Design and development of a novel test cell for low-voltage, high-speed interior permanent magnet synchronous machines

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Conventional internal combustion engine (ICE) based vehicles suffer from high emissions and high fuel consumption, especially during cold cranking and acceleration in frequent start-stop cycles. The integrated starter alternator (ISA) maintains the functions of the conventional starter and generator in an ICE vehicle, and provides a smooth start to the stopped engine. In this proposed project, a unique test cell will be designed and developed with our industry partner, D&V Electronics, to test and evaluate low-voltage, high-speed interior permanent magnet synchronous machines (IPMSM) for belt driven ISA applications. Considering the available voltage with the use of low-voltage batteries and the conversion ratio of the belt between the engine and ISA, the IPMSM under test will operate with a terminal voltage of up to 60V and generate within an extended speed range of up to 20,000 rpm. The test cell will incorporate all the hardware and software required to provide for the interconnection, operation, and evaluation of the machine being tested. Special attention will be given to investigating the technical issues and developing the proper controller for stable operation of IPMSM in torque control mode during cranking and flux weakening mode at high speeds under low terminal voltage. Moreover, the inverter, which will operate in high current conditions due to the low terminal voltage constraint, will be designed with proper thermal management and packaging to achieve high power density. Different aspects of the design and implementation of the challenging low-voltage, high-speed IPMSM drive will be covered in this proposed project. Therefore, significant knowledge and hands-on experience will be created both for our university research group and our industry partner. The expertise developed by the trained HQP will be significantly valuable to the industry for not only developing ISA for electrified powertrain applications, but also for developing the next generation of electrified vehicle architectures, such as hybrid electric and battery electric vehicles.