E-VECTOORC (Electric Vehicle Control of Individual Wheel Torque for On- and Off-Road Conditions) 1st September 2011 – 31st August 2014 Project Coordinator: Aldo Sorniotti (University of Surrey, UK) [email protected] SWITCHED RELUCTANCE MOTOR TECHNOLOGY – INVERTO John De Clercq Kevin Verhaege E-VECTOORC Dissemination Event Heritage Centre, Gaydon 28th August 2014 Content Inverto Program Principle Characteristics Development Tooling Traction System Performance Maps TCU Architecture Impact of DC Link Voltage Roadmap 28.08.2014 Inverto - Dissemination Event 2 Inverto - History 28.08.2014 Inverto - Dissemination Event 3 Inverto - Facilities Inverto n.v. Belgium Inverto s.r.o. Slovakia Management R&D Sales & Marketing Prototyping Logistics After Sales Finance Production Production Engineering Process Engineering Subcontractors (metal, PCBA, cables) 28.08.2014 Inverto - Dissemination Event 4 Inverto - Technologies Technology provider to international state-of-the-art companies for both engineering and industrial production 25 years of accumulated experience and know how state-of-the-art power electronics 5 business lines and core technologies Lighting Electronics Main lighting companies Electronics lamp ballasts and drivers Wireless Energy Conversion LED-displays Green Power LED large screen display rental companies Companies active in renewal energy applications Inverto is linked to leading wireless power companies Power electronic converters and systems for renewal energy Power Electronic components for wireless charging applications LED screens for high end segment & Processing platforms SR-Technology Inverto Shareholders SR motor and drive HSSR motor and drive Industrial Automotive + Industrial 28.08.2014 Inverto - Dissemination Event 5 Inverto –Customers Portfolio Lighting Electronics LED-displays Green Power Wireless Energy Conversion SR-Technology Inverto Shareholders Electonic Ballast 500V UV lamp for water desinfection - Substation in cities - Ships (new legislation) LED screens - 20 mm - 10 mm - 3 mm CHP - Grid Inverter - Generator Inductive heating Wireless charging - Bus - Car (slow + fast) Industrial SR traction - motor - electronic drive HSSR - motor - electronic drive Automotive + Industrial 28.08.2014 Inverto - Dissemination Event 6 Inverto – Electronic Power in/for the Future B / NL / ESP H2 <> Power: Fuel Cells & Electrolyse Midscale wind energy CHP B B/D Zero emission & Renewal energy Automotive traction and auxilaries Wireless charging Industrial wireless D Wireless Energy & Inverto China / US Processing platform for large LED displays LED imaging Industrial high efficiency motors UV water disinfection SR traction SR eSuspension SR Range Extender SynRM Electronic Lamp Ballast B/D Canada 28.08.2014 Inverto - Dissemination Event 7 Inverto Partners & Research Partners SR traction HSSR SR traction Wireless charging Ugent Flanders’ Drive FMTC Inverto e Supsension Motor iCleantech Several other universities and research institutions through EU High efficient motors for industrial processes SR traction Vehicle stability with SR 28.08.2014 Inverto - Dissemination Event 8 Switched Reluctance Program 01/2013: Motor + motor drive Inverto SRMOTIF project Funded by Flemish government 10/2013: 2WD Landrover Evoque Flanders’ Drive Clean Powertrain RepMep 04/2014: 4WD Landrover Evoque FP7 project EVECTOORC: study on vehicle dynamics - 4WD Funded by EC 28.08.2014 Inverto - Dissemination Event 9 Switched Reluctance Principle Salient stator, salient rotor + concentrated windings Torque mechanism Flux tries to minimize reluctance (=magnetic resistance) • • R R MIN -> poles aligned (A) MAX -> poles unaligned (U) Torque sense Independent of current sense Sequence related : rotor poles attracted to active stator poles • • • • Approaching poles (MOTOR) Leaving poles (GENERATOR) Control by electronic commutation by switching the flux Position feedback needed Non-linear due to saturation 28.08.2014 Inverto - Dissemination Event 10 Switched Reluctance Key Charateristics Absence of magnets Sustainable Low cost Controlled back-emf No demagnetization Robust (mechanically/electrically) Safe operation High efficiency Very long constant power region Rugged structure High speed operation 28.08.2014 Inverto - Dissemination Event 11 Switched Reluctance Development Tooling (1) motor6_proto_new.srd - U = 300V - wref = 209.4rad/s - iref = 99.46A - 2 i-transducers - aon = 33.7° - afw = 47.2° - aoff = 51.9° - PFe = 337W - PCu = 1255W - n = 88% - a = 476rad/s2 SR Analytical Models current (A) phase current (A) phase voltage (3V/A) flux linkage (scaled) inductance@0A (0.1mH/A) 50 0 -50 -100 0 10 20 30 40 50 rotor pole position (°mech) 60 70 80 90 0.3 flux linkage (Wb) Reluctance models FE models Identification of motor parameters Simulation of both motor and control 100 0.2 0.1 0 0 10 20 30 40 50 phase current (A) 60 70 80 90 100 80 torque (Nm) phase torque (Nm) mean torque = 55.8Nm Tmcorr = 54.1Nm torque ripple = 0.83pu torque ripple std= 0.29pu PFe: sp=80W, sy=203W, rp=25W, ry=29W 60 torque (Nm) • Steady state • Transient 40 20 0 -20 0 10 20 30 40 50 rotor pole position (°mech) 60 70 28.08.2014 Inverto - Dissemination Event 80 90 12 Switched Reluctance Development Tooling (2) SR control optimization Trade-off motor performance POWER DENSITY EFFICIENCY • Efficiency • Torque Ripple • Noise i* (A) 10 8 θDWELL (°) PCu (W) PFe (W) η Tripple aeff (m/s2) 6.5 121.2 158 72 0.703 0.48 123 7.5 8.5 10.0 97.8 86.4 76.8 162 176 203 49 39 33 0.740 0.736 0.717 0.79 1.31 1.91 57 53 23 torque ω = 100 rad/s, T = 6 Nm 12 current (A) TORQUE RIPPLE NOISE MAXIMUM TORQUE 6 4 2 0 0 60 120 180 electrical position (°) 240 300 360 speed 28.08.2014 Inverto - Dissemination Event 13 SR Development Tooling (3) Inverto test bench • • • • • • Load motor + 4Q drive (vector control + power feedback unit) – Nominal 400Nm, 120kW – Peak 150% 60s – Maximum speed 9000min-1 Torque sensor – Flange torque transducer with special couplings – 500Nm, overload 200% 200kW load bank and dissipator control unit 100kW 800V DC link, 120kW 560V DC link, 80kW 400V DC link Liquid water cooling system for SR motor and drive dSpace 28.08.2014 Inverto - Dissemination Event 14 Switched Reluctance Traction System 2 wheel drive unit (double motor-gear i=1:10.41) MOTOR DRIVE SYSTEM SPECIFICATION TORQUE/POWER @800V +/-10% Peak (30s) Nominal (continuous) Maximum speed 200Nm, 100kW 80Nm, 35kW 15000min-1 Motor dimensions (LxD) Motor weight Motor inertia (without gearbox) 215x265mm (11.5l) 50kg 21087kgmm² Drive dimensions (WxHxD) Drive weight 500x155x280mm (19l) 15kg Liquid cooled Protection class 10l/min, 50°C max inlet IP68 28.08.2014 Inverto - Dissemination Event 15 Performance Maps (1) Measurement Setup Motor & drive system measured efficiency map (motoring) DC LINK POWER DRIVE TEMPERATURE TEMPERATURE FLOW COOLING SYSTEM POWER TEMPERATURE TEMPERATURE SRM ROTOR ANGLE TEMPERATURE POWER = TORQUE x SPEED LOAD MOTOR speed controlled Detailed mapping available in both simulated and validated environment 28.08.2014 Inverto - Dissemination Event 16 Performance Maps (2) Torque ripple Periodicity Nph x Nr = 24 / mech motor revolution 100km/h 5km/h ~ 7452rpm (i=10.41, 235/55/R19) ~ 24 x 124Hz = 2981Hz ~ 373rpm (i=10.41, 235/55/R19) ~ 24 x 6Hz = 149Hz Low speed (<400rpm) ripple reduction from >45% to <5% - TORQUE LEVELLING - 28.08.2014 Inverto - Dissemination Event 17 Performance Maps (3) NVH analysed by 28.08.2014 Inverto - Dissemination Event 18 TCU Architecture (1) Functions CONTROL LOGIC Torque Estimator 1 Torque Estimator 2 Requested Torque STAT IC 1ms Motor Speed THERMAL MANAGEMENT Estimated Torque Peak T orque (MOT /GEN) + Boost Time DYNAMIC 10ms Torque Demand Rotor Speed T emperature Coolant, Coil & Heat Sink Inverter Status OPEN LOOP TORQUE CONTROLLER ST AT US 10ms Rotor Angle Phase Currents FLEX RAY 12V SUPPLY Position & Speed Estimator Coolant Temp. Sensor HW Disable POWER DRIVERS Angle Senor Module Temp. Sensors POWER MODULES DC Link Voltage Sensor HV Battery DC Link Current Sensor Phase Current Sensors Stator Rotor TM Coil Temp. Sensor DC CAPACITOR MOTOR ASSEMBLY POWER UNIT MOTOR DRIVE (TCU) 28.08.2014 Inverto - Dissemination Event 19 TCU Architecture (2) Motor Drive Power Section PHASE A EXCITATION BATTERY + θ H-DRIVER VOLTAGE TRANSDUCER DC LINK H-DRIVER <PHASE B> L-DRIVER PHASE B <PHASE C> L-DRIVER SINE COSINE ϑHEAT SINK H-DRIVER <PHASE A> 500µF RESOLVER L-DRIVER BATTERY PHASE C CURRENT SENSOR DC LINK CURRENT SENSOR PHASE A CURRENT SENSOR PHASE B ϑCOIL CURRENT SENSOR PHASE C ϑCOOLING T Motor Drive Control Section WATER INLET WATER OUTLET Safety µC : TMS570 Vehicle Interface : CAN / FlexRay + hardware disable CONTROLLER 12V POWER(DC/DC) CURRENT SENSOR DC LINK CURRENT SENSOR PHASE A 1ms frame H-DRIVER PHASE A CURRENT SENSOR PHASE B 2ms / 10ms & 100ms frames L-DRIVER PHASE A CURRENT SENSOR PHASE C µC-TMS570 H-DRIVER PHASE B VOLTAGE TRANSDUCER DC LINK L-DRIVER PHASE B ϑHEAT SINK H-DRIVER PHASE C ϑCOIL L-DRIVER PHASE C ϑCOOLING FLEX RAY SINE COSINE RESOLVER TO DIGITAL CONVERTER RESOLVER EXCITATION CAN EXCITATION CONTROL LOGIC POWER DIAGNOSTICS Safety concept implemented • • • • • Sequence counter Heartbeat Timeout DataID Checksum 28.08.2014 Inverto - Dissemination Event 20 TCU Architecture (3) Torque Estimation • 2 Methods blended METHOD 1 (@HIGH SPEED) » Based on electrical power and motor speed METHOD 2 (@LOW SPEED) » Based on motor phase currents • Estimation error <5% F.S. 28.08.2014 Inverto - Dissemination Event 21 TCU Architecture (4) Thermal Management System FUNCTION - Clamp torque for hardware protection (mainly motor coils) - Broadcast peak torque + boost time TARGET Maximize performance & robust protection Peak system thermal response much faster than sensor dynamics • Electrical sensor isolation = thermal barrier • Temperature gradient in coils • Limited thermal heat capacity (of stator coils) for peak load ⇒ Kalman filter estimates real coil temperature ⇒ Thermal margin dynamic torque limiter 28.08.2014 Inverto - Dissemination Event 22 Impact of DC Link Voltage Design according 800V battery spec (+/- 10%), initial tests at a 400V battery pack, today finalized to 600V Consequences Peak motor power ~ VA-availability Thermal derating for lower voltage only near high speed peak power (pure voltage control) Limited ampère-turns of motor Thermal derating figure (simulation) @800V 80Nm/35kW nominal @600V 80Nm/35kW nominal @400V 80Nm/25kW nominal similar thermal loading along peak line 28.08.2014 Inverto - Dissemination Event 23 Switched Reluctance Roadmap Increase power density +20% on SR motor +35% on motor drive Exploit SR technology to Niche automotive markets Small busses City Utility Vehicles … 28.08.2014 Inverto - Dissemination Event 24 Many thanks for your attention
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