;
                                                                      electronic modules, but SR drives have an inherent
   2)   at light loads, a reduction in the flux can
                                                                      degree of fault tolerance.
        significantly reduce the acoustic noise; however,
                                                                  • Since their operating is based on the sequential
        as the load is increased the noise can increase as
                                                                      excitation of diametrically opposite stator coils in
        the flux is reduced;
                                                                      machines having the basic 6/4 and 8/4 stator/
   3)   the optimal flux level for the lowest noise
                                                                      rotor pole number combinations, the acoustic
        emissions increases with the load.
                                                                      noise, vibration, and torque ripple tend to be
    Since both vector control and direct torque control,              relatively high.
either indirectly or directly, control the flux and torque,       The high-speed operating capability of SRMs, their
optimal flux control can be readily exercised. However, the   relatively wide constant power capability, and the minimal
optimal flux level for each specific torque and speed         effects of temperature variations offset, to some degree,
their relatively lower power factor. Thus, SRMs have                    3) the degree of saturation in the magnetic circuit;
significant potential for use in vehicle propulsion systems             4) the allowable temperature rise.
[7], [17]–[19].                                                         Thus, a high overload capability requires thicker stator
    Typical SRMs are shown in Fig. 7, together with one             and rotor back-iron and appropriate thermal management.
phase leg of the inverter. When a stator pole is aligned            Above base speed in the constant power region, when the
with a rotor pole, the phase inductance is a maximum,               inverter supply voltage is limited, commutation advance is
while in the unaligned position the inductance is a                 required. Thus, both the turn-on and turn-off angles are
minimum. When operated as a motor, the phase windings               gradually advanced as the speed is increased, and the
are excited during the period when the inductance is                machine eventually enters the single pulse mode of
increasing as the rotor rotates. When operated as a                 operation. When the machine is motoring, the peak
generator, the phases are commutated on and off during              current is determined solely by the turn-on angle, while
the period when the inductance is reduced as the rotor              when generating, both the turn-on and turn-off angles
rotates. The higher the ratio of the aligned inductance to          influence the peak current [22]. At very high rotational
the unaligned inductance, the higher the torque/power               speeds, i.e., region III of Fig. 3, further commutation
capability. In general, it requires the rotor pole arc to be        advance is limited due to the influence of the back-EMF
slightly wider than that of the stator poles. Comparatively,        and the winding inductance, since the phase current
SRMs have relatively few feasible stator/rotor pole                 waveforms become continuous. However, as will be
number combinations (6/4, 8/6, and integer multiples                described later, by employing two-phase overlapping
thereof being the most common). Further, the stator                 excitation and continuous conduction the power capability
poles are generally parallel-sided and carry a concentrated         at high rotational speeds can be enhanced. Clearly, the
coil, as illustrated in Fig. 7. However, several alternative        foregoing operational characteristics of an SRM are
SRM topologies have been proposed, of which the long-               appropriate for traction applications.
pitched winding SRM [20] which utilizes the variation of
the winding mutual inductances, rather than the variation           C. Constant Power Operation
of the phase self-inductances, to produce torque, and the               An SRM is capable of extended constant power
segmented rotor SRM [21] are arguably the most notable,             operation, typically up to 3–7 times the base speed [23].
since they may produce a similar torque density to that             This is usually achieved by phase advancing the excitation
of conventional SRMs.                                               until overlap between successive phase currents occurs.
                                                                        The high-speed performance of an SRM depends
B. Operational Characteristics                                      heavily on the rotor pole design, and in general, requires
    SRMs are usually operated in the discontinuous                  a compromise between the constant torque and constant
current mode, although continuous current operation                 power capabilities. For example, in [23] it was shown that
may be advantageous under certain operating conditions.             when the leading dimensions of 6/4 and 8/6 SRMs were
As was shown in Fig. 3, three operational modes generally           fixed, and the rotor pole arc was varied, the constant power
exist for traction drives. Thus, in the constant torque             range was extended to 9 6 times base speed when the rotor
region I, the phase currents are controlled by PWM to               pole arc was narrower than the stator pole arc and the
produce the desired output torque, the peak torque                  depth of the rotor pole was relatively large. However, the
capability depending on:                                            machines under consideration had relatively low torque
    1) the allowable maximum current from the inverter;             densities. The constant power capability also depends on
    2) the rate of rise of the current after a phase                the number of stator and rotor poles. When the number is
         winding has been commutated on;                            increased the constant power capability and the overload
                                                                    capability are reduced, albeit the higher the torque/power
                                                                    density and the higher the power factor and efficiency. By
                                                                    way of example, [23] shows that a 6/4 machine exhibits a
                                                                    much wider constant power range (viz. up to 7 times
                                                                    base speed) than an 8/6 machine (viz. up to 4 times base
                                                                    speed), which compares to a constant power operating
                                                                    speed range of 2 times base speed for a 24/16 SRM [18].
                                                                    Often, however, the number of stator and rotor poles is
                                                                    dictated by the space envelope constraints. In summary,
                                                                    not only is the ratio of the aligned to unaligned inductance
                                                                    reduced as the number of stator and rotor poles is
                                                                    increased, but the constant power operating speed range is
                                                                    compromised due to the limited scope for phase advan-
Fig. 7. Typical SRMs and one phase leg. (a) Three-phase, 6/4 SRM.   cing, and although the constant power performance could
(b) Four-phase, 8/6 SRM. (c) One-phase leg of inverter.             be enhanced by reducing the number of turns per phase,
Fig. 8. SRM with integrated flywheel and clutch for mild-hybrid vehicle   enhanced at both low and high speeds. However, the
[25]. Cranking: 45 Nm (0–300 rpm), continuous motoring: 200 Nm
(300–1000 rpm), transient motoring: 20 kW (1000–2500 rpm),
                                                                          improvement in performance gradually reduces as the
continuous generating: 15 kW (600–2500 rpm), transient generating:        excitation current is increased and the magnetic circuit
25 kW (800–2500 rpm). (a) Schematic. (b) Rotor/stator without             becomes more highly saturated.
winding. (c) Assembled unit.                                                  Finally, a control strategy which employs freewheeling
                                                                          diodes in parallel with the power switching devices in a
                                                                          conventional half-H-bridge inverter together with an
                                                                          appropriate zero-voltage period (Fig. 11) can also be used
                                                                          to boost the power capability when an SRM is operated as a
this compromises the torque capability for a given inverter               generator [22], [27].
voltage-ampere rating.
    Alternatively, the extended high-speed constant power
operation can be improved with continuous phase current
excitation, by increasing the number of turns per phase.
The torque per ampere capability below base-speed is then
not significantly compromised, as has been demonstrated
for a 24/16 SRM [24] and an 18/12 SRM [25] (Fig. 8),
which shows an SRM which was developed for a mild
hybrid vehicle application.
    The use of conduction overlap between two phases to
increase the torque and to reduce torque pulsations is
common practice [6]. Fig. 9 illustrates overlapping
conduction by advancing [6] or retarding [24] long-dwell
commutation [15], both also incorporating phase advance.
    Bipolar excitation (Fig. 10) [6], [22], [26] can also be
employed to improve the torque density and reduce torque
pulsations, as well as to increase the efficiency. The long
flux paths that are associated with SRMs supplied from
conventional unipolar drives then become short flux
paths, and the torque and efficiency are significantly                    Fig. 10. (a) Conventional excitation. (b) Bipolar overlapping excitation.
Fig. 11. Freewheel diode configuration and (a) ‘‘þ1’’; (b) ‘‘0’’;
and (c) ‘‘1’’ commutation.                                         very effective when SRMs are operated in both single
                                                                    pulse mode and PWM voltage control, it is much less
                                                                    effective with PWM current control, since this results in a
                                                                    varying PWM switching frequency. A fixed frequency
                                                                    current controller can, however, alleviate the problem.
D. Acoustic Noise, Torque Ripple, and                               Further, the technique is less appropriate for application
Their Reduction                                                     to SRMs which exhibit multiple resonances. The vibration
    The acoustic noise which is radiated from an SRM is             and acoustic noise can also be reduced [38] by employing
often cited as a major disadvantage. At low rotational              two-phase overlapping excitation, which, as stated earlier,
speeds the acoustic noise is due predominantly to                   is beneficial for extending the constant power operating
resonances that are induced by the torque ripples, and              range. In general, however, the acoustic noise emissions
may be reduced by appropriate profiling of the phase                from SRMs remain a significant issue.
current waveform. The key to obtaining the optimal
current profile is an effective method for estimating the
instantaneous torque. At high rotational speeds the                 I V. PERMANENT- MAGNET
acoustic noise is dominated by radial vibration resonances          BRUSHLESS MACHINES
[28]. The acoustic noise becomes significantly higher at
high rotational speeds and loads. However, various                  A. Brushless DC and AC Machines and Drives
techniques have been proposed for reducing the vibration                Due to the permanent-magnet excitation, PM brushless
and acoustic noise. The most effective method is to employ          machines are inherently efficient [39]–[48]. They are
a relatively thick stator yoke [29], [30] since this increases      generally classified as being either sinusoidal or trapezoi-
the mechanical stiffness and, thereby, reduces the vibra-           dal back-EMF machines [48] (Fig. 12). The corresponding
tional response. However, the outer diameter is then in-            control strategies are usually classified as being either
creased, but this, in general, is advantageous in improving         brushless DC (BLDC), or brushless AC (BLAC). In a BLDC
the overload capability since the stator yoke becomes less          drive, the phase current waveforms are essentially
saturated. Reducing the supply voltage is also usually              rectangular, while in a BLAC drive the phase current
helpful in reducing the acoustic noise at light load. SRMs          waveforms are essentially sinusoidal. Ideally, in order to
also generate significantly lower noise when operated               maximize the torque density and minimize torque
under voltage control rather than current control, due to           pulsations, it is desirable to operate a machine which has
the fact that random switching of the current controller            a trapezoidal back-EMF waveform in BLDC mode, and a
results in a wide-band harmonic spectra, thereby increasing         machine which has a sinusoidal back-EMF waveform in
the likelihood of inducing mechanical resonances [31],              BLAC mode. In practice, however, the back-EMF wave-
[32]. In [33], the relationship between the vibration of the        forms may depart significantly from the ideal, and, indeed,
stator and the rate of change of the phase currents at turn-        irrespective of their back-EMF waveform PM brushless
off was highlighted, while a current shaping algorithm to           machines may be operated in either BLDC or BLAC mode,
limit the rate of change of current at turn-off and, thereby,       although the performance, in terms of efficiency and
achieve a smoother radial force waveform was described              torque ripple, for example, may be compromised. Similar
in [34] and [35]. However, the method proposed in [36] is           to induction machine drives, when operating at low torque
arguably the most effective, in that it introduced a zero-          an optimal flux level exists for minimum iron and copper
voltage loop between two step changes in the applied                loss, and hence, maximum efficiency.
voltage, such that, together with a knowledge of the stator             Fig. 13 shows a schematic of a typical PM brushless
natural frequencies, anti-phase stator vibrations were              drive. In both BLDC and BLAC drives, rotor position
induced. However, it has limitations [37], since, while it is       information is necessary, although the required position
Fig. 21. Generator for EV auxiliary power unit [63]. 9 kW at 4200 rpm,
sintered ferrite magnets (remanence = 0. 38 T), max. air-gap flux
density: 0.6 T. (a) Stator. (b) Rotor. (c) Flux distribution.
bipolar, while the phase back-EMF waveform is, again,              power factor [79], [80]. This impacts significantly on the
essentially trapezoidal. Such a machine topology exhibits a        associated VA rating of the power electronics converter,
low winding inductance, while the magnets are more                 which has inhibited its application.
vulnerable to partial irreversible demagnetization. In
addition, significant induced eddy-current loss may be             C. Design and Control Issues for PM Brushless
induced in the magnets, which also experience a                    Traction Machines
significant radial magnetic force. Further, since the air-             As stated earlier, traction machines are required to
gap flux density is limited by the magnet remanence, the           have a high torque density, a high overload capability, a
torque density may be compromised.                                 wide operating speed range, and a high efficiency, while it
       c) Permanent Magnets in Stator TeethVFlux-Switching         is desirable that they have a degree of a high fault tolerance
PM Machine: This machine topology is also referred to as a         and are low cost. In this section, design considerations
flux-switching permanent-magnet machine [Fig. 22(c)]               related to the above issues are discussed. However, they
[69]–[71]. The stator consists of BU[-shaped laminated             often contradict each other. For example, reduction of the
segments between which circumferentially magnetized                cross-coupling magnetic saturation may also reduce the
permanent magnets are sandwiched, the direction of                 saliency ratio and consequently the reluctance torque;
magnetization being reversed from one magnet to the                the selection of the base-speed is usually a compromise
next. Each stator tooth comprises two adjacent laminated           between the constant torque performance at low speed
segments and a permanent magnet. Thus, flux-focusing may           and the constant power performance at high speed.
be readily incorporated, so that low-cost ferrite magnets can
be employed [70]. In addition, in contrast to conventional             1) Torque Density and Overload Capability: The general
PM brushless machines, the influence of the armature               torque equation for a PM brushless machine, which has
reaction field on the working point of the magnets is              both excitation torque and reluctance torque components,
minimal. As a consequence, the electric loading of flux-           is given by
switching PM machines can be very high. Therefore, since
the phase flux-linkage waveform is bipolar, the torque
                                                                                    3                                  
capability is significantly higher than that of a doubly salient                  T¼ p       m Iq    ðLq  Ld ÞId Iq        (5)
PM machine [65]. The back-EMF waveform of flux-                                     2
switching PM machines is essentially sinusoidal, which
makes them more appropriate for BLAC operation. In                 where p is the number of pole-pairs, m is the stator
addition, since a high per-unit winding inductance can             winding flux-linkage due to the permanent magnets, and
readily be achieved, such machines are eminently suitable          Ld , Lq and Id , Iq are the d- and q-axis inductances and
for constant power operation over a wide speed range.              currents, respectively. In order to maximize the torque
                                                                   density, it is desirable to increase m by reducing the
   3) Other PM Brushless Machine Topologies                        leakage flux. This can be achieved by introducing airspace
       a) Axial-Field Machines: Axial-field PM machines have       flux barriers or interpole magnets, as illustrated in Fig. 23.
an axially directed air-gap flux [72], [73] and can comprise a       m can also be increased by utilizing flux focusing
single-sided stator and a single rotor, a double-sided stator      [4], [63], as illustrated in Fig. 24. The torque density can
and a single rotor, or a single stator and a double-sided rotor.   also be enhanced by increasing the saliency ratio [3], [81],
In each case, a large axial force exists between the stator and    as illustrated in Fig. 25. Further, since the short-duration
the rotor. As with conventional radial-field PM brushless          torque capability is determined primarily by the demag-
machines, the stator can be slotted or slotless, although it is    netization withstand capability of the magnets and the
more difficult to manufacture a slotted stator for axial-field     level of magnetic saturation, reducing the d- and q-axis
machines. Thus, slotless designs are more common.                  cross-coupling magnetic saturation by incorporating air
However, while this eliminates cogging, it exposes the             flux barriers, as illustrated in Fig. 26, can enhance the
winding air-gap flux. Hence, a multistranded conductor or          overload capability.
Litz wire may be required to minimize the eddy-current
loss. Further, since the effective air gap is large, the winding      2) Flux-Weakening Capability: It is well known [62], [82]
inductance is generally relatively small, which may limit the      that the maximum flux-weakening capability, defined as
constant power speed range.                                        the ratio of the maximum speed to the base-speed, under
       b) Transverse-Flux Machine: Generally, transverse           supply inverter voltage and current limitations, can be
flux machines have a relatively large number of poles, all         achieved when a PM brushless machine is designed to have
of which interact with the total ampere-conductors of              1.0 per-unit d-axis inductance such that
each phase. This enables very high electric loadings and,
hence, high torque densities to be achieved [74]–[78].
                                                                                             m            Ld Ir
However, they have a significant leakage flux and a                                  Ld ¼           or            ¼1         (6)
relatively high winding inductance, as well as a poor                                       Ir              m
D. Recent Developments
                                                                Fig. 30. Three-phase, 12-slot, 10-pole, fractional slot PM machines
    1) Fractional Slot Machines: SPM brushless machines         [97]. (a) All teeth wound. (b) Alternate teeth wound.
which have a fractional number of slots per pole and a
concentrated winding have been the subject of recent
research. They have an inherently low cogging torque,
short end-windings and, hence, a low copper loss, a high        skew. However, the reluctance torque component is neg-
efficiency, and a high power density, as well as excellent      ligible even when an IPM rotor is employed.
flux-weakening performance [85], [94]–[100]. The stator
coils may be wound either on all the teeth or only on              2) Hybrid PM and Current Excitation: Since the PM ex-
alternate teeth (Fig. 30) [95], [97]. In the latter case, the   citation is fixed in a PM brushless machine, the current
phase windings are effectively isolated, both magnetically      phase angle has to be progressively advanced as the speed
and physically, and a high per-unit self-inductance can         is increased above base-speed so that a demagnetizing
readily be achieved to limit the prospective short-circuit      d-axis current component is produced which reduces the
current, by utilizing the relatively high air-gap inductance    flux-linkage m with the stator winding. Ultimately,
and the leakage flux at the slot openings. Due to the           however, this may cause partial irreversible demagnetiza-
physical separation of the coils and the negligible mutual      tion of the magnets. At the same time, due to the inverter
inductance between phases, the possibility of a phase-to-       voltage and current limits, the torque-producing q-axis
phase fault is minimized. Therefore, the fault tolerance        current component has to be reduced correspondingly.
and flux-weakening capability of such machines can be           Consequently, the torque and power capability are limited.
significantly higher than for more conventional machine         Thus, a compromise has to be made between the low-speed
designs. Fig. 31 shows a three-phase, 24-slot, 22-pole, PM      torque capability and high-speed power capability.
BLAC machine which was developed for a supercapacitor-              Hybrid permanent magnet and field current excitation
based electrical torque boost system for vehicles equipped      has been shown to be beneficial in improving the power
with down-sized IC engines [99]. However, since the             capability in the extended speed range, enhancing the low-
torque is developed by the interaction of a stator space-       speed torque capability, and improving the overall
harmonic MMF with the permanent magnets, a relatively           operational efficiency. There are several ways of realizing
high rotor eddy-current loss can result from the funda-         such hybrid excitation. For example, dc winding may be
mental and low-order space-harmonic MMFs which rotate           located on the rotor [101] or the stator [102]–[107], which
relative to the rotor [88], [89]. As stated earlier, however,   is preferable since it does not require slip-rings. The
the magnets can be segmented to reduce the eddy-current         magnetic circuit associated with the dc excitation may be
loss. A further advantage of such machines is that, due to      either in series or in parallel with the magnetic circuit
the fractional number of slots per pole, the cogging torque     associated with the PM excitation. However, although
is very small without employing design features such as         series excitation is simple it requires a higher excitation
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