Design and Voltage Limit Characteristics of 150kW Class Traction IPMSM

Abstract

As the demand and use of fossil fuel has been rapidly increased, many studies on the interior permanent magnet synchronous motors (IPMSM) have been recently conducted in a government and enterprise level. As a key driving source of the echo-friendly vehicles, such as electric vehicles and hybrid electric vehicles, IPMSMs are to be installed in substitutive transportations as a response to mounting air pollution and exhaust of resources. In this flow, the interior permanent magnet synchronous motors (IPMSM) are appropriate to be used as the key driving sources of the shuttle bus for transporting in short-distance and the commercial trucks due to its high torque, high power, and the wide range of driving, however the high current and the low voltage should be guaranteed due to the availability of inverters and the limit of battery voltage. Therefore, on designing, there are numerous difficulties in designating the voltage limits according to the induced voltage when controlling, the saturation of the electrical steel, and the features of the reverse salient pole that the interior permanent magnet synchronous motors (IPMSM) have. In this paper, as deciding the design direction of the interior permanent magnet synchronous motors (IPMSM) with 150kw capacity which is to mounted on the shuttle bus and the 3.5ton commercial truck, the design directions have been established so that the voltage the fundamental wave of Line Induced Voltage Limit without the harmonics and the limit meet the standard of the constraints of the controller. Also, bridges have been added into rotors to meet the voltage limits at the maximum speed and to enhance the mechanical strength that could not be satisfied in the basic model, and the procedures to find the detail direction of designing by comprising Ld, Lq 3D-Map through the torque equations of IPMSM for conducting the detail designing have been proposed. Also, the process of attaining the final model by analyzing the tendency of the line voltage limits and torque through sensitivity analysis according to each shape parameter has been included. Finally, when designating the initial voltage limits, it was difficult to estimate the possibility of actual operation, because of the little margin of designing due to the constraints of the controller. Therefore, to check the features of motor operation on controlling the switching frequency of PWM and d.q current with a real controller, the Finite Element Analysis (FEA) and control simulation’s co-analysis has been proposed and analyzed with comparison. Also, on designing the voltage limits at maximum speed in designing IPMSM electric motors, the standards have been established