Microsoft Word - B_41_Polak_R.doc
HUNGARIAN JOURNAL
OF INDUSTRIAL CHEMISTRY
VESZPRÉM
Vol. 39(2) pp. 317-320 (2011)
EFFICIENCY AND MASS OPTIMIZATION OF ELECTRIC PERMANENT
MAGNET MOTOR DRIVEN VEHICLE
J. POLÁK
Széchenyi István University, Department of Automotive and Railway Engineering
H9026 Győr, Egyetem square 1, HUNGARY
E-mail: polakj@sze.hu
The propulsion system of road vehicles could be realized with the use of electric motor and a transmission system.
Complex analysis of these systems has been the topic of many recent researches, so an existing drive train has been
chosen. The systems in this paper consist a permanent magnet 3 phase synchronous motor and switchable, continuously
variable as well a constant ratio propulsion system.
The most important variables in this study are the torque, RPM and power of motor, the combined efficiency dimensions
and mass of drive train, vehicle mass, speed levels, mode and way of vehicle use. Our target is to create such a drive train,
which has the best efficiency and lowest weight at a defined power level.
Keywords: efficiency, mass, optimization, vehicle
Introduction
The solution is an optimized selection, based on the
analysis of different construction variants and gear ratios.
From construction point of view, the most simple solution
is the direct drive electric motor, what requires high size
and expensive motor. Gearbox applied in order to extend
the RPM range will change dimensions, efficiency and
makes the system more expensive. Our goal is to find
the ideal combination for the given vehicle.
Dynamic investigation of vehicle drive trains in case
of internal combustion engine and electric motor
The combined operation of internal combustion engine
and vehicle can be described graphically on a Torque-
RPM diagram, where we plot the torque of the crankshaft
of the engine in the function of RPM, the constant
power curves, the different resistances of the vehicle at
different gear ratios and the specific consumption at
different load and RPM levels.
The torque of elevation and rolling resistance at the
engine crankshaft can be described by the following
equation:
Mψ = ψ·G·Rg·ihm / ηhm
The torque of drag projected as a resistance on the
engine crankshaft can be calculated by the following
equation (See on Fig. 1):
Ml = 2·ρl·Rg·A·cv·π
2·ihm
3 / ηhm
Figure 1: The torque of drag projected as a resistance
on the engine crankshaft
Figure 2: The torque of drag projected as a resistance
on the electric motor shaft
318
Based on the method above, the combined operation
of electric motor and vehicle can be described on a
Fig. 2. In the diagram, you can see the efficiency of the
electric motor instead of specific consumption.
The correspondences above gives possibility of
stationary study of different motor and transmission
combinations, what makes the foundation of further and
deeper analysis.
Electric motors applicable for vehicle drive
The heart of all electric driven vehicle is the electric
motor. They are existing in many variations, and belongs
to the most efficient drive units. Compared to the IC
engines, electric motors crates zero emission. Technically
there are 3 moving parts on a motor, and estimated
lifecycle is definitely longer then IC engines. The
applicable electric motors for vehicle drive are the
following:
● External excitation motors (coil or permanent magnet)
● AC motors
a) Reluctance motors (Switched Reluctance Motor,
SRM),
b) MCDC motors
c) 3 phase Electronic Commutation Direct Current
(ECDC) motors
d) 5 phase ECDC motors
e) BLDC motors
Different type of electric motors may be classified
based on the most important properties (Table 1).
Current state of the art vehicle drives uses 3 phase
PM synchronous motors, so we are going to study in
this paper this type only. In our environment we have
engineering know-how in design as well manufacturing
ability.
Table 1: Different type of electric motors
BDC BLDC/PMS AC Cont. excitat. Ext. excitation Reluctance Crossfield
Power High Small medium high good Good high
Mass Heavy Light Light light medium medium medium
Dimension Big Small Medium small medium medium big
RPM Low High High medium medium high Low
Cost medium expensive cheap Very expensive medium Cheap Very expansive
Transmissions applicable for vehicle drive
The following transmission types may be used for electric
motors
Constant ratio transmissions
● Chain drive
● Cogged belt drive
● Gear box type
● V-belt drive
Variable ratio transmissions
● Gear type
● Continuously variable transmission
● Planetary gear transmission
Efficiency of transmissions may vary between 20–95%
The value of efficiency of drive defined by technical
literature, but these facts concern general situation. In
this instance the correct choose of drive is with testing
bench.
Studying the transmissions, there are two main types
among them: Constant ratio and variable ratio. When
selecting a transmission type, two factors are taken into
consideration: mass and efficiency. Among this two
parameters, also important factors are the complexity of
transmission, what defines the manufacturing cost and
feasibility for the certain application, as well the necessary
auxiliary equipment parameters what has affect on overall
mass and efficiency of the unit.
Studying the transmission types for electric driven
vehicles available on the market, we may state that there
are 3 main types of transmissions:
Chain drive – most of the case on two wheel vehicles
Cogged belt transmissions – commonly used on two
wheeled vehicles and smaller four wheel vehicles
Planetary gear transmissions – medium and big sized
four wheel vehicles
Small mass, low weight, simple construction, easy
and fast repair are the advantages of the chain and
cogged belt drives. Meanwhile, because of the constant
ratio, it is hard to optimize the transmission for the ideal
conditions matching to the electric motor’s parameters.
The advantage of applying planetary gear drives are
the ability of changing gear ratios. This allows to operate
the electric motor on the best efficiency range among
different operation environment. Although considering
the switching mechanism, it makes a more complex and
heavier transmission.
Weight and efficiency optimization of transmission
Motor: By studying weight/power ratio of electric
motors, we can state, that the weight increase compared
to power increase is smaller. See on Fig. 3.
For the mass optimization of a drive train, we can
select dependent and independent variables.
Independent variables are: RPM of motor (n),
diameter of motor (Ǿ), mass of motor (mm), efficiency
of motor (ηm) gear ratio (zh), mass of transmission (mh),
efficiency of transmission (ηhm).
Dependent variables are the mass (mhl) and
efficiency (ηhl) of drivetrain.
319
Figure 3: The weight/power ratio of electric motors
Mass of drivetrain depends on the weight of motor
and transmission:
mhl = f(mm, mh)
Efficiency of drivetrain depends ont the efficiency of
motor and transmission
ηhl = f(ηm, ηhm)
mhl = mm + mh
Weight reduction of PMSM motors can be performed
on the following components:
o Weight reduction of Copper (mcopper),
o Iron rotor mass reduction (miron),
o Magnet mass reduction (mmagnet).
Other components int he motor (front and rear cover,
shaft, bearing etc) mass (mconst.) may considered as
constant elements. Mass of motor consist the mass of
these components, so the weigh of the motors equals to:
mPMS = mcopper + miron + mmagnet + mconst
Changing the mass and proportions of the above
mentioned components have effect on the PMSM motor
characteristics, operational properties and efficiency.
By applying transmission, beside the mass of the
motor the mass of transmission will count as well:
mhl = mPMS + mh
By increasing motor diameter, the torque derived by the
motor also can be increased, but this way the inertia
moment of motor will increase too, therefore the
acceleration to the set point of motor will be slower.
The torque is proportional to the dn/dt value of
acceleration.
πθ
M
dt
dn
dt
dn
πθM
2
2 =⇒⋅=
By studying moment of inertia of the rotor, we can state
that the moment of inertia is proportional to the square
of the distance measured from the center of rotation.
θ = m·r
By application of hub motors, the motor and wheel
common moment of inertia needs to be examined. By
installing transmission unit, an additional rotating mass
gets into the system, where the moments of inertia are
cumulated.
∑
=
⋅=
N
i
ii rmθ
1
2
Therefore by increasing diameter of the motor, such
motors can be designed, where the increasing torque and
reduced RPM (max. 200–1200 RMP) by appropriate
optimization the application of transmission unit may be
omitted.
By decreasing the diameter of the motor, the maximum
torque output will be reduced as well, but the RPM of
the motor can be increased (max. 4000–7500 RPM).
Although by reaching such RPM range, application of
transmission system will be necessary.
Efficiency of drivetrain depends on the transmission
and motor efficiency:
ηhl = f (ηm, ηhm)
Drivetrain efficiency in case of hub motor:
ηhl = ηm
By applying transmission in the drivetrain, we have to
take into consideration the transmission efficiency:
ηhl = ηm·ηhm
Visible that the analysis of vehicle drives and motor, the
work up convenient transmission system is a complicated
mathematical analysis. The first step we make the
adequate mathematical relation after we can test the
convenient transmission on testing bench. We can get
some results and these compare results with results of
testing bench.
Summary
Goal of the study, is to develop and create the most
efficient and lightest drivetrain and transmission to a
given parametric system, (weight, speed, application
area, etc.) vehicle. It is not possible to define the optimal
drivetrain to a certain vehicle type. Analyzing drivetrain
parameters based on the vehicle input data can be chosen
the most suitable drivetrain.
For drivetrain analysis, mathematic modeling can be
used, which leads to the most suitable drivetrain selection
based on the dependent and independent variables
considered in the system. By the use of math software,
one can simulate and analyze the drivetrains. By studying
the results, the drivetrain can be selected and built and
tested on test bench. Results of testing can be compared
against modeling. This comparison gives feedback for
further model creation, also it makes the optimization
process examinable and analyzable.
E
ff
ic
ie
nc
y
de
ns
ity
(k
W
/k
g)
320
SYMBOLS
Mψ - torque of elevation and rolling resistance on
engine shaft
Ml - torque of drag on engine shaft
ψ - rolling friction resistance
G - mass force of vehicle
Rg - rolling radius
ihm - total transmission ratio
ηhm - transmission efficiency
ρl - air density
A - Vehicle surface perpendicular to driving direction
cv - drag coefficient
Θ - inertia moment
n - RPM of motor
m - mass
r - distance measured from shaft
mhl - mass of drivetrain
ηhl - efficiency of drivetrain
Ǿ - motor diameter
mm - motor mass
zh - gear ratio
mh - mass of transmission
mcopper - copper (coil) mass
miron - iron rotor mass
mmagnet - magnet mass
mconst. - motor component mass
ηm - motor efficiency
ηhm - transmission efficiency
ACKNOWLEDGEMENTS
TAMOP-4.2.1/B-09/1/KONV-2010-0003: Mobility and
Environment: Research in the fields of motor vehicle
industry, energetics and environment in the Central- and
Western-Transdanubian Regions of Hungary The Project
is supported by the European Union and co-financed by
the European Social Fund”
REFERENCES
1. L. GUZZELLA, A. SCIARRETTA: Vehicle Propulsion
Systems, Springer-Verlag, Berlin Heidelberg, 2005,
ISBN 978-3-540-25195-8
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/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
>>
/Namespace [
(Adobe)
(Common)
(1.0)
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/OtherNamespaces [
<<
/AsReaderSpreads false
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(InDesign)
(4.0)
]
/OmitPlacedBitmaps false
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/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
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/ConvertColors /ConvertToCMYK
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/FlattenerPreset <<
/PresetSelector /MediumResolution
>>
/FormElements false
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>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice