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Electric Drives
Electric Drives
S.M.FERDOUS
CERTIFICATION OF APPROVAL
The thesis titled Performance Improvement of DC Electric Traction Motors using
a Novel Switching Technique submitted by S.M.Ferdous, student no. 092606 of
Academic Year 2009-2010 has been found as satisfactory and accepted as partial
fulfillment of the requirement for the Degree of Masters of Science in Electrical and
Electronic Engineering on 01 October, 2012.
Board of Examiners
1.
2.
3.
4.
..
Dr. Md. Ashraful Hoque
Professor
Department of Electrical and Electronic Engineering.
Islamic University of Technology (IUT)
Board Bazar, Gazipur-1704, Bangladesh.
................
Dr. Md. Shahid Ullah
Professor and Head
Department of Electrical and Electronic Engineering.
Islamic University of Technology (IUT)
Board Bazar, Gazipur-1704, Bangladesh
................
Dr. Md. Ruhul Amin
Professor
Department of Electrical and Electronic Engineering.
Islamic University of Technology (IUT)
Board Bazar, Gazipur-1704, Bangladesh
................
Dr. Muhammad Fayyaz Khan
Professor
Department of Electrical and Electronic Engineering.
United International University (UIU),
Dhanmondi, Dhaka, Bangladesh.
II
Chairman
(Supervisor)
Member
(Ex-Officio)
Member
Member
(External)
DECLARATION OF CANDIDATE
It is hereby declared that this thesis or any part of it has not been submitted elsewhere for
the award of any Degree.
..................
Dr. Md. Ashraful Hoque
Supervisor and Professor
Department of Electrical and Electronic
Engineering.
Islamic University of Technology (IUT)
Board Bazar, Gazipur-1704, Bangladesh.
.
S.M.Ferdous
Student No. 092606
Academic Year 2009-2010
III
TABLE OF CONTENTS
LIST OF FIGURES...................................................................................................VII
LIST OF TABLES.......................................................................................................X
ACKNOWLEDGEMENTS .......................................................................................XI
ABSTRACT ..............................................................................................................XII
CHAPTER 1. INTRODUCTION
1.1 ELECTRIC TRACTION
1.1.1 ELECTRIC TRACTION DRIVE
1.1.2 ADVANTAGES OF ELECTRIC DRIVE
1.1.3 DISADVANTAGES OF ELECTRIC DRIVE
1.2 CHARACTERIZATION OF ELECTRIC MOTORS FOR TRACTION
APPLICATION
1.3 GENERAL FEATURES OF TRACTION MOTORS
1.3.1 MECHANICAL FEATURES
1.3.2 ELECTRICAL CHARACTERISTICS
1.4 MOTORS USED FOR ELECTRIC PROPULSION SYSTEMS FOR EV
AND HEV DESIGN
1.5 STATEMENT OF THE PROBLEM AND PURPOSE OF THE WORK
1.6 OUTLINE OF METHODOLOGY
1.7 THESIS ORGANIZATION
1
1
3
3
5
7
8
9
12
15
20
IV
21
22
24
27
29
32
33
33
34
35
36
37
40
41
43
44
47
50
51
54
INTRODUCTION
CONVERTER DESIGN
OPERATION OF CLASS C DC-DC CONVERTER
SIMULATION OF THE CONVERTER
SUMMERY
55
55
56
57
65
INTRODUCTION
SYSTEM SIMULATION IN SIMULINK
SUMMERY
66
66
71
CHAPTER 6. CONCLUSION
6.1 SUMMERY
6.2 SUGGESTION FOR FUTURE WORK
6.3 CONCLUDING REMARKS
72
73
73
REFERENCES
75
APPENDIX -A
78
APPENDIX -B
79
VI
LIST OF FIGURES
FIG.1.1
FIG.1.2
FIG 1.3
FIG.1.4
FIG.1.5
FIG.1.6
FIG.1.7
FIG.1.8
FIG.1.9
FIG.1.10
4
5
8
12
15
20
22
24
25
28
FIG.2.1
30
FIG.2.2
33
FIG.2.3
34
FIG.2.4
35
FIG.2.5
40
FIG.3.1
41
FIG.3.2
45
VII
FIG.3.3
48
FIG.3.4
49
FIG.3.5
50
FIG.3.6
The torque profile of the load as seen from the motor shaft
51
FIG.3.7
52
FIG.3.8
FIG.3.9
Axle torque profile though out the entire time of run of the vehicle
Armature Current vs Vehicle Speed
53
FIG.3.10
55
FIG.3.11
FIG.3.12
54
56
57
FIG.3.14
FIG.4.1
60
FIG.4.2
62
FIG.4.3
64
FIG.4.4
66
FIG.4.5
67
FIG.4.6
68
FIG.4.7
69
FIG.4.8
70
FIG.3.13
VIII
58
59
FIG.4.9
FIG.4.10
converter
FIG.4.11
FIG.4.12
FIG.5.1
70
72
72
73
FIG.5.2
74
FIG.5.3
FIG.5.4
74
FIG.5.5
75
FIG.5.6
76
FIG.5.7
76
FIG.5.8
76
75
IX
LIST OF TABLES
Table 1.1: ENERGY STORAGE CAPABILITY OF DIFFERENT TYPES
OF FUELS
Table 1.2: TYPICAL TORQUE DENSITY VALUE OF DIFFERENT
MOTOR TYPES.
8
12
ACKNOWLEDGEMENTS
I would like to first acknowledge my supervisor, Dr. Md. Ashraful Hoque, for his
support and advice throughout my graduate program. His power electronics courses and
his dedication to his students gave me the best experience during the program. I would also
like to express my sincere appreciation to my other thesis committees, Dr. Md. Shahid
Ullah and Prof. Dr. Md. Ruhul Amin for review of this thesis in detail and their important
feedback.
I would like to thank my colleagues and friends, Mr. Ahmed Mortuza Saleque and
Mr. Ahmed Al Mansur for their effective ideas and feedbacks are incorporated in this
thesis. Also, thanks to lab assistants, technicians for their support and willingness to help
me out during various stages of my thesis.
Finally, I take the opportunity to express my greatest admiration for my parents
who constantly motivated and encouraged me to keep working towards this goal. I also
thank all my other family members for all the support given during difficult times.
S.M.Ferdous
XI
ABSTRACT
A motor capable of operating in a wide constant power range would suit most for any kind
of traction application. At the same time it must be capable of producing sufficient amount
of torque to meet up the initial starting load demand and acceleration characteristics. In
this thesis a novel concept of controlling a DC motor is proposed where a DC compound
motor is being used for a traction purpose with a provision of winding switch over
technique which will enable the motor to operate in three common forms- Compound,
Series and Shunt configurations respectively. These three separate and independent
configurations will enable the motor to operate in such a way that, it would suit most to
match the Torque-Speed characteristics or the load profile of any conventional traction
load. A detail investigation of the motor as well as the load characterization with the
proposed method has been presented in the paper in terms of torque, speed and power
consumption. A 2 Quadrant Class C DC-DC converter is designed as the main component
of the motor controller which will help the motor to operate at variable speed during motor
mode operation where as using the same converter regeneration is also possible during
braking. Several controller circuits are developed for the purpose such as winding change
over controller, speed sensor, PWM signal generator with variable duty cycle, Hysteresis
current controller for current limiting purpose and magnetic contactors for forward and
reverse motion of the motor. Mathematical model of the DC Compound motor is
developed which is highly non-linear in nature and its characteristics. Hence the system is
linearized and transfer function with associated block diagram is obtained. Both
MATLAB codes and SIMULINK were used to analyze and represent the system. The
response curve for Speed, Torque, Current and Power were obtained. The converter is
simulated using LTSpice for various duty cycles to observe the adaptability and
compliance of it when integrated with the system for variable speed operation. Significant
improvements in vehicle performance were observed such as higher staring torque, rapid
acceleration with smaller acceleration time and the most important achievement is to attain
a higher final vehicle speed which is not possible to obtain using any other types of motor
with such power ratings. This point simply implies the fact that, this novel switching
technique maximizes and utilizes the full capacity of the motor which is capable of
operating at high torque and low speed during starting where as at low torque and high
speed at rated condition. But obviously, for a higher speed operation the load torque
demand and the power consumption will be more. That means a higher speed operation
along with improved vehicle performance will be achieved at the expense of larger energy
consumption. The results suggest that, though conventional DC motors are no more being
used for modern traction purpose, but yet it may be proven as an eligible candidate for
automotive traction once again using this new technique as the results showed
considerable performance improvement.
XII
CHAPTER 1
INTRODUCTION
1.1
ELECTRIC TRACTION
The act of drawing or the state of being drawn i.e. the propulsion of vehicle is called
the Traction and the system of traction involving the use of electricity is called
Electric Traction System. There are various systems of traction prevailing in the
world such as steam engine drive, internal combustion engine drive, diesel electric
drive, battery electric drive, straight electric drive and the most recent trend of hybrid
electric drive. These systems of traction may be classified broadly into two main
groups namely(i) The traction systems which do not involve the use of electricity at any
stage and called non-electric traction system such as steam engine drive, internal
combustion engine drive etc.
(ii) The traction systems which involve the use of electricity at some stage or
the other and called electric traction system such as diesel electric drive, straight
electric drive, battery driven drive etc.
System of electric traction can further be divided into two main groups(i) The group consisting of vehicles which receive power from a distribution
network fed at suitable points from either a central power station or substations
suitably spaced such as tramways, trolley bus, electric railways etc.
(ii) The group consisting of self contained locomotives such as diesel electric
trains, ships, petrol electric trucks and Lorries, battery driven road vehicles.
1.1.1
Electric drives are more reliable, flexible and suitable for traction purpose rather than
conventional engine driven vehicle. But storage of electrical energy is the main
obstruction in this technology as batteries stores a much less amount of energy
compare to the energy stored in fuels. Therefore the mileage of an electric vehicle is
1
much less than conventional vehicle. The problem can be solved by increasing the
capacity of the batteries, which is not a good solution considering the both technical
and economical viability. One possible solution can be obtained by reducing the
power consumption of the traction motor. To reduce the power rating of the motor
with a given vehicle performance and energy storage, the motor is required to have a
long constant power range to meet the load torque and demand [1]
The ideal characteristic of an electric motor drive for traction application are high
torque at low speed region for fault acceleration, hill climbing and obstacle
negotiation and low torque at high speed for normal driving. To minimize the power
of the motor as well as the energy storage power rating as a given vehicle
performance, the motor drive is required to have long constant power rage
application [1]. The essential requirements for electric traction are
Power to weight ratio of the traction motor should be high so that it occupies
less space.
1.1.2
Electric drives for traction purpose are available in wide range of torque,
speed and power. Electric motors have high efficiency, low losses and
considerable amount of overloading capacity. They are adaptable to almost
any operating condition.
Electric drives can be used operate in all four quadrants of speed torque plane
which is very suitable for forward and backward movements of the vehicle as
well as braking.
Better flexibility in operation and less maintenance (about 50% less compare
to engine driven system) [6].
storage system such as battery or recently developed fuel-cells. The following Table
1.1 can visualize a clear idea on this subject.
TABLE 1.1: ENERGY STORAGE CAPABILITY OF DIFFERENT TYPES OF FUELS AND
ELECTROCHEMICAL/ELECTROMECHANICAL SYSTEMS [6]
Sl.
No.
Energy contain
Energy Contain
(Wh/kg)
(Wh/Litre)
Gasoline
12300
9348
Natural gas
9350
7480
Methanol
6200
4904
Kerosene
5300
4500
Coal
8200
Battery (Lead-Acid)
35
40-100
Electrochemical Capacitor
5-15
Flywheel
15
10
Spring
0.1-.0.3
11
Solar Thermal
900 Wh/day
12
Solar PV
500 Wh/day
Small capacity of the battery and the necessity of frequent charging. the
charging time is more or less very long.
Limited battery life. Needs to be replaced after 3-4 years at a regular interval.
Batteries are costly and their frequent and regular replacement may not be
proven economically viable and cost effective.
1.2
Ideal profile of torque speed characterization of EV is divided into two parts i.e. the
constant torque region and the constant power region. The vehicle performance is
completely determined by the profile of tractive effect verses vehicle speed. For a
power source with a given power rating, the profile of tractive effort versus vehicle
speed should be constant power in the speed range that is the tractive effect drops
hyperbolically with the increase of the vehicle speed as shown in Figure 1.1.
allow the motor to operate at any point in the torque-speed plane. It is the profile of
this envelops which determines the drive selection criteria and design.
A typical traction load characteristic curve is shown in Figure 1.2.
Figure 1.3. Acceleration and Final Speed (Balancing Speed) of electric vehicle. The
point of balancing speed is the operating speed of the motor which determines the
final speed of the vehicle. [12]
1.3
The primary requirements of electric motors used for traction purpose are1.3.1
MECHANICAL FEATURES
A traction motor must be robust and capable to withstand continuous
vibrations since service conditions are extremely severe.
The traction motor must be totally enclosed type, particularly when mounted
beneath the locomotive or the motor coach, to provide protection against
ingress of dirt, dust, water and mud etc.
For magnetic circuit of traction motor cast iron, which cannot suitable
continuous vibration, is not suitable. Use of cast steel or fabricated steel,
which gives more mechanical strength, is made in place of cast iron. Those
parts of the motor, which are not highly stressed, must be made of pressed or
fabricated steel plates and light alloys.
1.3.2
ELECTRICAL CHARACTERISTICS
Simple speed control The traction motor must be amenable to simple speed
control as the an electric train or vehicle have to be started and stopped very
often.
Parallel running In traction work, usually more than one motor (two or four
motors per car) are required. Traction motors, therefore, should be of such
speed-torque and current-torque characteristics that, when they are operated
in parallel and mechanically coupled, they share the loads almost equally.
No such motors meet the all the requirements mentioned above. Most suitable
motors for DC traction systems are series and compound motors whereas for ac
traction systems single phase series and three phase induction motors are
employed.
TABLE 1.2: TYPICAL TORQUE DENSITY VALUES FOR DIFFERENT MOTOR TYPES [1]
Permanent Magnet
T/Volume envelop
(N-m/m3)
28860
T/Cu mass
N-m/kg-Cu
28.7-48
Induction motor
4170
6.6
Switch Reluctance
6780
6.1
Machine Type
Table 1.2 shows that the PM machines provide the highest torque density and
therefore will potentially have the lowest weight for given torque and power rating.
However, the fixed flux limits its extended speed range as the feature of field
weakening like brushed DC motors are not available. The induction motor and switch
reluctance motor have the similar torque densities.
10
demonstrates
long
field
weakening
operation[ 10].
This approach,
A contactless control
scheme for extending the speed range of a four-pole induction motor was presented
in [9]. This scheme uses two inverters, each of half the rated power rating that, in
theory, can extend the constant power
Operating range to 4 times the base speed, for a motor, that would otherwise be
limited to 2 times the base speed. It may be mentioned here that the torque control in
induction motor is achieved through PWM control of the current. in order to retain
the current control capability in the extended speed constant power range, the
motor is required to enter the field weakening range before reaching the base
speed, so that it has adequate voltage margin to control the current[l2]. This would,
however, oversize the motor slightly. Current regulation with synchronous current
regulator [I31 may be preferred choice. It can regulate current with lower voltage
margin. The availability of a long field weakened range, obviously, makes the
induction very suitable for vehicle application.
11
SRM can inherently operate with extremely long constant power range. The serial
design and simulation results, performed in the SRM research group at Texas
A&M University, show that the speed ratio can reach up to 6-8 times. This long
constant power range makes SRM highly favorable for vehicle traction application.
Electric motor driven small vehicles (Auto-Rickshaws) namely Easy bike or Polly
bike are extensively used in Bangladesh all over the country. They are three
wheeled vehicles providing the purpose of transportation. Although the vehicles are
not designed in Bangladesh and not even been tested to suit the environment of
Bangladesh, a detail study is needed to be carried out in this field as it seems to be an
emerging practice throughout the whole country.
Electric drives are more reliable, flexible and suitable for traction purpose rather than
conventional engine driven vehicles. But storage of electrical energy is the main
obstruction in this technology as batteries stores a much less amount of energy
compare to the energy stored in fuels. Therefore the mileage of an electric vehicle is
much less than conventional vehicle. The problem can be solved by increasing the
capacity of the batteries, which is not a good solution considering the both technical
and economical viability. One possible solution can be obtained by reducing the
power consumption of the traction motor. To reduce the power rating of the motor
with a given vehicle performance and energy storage, the motor is required to have a
long constant power range to meet the load torque and demand [1]. By analyzing the
different characteristics of different types of motors, it has been found that, DC series
12
motors are the most suitable type of motor for traction. But for a reliable operation
the motor rating must be increased to such a value which would increase the total
cost of the system. On the other hand DC motors has some disadvantages like field
control method is not flexible, speed of the motor is less than other types of up to a
certain region and finally, effective regenerative braking is not possible as the motor
becomes unstable during regenerative braking.
The objective of the thesis will be to design a control circuit to verify the theory that
has been stated above. Only a few studies have been carried out in this topic by
several researchers. To strengthen the theory, the family of curves shown in figure 2
should be closely observed [1].
Fig.1.4 : Tractive effort and power versus vehicle speed with different speed
13
Fig. 1.4 shows that with higher value of speed ratio (i.e. low base speed) the power
rating of the motor will be less. But the final speed of the vehicle will be very less
which implies that the vehicle will move with a very low speed. By observing the
Torque- Speed Characteristics of DC motors, it has been found that the speed of a
shunt motor will be much higher than the series motor within a particular region. As
the full load torque of a vehicle is much less than the starting torque the (the value of
the load torque changes hyperbolically), conversion of the motor from series to shunt
will match the load torque and the same time speed of the vehicle will be increased.
In addition to these, the final speed of the vehicle can be increased by 2-3 times
which will certainly be a great outcome from the project. Figure 1.5 shows the
relation between the power rating and speed ration of a traction motor.
14
Longer constant power range operation of the motor effectively reduces the
motor power rating.
So, if any motor chosen and designed for the purpose of electric traction is capable of
prolonging its constant power range operation, it would suit most for the traction
application as its characteristics would exactly represent the characteristics expected
from a traction motor. A figure in terms of Power, Tractive Effort, Speed and
Traction load would provide a detail idea as shown in Figure 1.6.
Figure 1.6. . Tractive effort along with Motor Power, base speed and final speed.
A Compound motor provided with winding change over facility should outdo the
performance of DC series motor. This will enable the motor to operate at three
different configurations Compound, Series and Shunt where later it would be
shown that, only two configurations are suffice to obtain the desirable performance,
i.e. the compound and shunt. This is due to the fact that, whatever the characteristics
desired from series configuration can very well be achieved from the compound
15
configuration. This would suit the traction characteristics more. Switching between
the windings will prolong the constant power range operation of the motor.
An experimental investigation on the Torque-speed characteristics would provide the
justification of the claim as shown in Figure 1.6.
for a self excited motor which includes all possible combination of the motor. Thus
the motor exhibit such characteristics which are highly expected for an ideal traction
motor and very much suitable for traction application.
Figure 1.8. . Power and Torque profile of a DC machine for three different
configurations
According to the traction load characteristic, it can be very easily obtained from
Figure 1.9 that, winding change over feature would enable the vehicle to operate at a
higher final velocity. The overall speed, torque and power profile due to winding
change over are given in Figure.10.
17
Figure 1.9. . Torque and speed profile of a DC machine for three different
configurations to show the possibility of achieving a higher starting torque and
higher final vehicle speed if change over in configuration takes place.
Figure 1.10. Torque and Power profile of the motor as a function of speed due to
change in its configurations by the feature of winding change over.
18
It is to be noted that, the accelerating torque for acceleration is very high due to
compound configuration where as the winding change over enables the vehicle to
attain a relatively higher speed due to change over into shunt configuration.
A controller circuit will be needed to perform the switching action between the two
separate windings. The purpose of the controller circuit would be to sense the load
condition and depending on that, perform the switching action. At constant torque
region the motor should operate at in series connection. At the end of acceleration
period (as the required tractive effort will be much less compare to the starting
condition) the switching must be taken place to increase the speed of the motor as
well as the vehicle.
1.6.1
Due to winding change over a high final speed is attained with a drop in Load
Torque.
Saving in energy is increased as the kinetic energy of the vehicle will be used
to charge the battery through regenerative braking which implies as almost
30-40% of energy can be saved by the system.
19
Chapter 1 describes the introduction of electric traction systems, types and different
features of it. General criteria of traction motor has been discussed from where it has
been found that, a motor with constant power range operation is certainly the best
choice for traction application. Finally a brief overview of the proposed method is
discussed and its applicability for electric traction is analyzed.
Chapter 2 describes the modeling, analysis and design of the compound motor that
will be used for traction purpose. Different characteristic equations have been
developed and simulated to predict the performance of the motor. The non-linear
model of the motor is developed and finally using the linearization technique, the
model is linearized and hence transfer function of the motor is obtained.
Chapter 3 describes in detail the dynamics of a traction load and hence the modeling
of the electric vehicle is done. From initial acceleration to final speed operation of the
vehicle had been calculated, simulated and presented along with all the necessary
mathematical calculation and analysis.
Chapter 4 discusses the modeling and Simulation of 2 quadrant Class C DC-DC
converter used for motor control. The novel integration of PWM voltage and
Hysteresis current controller is discussed in detail and simulated using LTSpice. All
the necessary controller circuit required for the operation of the vehicle along with
the winding change over controller, Speed Sensing, braking, speed controller and
others are designed, discussed and analyzed.
Chapter 5 provides the complete simulation of the entire electromechanical system
using Simulink. The response of the motor along with the vehicle is determined and
optimized. Finally, the obtained result is compared with the characteristics of a
conventional DC series motor to show the superiority and effectiveness of the
proposed method compare to any conventional vehicle traction system.
Chapter 6 concludes the overall thesis with some recommendations for future work.
20
CHAPTER 2
MODELLING AND ANALYSIS OF COMPOUND
MOTOR
2.1 INTRODUCTION
DC drives are widely used in application requiring adjustable speed, good speed
regulation and frequent starting, braking and reversing. In case of traction application
DC series motors are dominating long since. But in this study it will be shown that, a
compound motor can be more efficient in traction purpose if it is modified and added
with some special features. Generally compound motors are of two typesCumulative and Differential compound motor where the Differential compound
motor is seldom used. For this particular thesis work where a compound motor is
chosen for vehicle propulsion system, it is obvious that, Cumulative compound motor
will be the best choice between these two types. Comparing to DC series motor a
compound motor can exhibit a more stable operation and also provides a finite and
safe no load speed (which is not possible in case of DC series motor as its no load
operation would produce a dangerously high speed due to very low value of field
flux) that depends on the strength of the shunt field. The slope of the Speed-Torque
characteristic depends upon the strength of the series field. Cumulative compound
motors are used in those applications where a dropping characteristic is similar to
that of a series motor and at the same time a no load speed is limited within a safe
value. The best application of such motor is loads with intermittent duty cycle where
load varies from almost no-load (constant speed operation of the vehicle at steady
state) to very heavy load (during starting). In these applications a fly wheel may be
mounted on the motor shaft for load equalization. Apart from load equalization, use
of compound motor permits the use of a motor with smaller size and less power
rating.
21
A cumulative compound motor has a definite no load speed and so it does not "run away"like
series motor when load is removed.It also developed a high starting torque when load is
increased. This makes it suitable for such applications like rolling mills, shears and punching
presses. It is also a preferred motor for application of such as cranes and elevators that requires
(a) high starting torque, (2) are prone to sudden load change and (c) present a possibility of going
from no load to full load.
2.2 CHARACTERIZATION AND CONFIGURATION OF THE COMPOUND MOTOR
General characterization of the motor :
=
Field Current, =
+
R Total
(2.1)
(2.2)
EB = Back EMF
RTotal = Total Resistance of the armature circuit = Ra+Rse
Ra = Resistance of the armature
Rse = Resistance of the series winding
RF = Resistance of the field winding.
= =
(2.3)
2
60
V Ia R T
V Ia R T
V Ia R T
=
=
KB
K B se + sh K B K sh IF + K B K se Ia
(2.4)
(2.5)
Now,
T = K T Ia = K T se + sh Ia = K T (K sh IF + K se Ia )Ia = K T K sh IF Ia + K T K se Ia 2
(2.6)
where, C1 = K T K sh IF and C2 = K T K se
T = C1 Ia + C2 Ia 2
(2.7)
Now, from Eq. (2.7), expression for the current can found in terms of developed torque as,
Ia =
C1 C1 2 + 4C2 T
2C2
(2.8)
23
C 1 C 1 2 +4C 2 T
2C 2
K B K sh IF + K B K se
=
C 1 C 1 2 +4C 2 T
2C 2
C 1 +C 1 2 +4C 2 T
K1 + K 2
RT
2C 2
RT
C 1 +C 1 2 +4C 2 T
2C 2
2C2 V + C1 R T R T C1 2 + 4C2 T
2
2C2 K1 K 2 C1 + K 2 C1 + 4C2 T
(2.9)
24
2500
65
= 38.46 rad/sec
This primarily calculated value will be used to design and calculate different parameters of the
motor.Now, from Eq. (2.3)
= 38.46 =
KB =
EB
KB
EB V Ia R T 60 (40 0.15)
=
=
= 1.42
38.1
T = 65 = (K T )40
KT =
65
= 1.625
40
(2.10)
(2.11)
25
K T = 1.144K B
K B se + K B sh = 1.42
K T se + K T sh = 1.625
Let us assume 70% of the total flux is provided by the series field and 30% of the flux are
(2.12)
(2.13)
(2.14)
(2.15)
Similarly,
0.4875
= 0.0852
1.1444 5
K B K se =
1.1375
= 0.02485
1.1444 40
(2.16)
(2.17)
K B K sh
0.0852
=
= 3.4286
K B K se 0.02485
K sh = 3.4286K se
sh
= 3.4286 se
IF
Ia
26
sh = 3.4286
5
se = 0.4286se
40
sh = 0.4286se
(2.18)
KB =
K B se + sh = 1.42
1.42
= 99.4 V/rad. Wb
0.01 + 0.004286
sh
IF
K se =
2.3
0.004286
= 0.0008572 Wb/A
5
se 0.01
=
= 0.00025 Wb/A
Ia
40
dia
+ Ia R T + EB
dt
diF
+ IF R F
dt
EB = K B se + sh
(2.19)
(2.20)
(2.21)
27
T = K T Ia = K T se + sh Ia
= K T K sh IF Ia + K T K se Ia 2
(2.22)
(2.23)
TL is the torque required to drive the load then, then the developed torque balance equation can
be written as;
T=J
d
+ B + TL
dt
(2.24)
Using Eq. (2.19) to Eq. (2.24) the electromechanical model of the motor can be obtained. But
due to the product of variable type non-linearities present in Eq. (2.23), it is not possible to
obtain a transfer function of this model. However, these equations can be linearized by
considering a small perturbation at the operating point. Before deriving the linearized transfer
fuction, let us develop a complete block diagram of the motor considering the non-linearities
which is shown in Figure 2.2.
28
Assuming the field current is constant, this block diagram can be further simplified into the
following based on Eq. (2.4) and Eq. (2.6).
Figure 2.3. Non-linear block diagram representation of the compound motor, assuming field
current is constant
2.4
REPRESENTATION :
All the system parameters can be defined around their operating point as follows;
V = V0 + V;
T = T0 + T;
EB = EB0 + EB ;
Ia = Ia0 + Ia ;
TL = TL0 + TL ; = 0 +
IF = IF0 + IF ;
The following basic equations will be needed to describe and represent the electromechanical
system of compound motor along with its load.
V = LT
dia
+ Ia R T + EB
dt
EB = K B K sh IF + K B K se Ia
V = LF
diF
+ IF R F
dt
29
T = K T K sh IF Ia + K T K se Ia 2
T=J
d
+ B + TL
dt
Recognizing that, Ia0 and (Ia )2 are very small and hence tending to zero, all the above
Equations can be linearized to;
V = R T Ia + LT
d(Ia )
+ EB
dt
(2.25)
d(IF )
dt
(2.27)
EB = K B K se (Ia0 + Ia 0 ) + K B K sh (IF0 + IF 0 )
V = R F IF + LF
d()
+ B() + TL
dt
(2.26)
(2.28)
(2.29)
These five equations are sufficient to establish the block diagram of a DC Compound motor
drive as shown in Figure. 2.4.
A further simplification in the block diagram can be possible by rearraging the blocks as shown
in the following Figure. 2.5.
Figure 2.5. Linearized Block diagram of the compound motor assuming field current is constant
After using the block diagram simplification technique, the final linearized transfer function of
the motor is obtained as,
T(s) =
where;
C1 (SLF + R F C2 ) + C3 (SLT + R T + C4 )
(Js + B)(SLF + R F )(SLT + R T + C4 ) + C1 C5
(2.30)
C3 = K T K sh Ia0
C4 = K B K se 0
C5 = (K B K se Ia0 + K B K sh IF0 )
31
s + b0
+ a 2 s 2 + a1 s + a 0
R F C1 + R T C3 + C3 C4 C1 C2
LF C1 + LT C3
a0 =
a1 =
s3
BR F R T + BR F C4 + C1 C5
JLF LT
(2.31)
(2.32)
(2.33)
(2.34)
(2.35)
rated = T rated = K
rated
P rated
T I a (rated )
2500
65
32
CHAPTER 3
DYNAMICS OF TRACTION LOAD AND MODELING
OF ELECTRIC VEHICLE
3.1 INTRODUCTION
Modeling of electric vehicles will make it more convenient to predict its performance
and characteristics. The primary parameter to be modeled is vehicle performance. By
performance we mean acceleration and top speed, an area where electric vehicles
have a reputation of being very poor. It is necessary that any electric vehicle has a
performance that allows it, at the very least, to blend safely with ordinary city traffic.
Another vitally important feature of electric vehicles that we must be able to predict
is their range. This can also be mathematically modeled, and computer programs
make this quite straightforward. The mathematics we will develop will allow us to
see the effects of changing things like battery type and capacity, as well as all other
aspects of vehicle design, on range. This is an essential tool for the vehicle designer.
We will go on to show how the data produced by the simulations can also have other
uses in addition to predicting performance and range. For example we will see how
data about the motor torque and speed can be used to optimize the compromises
involved in the design of the motor and other subsystems.
The first step in vehicle performance modeling is to produce an equation for the
tractive effort. This is the force propelling the vehicle forward, transmitted to the
ground through the drive wheels.
Let us consider a vehicle of mass m, proceeding at a velocity v, up a slope of angle
, as in Figure 3.1. The force propelling the vehicle forward, the tractive effort, has
to accomplish the following:
33
Figure 3.1: The forces acting on a vehicle moving along a slope. [6]
3.2.1
The rolling resistance is primarily due to the friction of the vehicle tyre on the road.
Friction in bearings and the gearing system also play their part. The rolling resistance
is approximately constant, and hardly depends on vehicle speed. It is proportional to
vehicle weight. The equation is:
Frr= rrmg
(3.1)
Where rr is the coefficient of rolling resistance. The main factors controlling rr are
the type of tyre and the tyre pressure. The free-wheeling performance of a vehicle
becomes much better if the tyres are pumped up to a high pressure, though the ride
may be less comfortable.
The value of rr can reasonably readily be found by pulling a vehicle at a steady very
low speed, and measuring the force required. Typical values of rr are 0.015 for a
34
radial ply tyre, down to about 0.005 for tyres developed especially for electric
vehicles.
3.2.2
AERODYNAMIC DRAG
This part of the force is due to the friction of the vehicle body moving through the
air. It is a function of the frontal area, shape, protrusions such as side mirrors, ducts
and air passages, spoilers, and many other factors. The formula for this component is:
Fad = 0.5CdAv2
(3.2)
Where is the density of the air, A is the frontal area, and v is the velocity. Cd is a
constant called the drag coefficient.
The drag coefficient Cd can be reduced by good vehicle design. A typical value for a
saloon car is 0.3, but some electric vehicle designs have achieved values as low as
0.19. There is greater opportunity for reducing Cd in electric vehicle design because
there is more flexibility in the location of the major components, and there is less
need for cooling air ducting and under-vehicle pipe work. However, some vehicles,
such as motorcycles and buses will inevitably have much larger values, and Cd varies
around 0.7 are more typical in such cases.
The density of air does of course vary with temperature, altitude and humidity.
However a value of 1.25 kg.m3 is a reasonable value to use in most cases. Provided
that SI units are used (m for A, m.s1for v) then the value of Fad will be given in
2
Newton.
3.2.3
The force needed to drive the vehicle up a slope is the most straight forward to find.
It is simply the component of the vehicle weight that acts along the slope. By simple
resolution of forces we see that:
Fhc= mg sin ()
(3.3)
35
3.2.4
ACCELERATION FORCE
If the velocity of the vehicle is changing, then clearly a force will need to be applied
in addition to the forces shown in Figure 3.1. This force will provide the linear
acceleration of the vehicle, and is given by the well-known equation derived from
Newtons second law,
Fla= ma
(3.4)
However, for a more accurate picture of the force needed to accelerate the vehicle we
should also
consider the force needed to make the rotating parts turn faster. In other
Figure 3.2: Arrangement for connecting a motor to a drive wheel using a belt system
with step up gear mechanism to increase the amount of torque. [6]
Referring to Figure 7.2, clearly the axle torque = Fter , where r is the radius of the
tyre, and Fte is the tractive effort delivered by the power train. If G is the gear ratio of
the system connecting the motor to the axle, and Tm is the motor torque, then we can
say that:
Tvech = Tm G
Tm =
Fte r
(3.5)
36
m = G vech = G r (rad/sec)
(3.6)
Tm = JG r
(3.7)
Where, J is the moment of inertia of the motor. The force at the wheels needed to
provide the angular acceleration (Fa) is found by combining this equation with Eq.
(3.7);
G2
Fa = J r 2 a
(3.8)
We must note that in these simple equations we have assumed that the gear system is
100% efficient, it causes no losses. Since the system will usually be very simple, the
efficiency is often very high. However, it will never be 100%, and so we should
rewrite the equation by incorporating the gear system efficiency g. The force
required will be slightly larger, so equation (7.8) can be rewritten to:
G2
Fa = J r 2 a g
(3.9)
2
Typical values for the constants here are 40 for G/r and 0.025 kg.m for the moment
of inertia. These are for a 30 kW motor, driving a car which reaches 60 kph at a
motor speed of 7000 rpm. Such a car would probably weigh about 800 kg. The right
hand side in equation (7.8) will have a value of about 40 kg in this case. In other
words the angular acceleration force given by equation (7.8) will typically be much
smaller than the linear acceleration force given by equation (7.4). In this specic (but
reasonably typical) case, it will be smaller by the ratio:
40
= .05 = 5%
800
It will quite often turn out that the moment of inertia of the motor J will not be
known. In such cases a reasonable approximation is to simply increase the mass by
5% in equation (7.4), and to ignore the Fa term.
37
3.2.5
(3.10)
Where,
Frris the rolling resistance force, given by equation (3.1);
Fadis the aerodynamic drag, given by equation (3.2);
Fhcis the hill climbing force, given by equation (3.3);
Flais the force required to give linear acceleration given by equation (3.4);
Fa is the force required to give angular acceleration to the rotating motor,
given by equation (3.9).
We should note that Fla and Fa will be negative if the vehicle is slowing down, and
that Fhc will be negative if it is going downhill.
3.3 MODELLING VEHICLE ACCELERATION
3.3.1
38
of motor, the torque falls in such a way that the power remains constant. The angular
velocity of the motor depends on the gear ratio G and the radius of the drive wheel r
as in equation (3.5) derived above. So we can say that:
For, m< base ; Tm = Tmax = 97.5 N.m
(3.11)
= T0 KG
(3.12)
Where,
vech = angular velocity of the velocity (i.e. angular velocity of the axle) (rad/sec)
m = angular velocity of the motor (rad/sec)
Eq. (3.11) represents motor torque in terms of angular velocity of the vehicle where
as Eq. (3.12) represents it in terms of linear velocity of the vehicle.
3.3.2
Tm = KTIa =
K T V
RT
m = 2vech = 2
Tm = KTIa =
K T V
RT
KT KB 2
v
RT
2K T K B 2
RT r
= 65015.384
At base speed, m = base;
= = 97.5 = 65015.384
551.33
15.984
= 35.84 rad/sec
(3.13)
(3.14)
(3.15)
(3.16)
(3.17)
(3.18)
39
3.3.3
Total tractive force required for the vehicle movement when it is moving in a road in
a smooth flat plane,
Fte= Frr+ Fad+ Fla+ Fa
as per Eq. (3.10). Hill climbing force can be considered zero because of assuming
zero inclination.
dv
(3.19)
Here the moment of inertia of the motor is not known, so we will adopt the expedient
suggested at the end of Section 7.2.5, and increase m by 5% in the linear acceleration
term only.
Torque required for the traction,
Tte = Fte x r
(3.20)
The motor is coupled with the axle through a gear. If G is the gear ratio, then the total
load torque for traction referred to motor shaft can be written asTm = Motor Torque =
T te
F te r
G
= [ + + 0.5 2 ]
where, = =
= [
+ + 0.0625 2 2 ]
(3.21)
(3.22)
= vehicle velocity
Let us put all the values in Eq. (3.22) to obtain a equation that will describe the
dynamics of traction load;
The electric vehicle has a mass of 380 kg, with a typical passenger of mass 180
kg (for 3 passengers with average mass of 60kg) so total mass m = (180+200)
= 380 kg.
To incorporate the angular acceleration of different rotating parts of the vehicle
along with motor, m is increased by 5% in the linear acceleration term only.
A value of 400 kg will thus be used from m in the final term of equation
(3.19).
40
Figure 3.3: The simplified diagram of the designed system of connecting the motor
with the driving axle of the vehicle with a geared mechanism.
41
Putting all the values in Eq. (3.22) the final equation can be obtained as = 9
+ 2.95 + 0.00075 2
(3.23)
= 60 + 2.95 + 0.03321 2
(3.24)
+ 0.0005535 2
= 1.576 0.0005535 2
(3.25)
When m base; i.e. v 5.376, motor torque is given by Eq. (3.16). Based
on that, Eq. (3.24) can be written as-
Tm = 65015.384m
= 65015.384
0.3
(3.26)
The total vehicle traction acceleration and final speed can be modeled using Eq.
(3.25) and Eq. (3.26). There are many practical and simple ways of solving these
differential equations using a simple initial condition that v = 0 when t = 0.
However, the most versatile next step is to derive a simple numerical solution, which
can then easily be used in MATLAB.
The derivative of v is simply the difference between consecutive values of v divided
by the time step. Applying this to equation (3.25) gives us:
+1
=
= 1.576 0.0005535 2
+1 = + t (1.576 0.0005535 2 )
(3.27)
42
(3.28)
Eq. (3.27) holds valid for velocities up to the critical velocity of 5.376 ms1, after
which we have to use equation (3.28), approximated in exactly the same way as we
have done for equation (3.27).
The MATLAB script le (discussed in Appendix-A) shows how to solve these
equations using this program. Figure 3.4 is a plot of the solution using a time step t
of 0.1s.
Figure 3.4: The initial acceleration and final velocity of the vehicle.
From the figure it is clearly evident that the vehicle takes just over 5 seconds to reach
its maximum speed of 22.5kmph. At this point the motor will rotate at a speed of
41.667 rad/sec which is very close to its rated speed (38.46 rad/sec).
43
Figure 3.5: The torque-velocity curve of the motor and vehicle respectively.
The maximum amount of torque obtained from the motor is around 95 N.m. This
torque is responsible to accelerate the vehicle. This maximum torque of 95 N.m is
maintained up to the base speed of the motor which corresponds to the vehicle speed
of (5.376 x 3.6) = 19.3536kmph. After that, the torque begins to fall and eventually
settles down to the balancing speed of the motor. At final or balancing speed, the
torque falls very sharply as the acceleration phase is over and it requires only to
overcome the rolling resistance and aerodynamic resistance of the vehicle when
speed becomes constant (as Fla becomes zero at constant speed due to zero
acceleration).
The total torque profile of the vehicle from zero to final speed can be visualized as
shown in Figure 3.6-
Figure 3.6: The torque profile of the load as seen from the motor shaft.
44
The constant torque region provides the maximum torque which in turn provides a
linear constant acceleration up to base speed that is 19.35kmph speed of the vehicle.
After that, the torque falls naturally as it enters to the natural characteristic region of
its operation. Finally the motor torque matches with the load torque which falls
significantly and continues to operate at this value.
The axle torque i.e. the vehicle torque with respect to vehicle speed and time are
shown in Figure (3.7) and Figure (3.8) respectively. It may be noted here that, the
axle torque will be around 2 times greater than motor torque due to the presence of a
step up gear. At the same time, considering an efficiency of 98% for the gear
arrangement, the actual torque will be .98 times of it.
Figure 3.7: Axle Torque of the vehicle with respect to its speed. It is exactly in the
same nature of the motor-vehicle speed curve of Fig. (3.5).
45
Figure 3.8: Axle torque profile though out the entire time of run of the vehicle
Axle Torque of the vehicle with respect time to show the maximum starting torque
along with final steady state torque value of the vehicle. As the acceleration phase is
over around 7.5 seconds, the torque falls significantly and settles to a new lower
value where it remains constant for the rest of the period of it operation.
The final parameter of the motor to be discussed and analyzed is motor current. As
the current is proportional to motor torque, it will vary itself according to the
variation of torque during different periods of its operation.
The current-vehicle speed and current-time curves are shown in Figure (3.9) and
Figure (3.10) respectively.
46
Figure 3.9: Armature current of the motor with respect to time. The current taken by
the motor is very small during steady-state operation.
47
Tm = KTshIa =
K T sh V
RT
= 195.0139.2333v
K T K B sh 2
RT
= 195.0131.385
(3.29)
Now, in the similar way of Eq.(3.25), we can develop another equation using Eq.
(3.29). It must be noted that, this Eq. (3.29) will be coming into the consideration
when the vehicle speed is equal to its final speed that is 22.5kmph i.e. 6.25m/s.
When, 41.667 rad/sec (i.e. vehicle speed, v6.25m/s);
(3.30)
(3.31)
( + 1) = 2.95 + 60
+ 0.03321 2
(3.31)
Axle or the vehicle torque for traction can be calculated as ( + 1) = 5.9 + 120
+1
+ 0.06642 2
(3.32)
0.24+0.1138 (+1)0.4875
0.057
(+1)
0.4875
(3.33)
(3.34)
So, the modified MATLAB script file (shown in Appendix-B) according to the
modification done in the system due to winding changeover would yield the
following set of output curves for speed, torque and current. This set of results will
be used to compare the performance between the vehicle fitted with winding change
over facility and the vehicles operated with series and compound motor only without
winding change over facility. The different output and input parameters of the motor
as well as the vehicle obtained by simulation in MATLAB are shown as follows one
by one along with description and significance of the figures for interpretation.
49
Figure 3.10: Simulated Speed and acceleration characteristic of the vehicle with the
feature of winding change over facility.
A comparative diagram showing the speed without and with the winding change over
facility would be more helpful to justify the improvement in the performances of
vehicle. A diagram of such kind is shown in Figure 3.11 in the following-
Figure 3.11: Comparative analysis showing the differences in terms of final speed
between the two types of motor.
50
Fig. (3.11) clearly indicates that, the motor with winding change over facility would
provide the highest final speed. The difference in their final is around 47.5kmph.
This is certainly being a great advantage for the latter one compare to the former one.
Figure 3.11: Torque speed characteristic of the motor with winding change over
facility. The sharp rise in torque is due to sudden change in current consumed by the
armature due to disconnecting the series field.
The total torque profile of the motor is shown in Figure 3.12.
Figure 3.12: Torque profile of the motor during entire period of its operation.
51
Figure 3.14: Torque profile of the vehicle from starting to winding change over to
steady state condition, when operated by a compound motor with winding change
over facility.
52
Figure 3.15: Speed-current characteristic of the motor. After winding change over,
the value of the current remains very during the entire period of its acceleration.
Figure 3.16: Current profile of the motor during its entire period of operation.
A very high current is being consumed by the current at the moment of winding
change over. This is due to the sudden reduction in the flux of the motor as the series
winding is disconnected from the armature at this instant. To sustain the same
amount of torque, the current of the motor rises to a very high value due to
compensate the reduction of flux. As the motor speed approaches towards its final
speed, the current starts to decrease and eventually settles down to a steady value. It
53
must be noted with great importance that, such amount of high current must not be
allowed to flow in the circuit as it may damage the winding as well as the motor. In
practice this current will be limited by using a hysteresis current controller which will
restrict the current within twice the maximum of its rated value (i.e. 40x2=80A). In
other words, the controller will allow a current to flow through the armature which
may be at best twice than its rated value. Such a limitation will obviously affect the
performance of the motor. Due to such restriction in current the torque produced by
the motor will be less and as result the acceleration of the vehicle beyond the instant
of winding change over will be reduced. But this will not affect the final speed of the
motor. Due to limited amount of torque available, the vehicle will take a relatively
long time to reach its final speed.
3.6 SUMMERY
This chapter deals with the modeling and simulation of electric vehicle. It is obvious
that, a vehicles mathematical model is crucially important in the design of electric
vehicles as it allows the designer very quickly to try out different design options,
virtually at no cost at all. Even a quite simple mathematical model used in this
chapter is sufficient to predict the performance parameters of a real vehicle.
54
CHAPTER 4
DESIGN OF CONVERTER AND CONTROLLER FOR
ELECTRIC VEHICLE
4.1 INTRODUCTION
This chapter presents the design of the controller of the motor. Choppers, also
commonly known as dc-to-dc converters which are used to get a variable dc voltage
from a dc source of fixed voltage. Because of the use DC voltage widely in electric
transportation and traction system, chopper controlled DC drives find a ready
application in that field.
DC-DC Converters are widely used for traction motor controls in electric
automobiles, trolley cars, marine hoists, forklift trucks and mine haulers. They
provide smooth acceleration control, high efficiency and fast dynamic response. DCDC converters can be effectively used in regenerative braking of DC motors to return
energy back into the supply and this feature results in energy savings for the
transportation systems with frequent stops.
Self commutated devices, such as MOSFETS. power transistors, IGBT (insulated
gate bipolar transistor), GTO ( gate turn-off thyristor) and IGCT (insulated gate
commutated thyristor). are preferred over thyristors for building choppers because
they can be commutated by a low power control signal and do not need commutation
circuit. Further, they can be operated at a higher frequency for the same rating. The
operation at a high frequency improves motor performance by reducing current ripple
and eliminating discontinuous conduction.
For any traction application a two quadrant converter with a pair of reversing switch
is necessary. Otherwise it is not possible for the motor to operate at all four quadrants
as it is mandatory for any motor to be capable of operating in all the four quadrants
employed for traction application.
55
In this design a Two Quadrant Class C DC-DC converter along with a pair of
reversing switch are used. The converter has a novel integrated feature of both PWM
and Hysteresis controller, where the PWM controller is used for variable voltage
operation of the motor (to run the vehicle at different speed) and hysteresis controller
is used for the purpose of current control. The designed system is shown in brief in
the following block diagram-
A typical class C converter is made of one pair of diode and one pair of switch.
Generally, it is made from one buck and one boost converter. For normal motoring
mode the circuit operates as buck controller. During braking of the motor which is
also known as regenerative braking, the converter operates as a boost converter to
feed back the stored kinetic energy of the motor to the source and thus reducing its
speed. A typical circuit is shown in Fig. 4.2.
56
57
The converter circuit is simulated in LTSpice in motoring mode. The output wave
shape of the converter are shown in the following-
58
Figure 4.4: Output current, voltage and PWM signal of the converter
59
60
The variable output voltage can be obtained by varying the duty cycle of the
converter. Variation of duty cycle is possible by varying the reference voltage of the
PWM comparator. Gate driving pulses with variable duty cycle are generated to
operate the motor in different speed. This signal along with the output of the
hysteresis controller are fed to an AND gate where the output of hysteresis controller
dominates over the PWM signal. If the Current of the motor at any point due to
application of the voltage exceeds the certain limit the output of the hysteresis
controller goes zero setting an output zero for and gate too and eventually turns of the
power supply to the motor.
Regenerative braking will be obtained as the converter operates in the 2nd quadrant.
Gate signal with appropriate duty cycle must be generated to provide the switching.
The circuit must contain a duty cycle varying feature where the duty cycle of the
gating pulses will be varied by sensing the terminal voltage of the motor during
regenerative braking. The duty cycle must be varied to keep the output voltage of the
converter fixed as the voltage of the motor will be gradually decreasing during the
period of regeneration and as a result the speed of the motor will be decreasing. If the
voltage at the output of the converter is not kept fixed and higher than the source
voltage, it will not be possible to feed the energy back to the source as current will
stop continuing to flow.
Simulation of regenerative braking is done assuming the stored kinetic energy will
eventually be given up and the motor will to come to a stop with no voltage across its
terminal. So, source voltage must be gradually decreasing during braking and to keep
the output voltage constant, the reference voltage of the comparator should be
increased accordingly to increase the duty cycle of gate driving signal. The simulated
circuit is shown in Figure 4.8.
61
62
Figure 4.9: Output Voltage and Current of the Boost converter during Braking
Figure 4.10: Generation of Reference signal to vary the duty cycle of the converter
63
Figure 4.11: Boost Converter Input Power due to the kinetic energy stored in the
vehicle
Figure 4.12: Boost Converter Output Power. The amount of energy which is equal to
the area under the curve, is feed back to the source
64
4.5 SUMMARY
This chapter has suggested such a design of the converter that is capable of varying
its output voltage and at the same time limits the excess current. The two quadrant
operation of the motor enables the motor to operate at both Forward motoring and
Forward regenerative braking. For reverse motoring reverse contacts are employed to
operate the motor in opposite direction.
65
CHAPTER 5
SIMULATION OF THE OVERALL SYSTEM
5.1
INTRODUCTION
5.2
SIMULATION RESULTS
All three sub systems are integrated and co-ordinated together to perform the
simulation work. The entire simulation is done for a 60 seconds run of the vehicle.
The simulated block in SIMULINK is shown in Figure.5.1.
66
67
Figure 5.2: Speed of the vehicle with winding change over technique.
69
Now for the purpose of comparison the simulated results for a series motor driven
electric vehicle with same characteristics as before will be presented in the following.
70
5.3
SUMMERY
Simulation of the overall system clearly signifies the fact that, the proposed method
of winding change over feature can improve the performance of an electric vehicle
when operated with a DC motor. The conventional traction loads are operated with
DC series motor. Final Speed obtained for the vehicle with the proposed system is
around 72kmph whereas, with conventional DC series motor, the obtained maximum
speed is 54kmph. But one thing that also should be focused here that, as the proposed
method is operating at a speed 18kmph higher than the conventional method energy
consumed by the motor will be more as the resistance force due to aerodynamic drag
offered by vehicle increases with the square of the velocity and hence power required
increases with the cube of the velocity.
71
CHAPTER 6
CONCLUSION
7.1
SUMMARY
A Novel Switching technique along with a new concept is proposed for the purpose
of traction. The ideal characteristics
of an electric motor
drive for
traction
application in an electric and hybrid electric vehicle are high torque at low speed
region for fast acceleration, hill climbing and obstacle negotiation, and low
torque at high speed for normal driving. A single DC motor cannot fulfill all these
ideal requirements. But according to the proposed method of using a compound
motor with winding change over, the characteristics will be very close to the ideal
one. To minimize the power rating of the motor drive, therefore, the energy
storage requirement, at a given vehicle performance, the electric motor drive is
required to have a long constant power range to meet the torque and speed
demand.
Once again this proposed method enables the motor to maximize its
capability by prolonging its constant power. The effect of the motor characteristics
on the vehicle performance is analyzed, and the characteristics of three major
electric motors- induction motor, permanent magnet brushless DC motor and
switched reluctance motor are studied for literature review, where it has been
concluded that, though DC machines are now almost become obsolete, still it has the
maximum torque density and the most suitable characteristics for traction
application. This technique can further enhance that capability of the DC motor for
traction application as the result suggests an improvement in its performance
compare to the traditional one. Results show a better acceleration performance and
significant improvement in final speed of the vehicle. This technique minimizes the
power rating of the motor as it is operating at a longer constant power range due to
change over in its configurations. The high torque operation of the compound and
series configuration is utilized as well as the field long constant power range
operation of shunt configuration by field weakening is also being made use of. The
simulation results show that, the extended speed operation of the motor can reach up
72
to 3.5 times of the base speed which can never be obtained without the feature of
winding change over. At the same time it is also evident that, this method will
consume more power to run the vehicle and it is obvious that, the power consumption
will be more for higher speed of operation.
As stated earlier, the proposed method demands a relatively larger amount of power,
the most important task still left is to calculate the energy consumption of the vehicle
for per Kilometer of operation. This would provide the final concluding remark of
this study.
From this the Mileage of the vehicle for a given battery capacity can be very easily
determined which has not been done yet. At the same time for nominal operation of
the vehicle, the battery size and its capacity has to be determined.
Comparative study with other types motor can be done and then the motor with
optimum performance for traction application can be chosen.
Microcontroller can be used as the prime controller of the entire system which should
perform all the necessary control action and this would make the system more
optimum, flexible and adaptable to any operating condition.
Advanced algorithms like Fuzzy logic or Neuro-Fuzzy controller may be introduced
for system operation. These adaptive advanced algorithms may also be used to
replace the brushed DC motor by a Brushless DC motor which would be more
advanced and efficient compare to the conventional one.
Long constant power range of vehicle traction motor can effectively reduce
the required motor power rating for the given vehicle acceleration performance
and
at
the
same time,
the gradeability
of the vehicle
can he
enhanced
73
74
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[2]
Y. Wong, Theory of Ground Vehicle, John Wiley & Son, Inc., 1978. Page
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A.R. Prasad, P.D. Ziagos & S. Manias, An Active Power Factor Correction
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K.D. Purton & R.P. Lisner, Average Current Mode Control in Power
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the Inpur Current Distortion of a Three-Phase Discontinuous Mode Boost
Rectifier system, Conference Record, IEEE PESC, pp:696-703,1993.
[31]
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E.H. Ismail & R. Erickson, A New Class of Low Cost Three-Phase High
Quality Rectifiers with Zero Voltage Switching, IEEE Trans. on Power
Electronics, vol.12no.4, July1997.
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77
Appendix-A
MATLAB SCRIPT FILE FOR SIMULATING VEHICLE PERFORMANCE
PARAMETERS WITHOUT WINDING CHANGE OVER TECHNIQUE
t=linspace(0,100,1001);
vel=zeros(1,1001);
d=zeros(1,1001);
T=zeros(1,1001);
Tv=zeros(1,1001);
I=zeros(1,1001);
dT=0.1;
for n=1:1000
if vel(n)<5.376
vel(n+1)=vel(n)+dT*(1.51-(0.000527*(vel(n)^2)));
elseif vel(n)>=5.376
vel(n+1)=vel(n)+dT*(10.271-(1.628*vel(n))(0.000527*(vel(n)^2)));
end
d(n+1)=d(n)+0.1*vel(n);
T(n+1)=2.95+(60*((vel(n+1)-vel(n))/dT))+(0.03321*(vel(n)^2));
Tv(n+1)=2*T(n+1);
end
for n=1:1000
I(n+1)=((sqrt(0.24+(0.1138*T(n+1))))-.4875)/0.057;
end
vel=vel.*3.6;
figure(1)
plot(t(1:1001),vel);
axis([0 50 0 30]);
xlabel('Time/seconds');
ylabel('velocity/kph');
title('full power Acceleration');
hold
figure(2)
plot (vel,T);
hold
figure(3)
plot(t(1:1001),T);
figure(4)
plot(vel,I);
figure(5)
plot(t(1:1001),I);
figure(6)
plot (vel,Tv);
hold
figure(7)
plot(t(1:1001),Tv);
*************************************
78
Appendix-B
MATLAB SCRIPT FILE FOR SIMULATING VEHICLE PERFORMANCE
PARAMETERS WITH WINDING CHANGE OVER TECHNIQUE
t=linspace(0,100,1001);
vel=zeros(1,1001);
d=zeros(1,1001);
T=zeros(1,1001);
Tv=zeros(1,1001);
I=zeros(1,1001);
dT=0.1;
for n=1:1000
if vel(n)<5.376
vel(n+1)=vel(n)+dT*(1.51-(0.000527*(vel(n)^2)));
elseif vel(n)>=5.376 && vel(n)<6.25
vel(n+1)=vel(n)+dT*(10.271-(1.628*vel(n))(0.000527*(vel(n)^2)));
elseif vel(n)>=6.25
vel(n+1)=vel(n)+dT*(3.0486-(0.1465*vel(n))(0.000527*(vel(n)^2)));
end
d(n+1)=d(n)+0.1*vel(n);
T(n+1)=2.95+(60*((vel(n+1)-vel(n))/dT))+(0.03321*(vel(n)^2));
Tv(n+1)=2*T(n+1);
end
for n=1:1000
if vel(n)<6.25
I(n+1)=((sqrt(0.24+(0.1138*T(n+1))))-.4875)/0.057;
elseif vel(n)>=6.25
I(n+1)=T(n+1)/.4875;
end
end
vel=vel.*3.6;
figure(1)
plot(t(1:1001),vel);
axis([0 50 0 30]);
xlabel('Time/seconds');
ylabel('velocity/kph');
title('full power Acceleration');
hold
figure(2)
plot (vel,T);
hold
figure(3)
plot(t(1:1001),T);
figure(4)
plot(vel,I);
figure(5)
plot(t(1:1001),I);
figure(6)
plot (vel,Tv);
hold
figure(7)
plot(t(1:1001),Tv);
79