Design and Emulation of Electric Vehicle Permanent Magnet Machines

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Power hardware-in-the-loop (PHIL) based electric machine emulation is increasingly being recognized as an effective approach for simplifying the testing of electric drive systems. In machine emulation, a power electronic converter emulates the behavior of an electric machine. Currently, for real-time PHIL emulation of electric machines, simplified machine models are used that do not include machine faults or thermal behavior. In addition, the demands on the main traction motor are increasing as performance requirements improve. Thus, additional work is needed to improve motor designs, as well as thermal modeling and to allow operation during extreme transients and faulted conditions. These issues are becoming increasingly important in the industry. In addition, it is very difficult to test real machines under faulted conditions. This project aims to develop improved designs and advanced machine models including thermal performance for permanent magnet synchronous machines (PMSM) for the purpose of meeting the industrial demands and real-time PHIL emulation. For example, the use of new and better materials to improve thermal performance can be analyzed mathematically and emulated even before the machine is built. These designs and models will be used in an emulator setup and the results obtained will be validated using results from dynamometer testing of physical machines. As a real-time simulator hardware and software manufacturer, Opal-RT will directly benefit from this since it will allow them to provide their customers with better and more technically competitive simulator solutions and attract more customers from around the world. Dana TM4 will benefit from the improved designs and be using the emulator system for comprehensive, rapid, inexpensive and safe testing of their drive systems. This reduces the overall cost and time to market of their drive products. Canada will benefit from the increased sales by the industrial partners and from the local expertise creating additional job opportunities.