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Mojgan Nikouei Harnefors| SHC 1
Mojgan Nikouei-Harnefors, Funding period: 2013-08-01 – 2015-03-31
Dept. Electrical Energy Conversion, KTH Royal Institute of TechnologySwedish Hybrid Vehicle Centre (SHC)
Granted funding: 1.58 MSEK
High-efficient, ultra compact integrated electric drives for tomorrow’s
alternative drivetrains
Mojgan Nikouei Harnefors| SHC 2
Motivation
Producibility Size/WeightCost
EMI Cabling
Fault tolerance Loss
Integration
Mojgan Nikouei Harnefors| SHC 4
Project overviewGear box limitations
Torque/ speed
Battery technology
Specifications
Torque dynamics and voltage stability
during transient
DC-voltage sharing between modules
Control in fault modes
Control
Forced air cooling on heat sinks integrated in
chassies
Water or oil or only air?
1,2 or 3 coolant loops
Cooling
Parallel or series connection of coolant
loops
Short circuit protection during short circuit
Low-voltage MOSFETs
Power converter
Interleaved switching to minimize battery losses?
Non-electrolytic capacitors
Where to place the modules?(close to end windings or in axial
middle)
Should battery be splitted into several, parallel modules?
Converter control first evaluated on the real time simulator
Thermal teeth?
Concentrated windings where each 3-phase set makes up a
module
Electric machine
Rotor ferrites+SynRel
Coolant loop design
Integrated electric drive
Performance
Level of fault tolerance of the
electric machine and power electronics
Total drive cycle losses
Mojgan Nikouei Harnefors| SHC 5
Project overview
Funding Ph.D studentSupervisor
Project team
Mojgan Nikouei Harnefors
Hui Zhang
Lebing J in
Oskar Wallmark
Mats Leksell
Swedish hybrid vehicle center (SHC)
Mojgan Nikouei Harnefors| SHC 6
1.
2.
N.
Multiple-star
PMSM
PCB Cell
PCB Cell
PCB Cell
CS1
CS2
CSNSPI
Central DSP
PC
PC
RS 232
USB
Battery
Power converter Electric machine
Stacked polyphase bridges (SPB)
Mojgan Nikouei Harnefors| SHC 7
Machine considerationsFractional-slot concentrated-winding (FSCW)- Short end-turns- Low cogging torque- High slot filling factor (segmented stator)
Challenges- Suitable slot/pole combinations to obtain:
- High fundamental winding factor- Low rotor losses- Ease of integration (identical converter sub modules)
- Fault tolerance to handle a converter sub module fault
Mojgan Nikouei Harnefors| SHC 8
Control considerationsConverter sub module- Current control- Field weakening
Master control- DC-link voltage control and communication (ongoing work)- Fault handling (ongoing work)
Mojgan Nikouei Harnefors| SHC 9
Technical summary
• New method of machine and converter integration• New converter topology (SPB converter)
• Low voltage Si MOSFETs provide very high efficiencies and allows reasonably high junction temperatures• Future GaN may enable even lower losses• Low voltage, high switch frequency → very small, non-
electrolytic capacitors• Potential fault tolerance (limp home) is “in built”
9/31
Mojgan Nikouei Harnefors| SHC 10
• Refine the design of the electric machine• Develop a robust control technique• Evaluate tolerance to faults• Investigate power electronic manufacturing techniques• Full-scale prototype evaluation• Identify suitable applications for the converter topology
Future/ongoing work
10/31
Mojgan Nikouei Harnefors| SHC 11
Mojgan Nikouei-Harnefors, Funding period: 2013-08-01 – 2015-03-31
Dept. Electrical Energy Conversion, KTH Royal Institute of TechnologySwedish Hybrid Vehicle Centre (SHC)
Granted funding: 1.58 MSEK
High-efficient, ultra compact integrated electric drives for tomorrow’s
alternative drivetrains