PERMANENT MAGNET SYNCHRONOUS MOTORS IN INNER- AND OUTER-ROTOR CONFIGURATIONS FOR TRACTION APPLICATIONS Univ.Prof. Dr.

Manfred Schrdl Institute of Energy Systems and Electrical Drives University of Technology, Vienna

Presentation at A3PS conference ECO-MOBILITY Austria Center Vienna, Nov. 15th, 2011

Contents 1. Introduction 2. Most important properties of the presented PMSM traction drives 3. Possible geometrical motor configurations 4. Control of the PMSM Sensorless approach 5. Example 1: 500 Nm outer rotor PMSM for wheel drives 6. Example 2: 100 Nm outer rotor PMSM for light vehicles 7. Example 3: 200 Nm inner rotor PMSM for drive trains 8. Example 4: 3.000 Nm railway traction drive 9. Conclusion and outlook

Introduction
Permanent magnet synchronous motors (PMSMs) for traction applications in different geometrical construction are presented, especially: Outer rotor configuration (e.g. for direct integration into wheels) Inner rotor configuration (e.g. for combination with gear-boxes) The presented motors have been built up and tested at Vienna University of Technology. The geometrical structures and the control concepts based on sensorless control (INFORM method and EMF model) are shown. Measurements of important properties are given.

Most important properties of the presented drives

High torque per volume Permanent short circuit is admissible Sensorless control up to double rated torque from standstill Using INFORM method Concentrated windings Advantages in production and isolation Robust construction large air gap, no mechanical sensors Large field-weakening range - constant power range is possible Application in gearless direct drives High efficiency up to 95 %

Possible geometrical motor configurations

Inner rotor configuration (e.g. for combination with gear-boxes)

Outer rotor configuration (e.g. for dirctly integrated wheel drives)

Disc rotor configuration (e.g. for small moment of inertia) Not treated in the presentation

PMSMs with air gap magnets and buried magnets

Buried magnets (enabling flux concentration)

Air gap magnets (protection against corrosion necessary)

Inner rotor configurations

Outer rotor configurations

PMSM inner rotors (examples)

Air gap magnets (left) Buried magnets without flux concentration (middle) (industry)

Inner rotor with flux-concentrating buried magnets (by TU Vienna)

PMSM outer rotor applications (examples)

Starter/Generator or mild hybrid application (ZF Sachs)

Gearless direct drive for tram applications

PMSM tooth coils (examples)

2 variants: a) Each tooth has a coil b) Each second tooth has a coil (industry examples)

Stators of outer rotor PM motors (upper pictures PMs by TU Vienna) Stator of inner rotor PM (left picture, constructed and built up by TU Vienna)

Control of the PMSM Sensorless approach

Classical strategy: Position-sensor-based current control (which is closely related to torque-control), maybe with superimposed speed-control Disadvantage: Expensive and place-consuming position sensor + cabling necessary

Presented new strategy: INFORM method for low speed and standstill combined with EMF method for high speed

Control of the PMSM Sensorless approach INFORM method

INdirect Flux detection by On-line Reactance Measurement

Basic idea: Measuring the current change vector due to a voltage test vector (lower figure) This signal is position-dependent. 3 different test directions are possible (right)
INF OR MAc hs e

INFORM

POS 3 symbolischer Rotor

POS 2 POS 1 y o (POS1)

y

(POS3) Richtung des angelegten Spannungsraumzeigers

y INFORM inverse INFORM-Reaktanz (Richtung der Stromnderung)

(POS2)

Control of the PMSM Sensorless approach - INFORM method Measurement of the characteristic INFORM curve
Characteristic INFORM curve

theoretical
measured at rated current (300Nm) measured at 3x rated current (500Nm)
INFORM
hs e

POS 3 symbolischer Rotor

POS 2 POS 1 y o (POS1)

y

IN FO RM -Ac

(POS3) Richtung des angelegten Spannungsraumzeigers

y INFORM inverse INFORM-Reaktanz (Richtung der Stromnderung)

(POS2)

Sensorless Control of the PMSM Combining INFORM method, EMF model and mechanical observer

EMF model is always active. INFORM stabilizes EMF model at low speed. Mechanical observer is synchronized by INFORM and/or EMF model.

Example 1: 500 Nm Outer Rotor PMSM for wheel drives

Main goals of the motor: Outer rotor construction high torque per volume ratio Sensorless control possible up to 3x rated current Large air gap easy mechanical assembly Concentrated windings simple production High efficiency (small rotor losses)
Data of presented PMSM

reference voltage reference current (continuous current) continuous output power continuous / peak torque reference speed per unit resistance at 120 C number of pole pairs number of teeth short-circuit current air gap diameter length of active iron

325 V (peak) 56.6 A (peak) 15 kW 310 / 500 Nm 673 rpm 0.036 15 36 43.6 A (peak) 34 cm 5 cm

Torque production

The torque depending on current magnitude was measured on a test stand.

Load motor (600 Nm)

Torque measurement PMSM Produced torque (including reluctance torque) over current magnitude: 300 Nm at rated current 500 Nm at 3x rated current

Efficiency measurements
The efficiency was measured in the speed / torque plane using a high-quality power measuring system.

14 kW isoline

Machine torque over rotor speed with efficiency and hyperbolic power-isolines Blue lines: Achievable range in the torque/speed plane at rated and 3xrated current

Short circuit behaviour

(Linear Speed change from 0 to 16% of rated speed)

If PMSM rotor cannot be decoupled from the drive train -> Short circuit must be admissible for permanent operation. Possible reasons: winding fault (short circuit) or Inverter fault (short circuit is safe condition)
Flux-parallel current component (yellow):
78% of rated current 100 Nm

is,d ,sc = is,q,sc =

2 PMls,q r + ls,d ls,q

2 s 2

Flux-normal current component (blue):

PMrs . 2 2 rs + ls,d ls,q

Torque

= PM is , q + (l s , d l s , q )is , d is , q . (red)

Short-circuit currents over machine speed (final= 16 %), Ch1: is,d,sc Ch2: is,q,sc Ch3: ti (35Nm/div.), is,d,sc|0.78

Thermal behaviour
The PMSM was air-cooled (natural cooling). The temperature rise at 70 % and 100 % of reference current is shown. The temperature behaviour can be modeled by a time constant of 25 min.

100% rated current

70% rated current

Dynamic behaviour of implemented sensorless INFORM/EMF control

The following picture shows a PMSM step response Sensorless controlled speed step from standstill to 30% of rated speed (coupled with load machine high moment of inertia).
Torque-producing current isq up to 220% of rated current (Torque up to 430 Nm)

Actual speed Reference speed

Estimated (green) and real (red) rotor position

Speed step is performed within 160 ms

Example 2: 100 Nm Outer Rotor PMSM for light wheel drives

Two variants of stator slots have been tested at same rotor geometry Outer rotor construction direct integration into wheel (see figure) Sensorless control possible up to 3x rated current Large air gap easy mechanical assembly Concentrated windings simple production

reference DC link voltage Continuous / peak output power continuous / peak torque per motor reference speed Constant torque range Constant power range number of teeth Number of poles short-circuit / continous current ratio

48 V 3/6 kW / motor 100 / 200 Nm 600 rpm 0-300 rpm 300-600 rpm 18 or 36 24 <1

PMSM with 24 rotor poles and 36 stator teeth

PMSM with 24 rotor poles and 18 stator teeth

Example 2: 100 Nm Outer Rotor PMSM for light wheel drives Integration into wheel
Wheel motors at laboratory test stands (left figures) Integration of wheel motors into light vehicle (golf caddy)

Example 3: 200 Nm Inner Rotor PMSM for drive trains

A high-performance inner rotor motor for electric / hybrid vehicles was developed and tested at TU Vienna. Large air gap easy mechanical assembly Concentrated windings simple production Liquid cooling necessary
Reference motor voltage Reference motor current Reference power Reference/maximum speed Motor diameter 250 V (rms) 220 A (rms) 90 kW 3500 /8000 rpm 250 mm

CAD construction (left) and realised PMSM at TU Vienna test stand (right)

Example 3: 200 Nm Inner Rotor PMSM for drive trains stator and rotor construction
The stator ist liquid-cooled and fitted with tooth-coil windings. The rotor has buried permanent magnets in flux-concentrating arrangement. The short-circuit current is smaller than the nominal current.

Figure: Stator and rotor of the PM inner rotor motor

Example 4: 3000 Nm Railway traction drive

TU Vienna supported construction, building up of 3000 Nm / 1.000 rpm outer rotor prototypes and lab test stand Upper figure: Industrial bogie with classical induction motors Left figure: Construction of innovative PM drive (1.. Bearing, 2..Rotor with buried permanent magnets, 3..Stator,4.. Housing, 5..wheel, 6.. Shaft)

Left: Stator Right: Rotor

Example 4 (continued): 3000 Nm Outer Rotor PMSM traction drive Assembly and testing at TU Vienna
Right figure shows assembly of stator and rotor (in vertical position) Lower figure shows test stand with1000 Nm / 4000 rpm DC drive, gear box 1:4 and PMSM under test (4000 Nm, 1000 rpm)

Example 4 (continued): 3000 Nm Outer Rotor PMSM traction drive Measurements during sensorless control
Upper figure: speed/torque-curve for cyclic testing of the motor (acceleration at rated torque, drive in fieldweakening range, breaking and standstill .. Repeated continuously) Lower figure: The curve shows sensor-based and sensorless control up to 4000 Nm, almost same behaviour. Furthermore, the characteristic INFORM curves up to 3xrated current are shown.

Example 4 (continued): 3000 Nm Outer Rotor PMSM Efficiency and energy consumption during standard test cycle compared to induction motor
Efficiency plots of PM motor/generator (left) and induction motor/generator (lower right) Including operating points along the test cycle (medium right curve) and corresponding energy consumption (upper right table)

Load motor (600 Nm)

Torque measurement PMSM

Produced torque (including reluctance torque) over current magnitude: 300 Nm at rated current 500 Nm at 3x rated current

Conclusion and outlook

Permanent magnet synchronous machines in inner and outer rotor configuration for electric traction have been presented. The most important properties have been discussed. Sensorless control up to overload even at standstill has been shown. All drives have high efficiency (up to 95 %) Some examples between 100 and 3.000 Nm have been built up at TU Vienna. Thank you for your attention! Manfred Schrdl, Institute of Energy Systems and Electrical Drives Vienna University of Technology Manfred.schroedl@tuwien.ac.at