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8, AUGUST 2021
Abstract—In this article, a variable-saliency-ratio perma- Currently, a type of interior permanent magnet brushless mo-
nent magnet motor is designed and optimized considering tor, where the saliency ratio ρ is larger than 1 (ρ = Lq /Ld > 1),
driving cycles. To satisfy the demands of multi-operation has been successfully applied to Toyota Prius [3]. To widen
conditions of EVs, a variable resistance is adopted and a
new variable-saliency-ratio design concept is proposed to motor speed range, the terminal voltage of dc bus of the motor
enhance output torque, widen speed range and lower irre- is boosted from 270 to 500 V, and even more than 630 V in the
versible demagnetization risk effectively. A multiobjective new generation of Prius IV. Moreover, since the large saliency
optimization considering driving cycles is proposed, where ratio ρ is employed, the resulting high reluctance torque is
the design objective of saliency ratio is firstly selected and
conducive to meeting the load capacity under high speed cruise
optimized with multiobjective genetic algorithm method.
Then, the operation performances of the motor in different condition. In addition, a 125 kW interior permanent magnet
operation conditions are investigated in detail. Finally, a motor with 72-slot/12-pole has also been successfully commer-
prototype motor is built and tested. Both the simulation cialized in the drive motor of BMW [4]. Since the topology of
and experimental results verify the validity of the proposed double-I permanent magnets and multilayer magnetic barriers
method.
are adopted, the difference between d-axis inductance and q-axis
Index Terms—Permanent magnet motor, multiple driving inductance is further increased, and the output torque capability
cycles, multiobjective optimization, variable-saliency-ratio.
and speed range are improved under the flux-weakening region.
And yet, limited by vehicle battery capacity and voltage level,
I. INTRODUCTION the online regulation of motor terminal voltage has a relatively
ITH increasingly complicated driving environments, the limited for widening the speed range. Besides, the excessive
W actual vehicle driving cycles are becoming diverse and
compound, where frequent start/stop, frequent acceleration or
terminal voltages would also increase insulation costs and safety
levels. On the other hand, to obtain high reluctance torque,
deceleration, climbing with heavy load, and high-speed cruise large negative flux-weakening current id is often required to
are involved [1]. To meet such diverse driving cycles, the ad- pass through multiple magnetic barriers, which may reduce the
vanced drive qualities of high power density, high efficiency efficiency especially in the flux-weakening control region.
over wide speed range and high reliability are often required In recent years, hybrid-excitation motors are proposed and
to achieve during the design and control of the electrical ve- investigated, in which the additional field windings serving as the
hicle (EV) motors. Hence, how to satisfy such critical design auxiliary excitation source are added to regulate the permanent
requirements under the complicated operation conditions has magnet (PM) flux flexibly [5]. By controlling the polarity and
becomes a hot issue in the research area of EV motors [2]. amplitude of the field current, the corresponding speed range
can be widened obviously [6], [7]. However, the excessive
Manuscript received February 1, 2020; revised April 30, 2020 and electric density and the resulting extra heat put forward stringent
May 28, 2020; accepted June 15, 2020. Date of publication July 10, demands for the cooling system of the type of motors, and
2020; date of current version April 27, 2021. This work was supported in
part by the National Natural Science Foundation of China under Grants
the additional copper loss may cause the efficiency reduction
51877099, 51937006, and 51991385, and in part by the Priority Aca- inevitably. To further widen the speed range and improve the
demic Program Development of Jiangsu Higher Education Institutions. efficiency, a type of memory motor equipped with low coercive
(Corresponding author: Xiaoyong Zhu.)
Xue Zhou, Xiaoyong Zhu, Zixuan Xiang, Yongfeng Liu, and Li
force PMs has attracted considerable attention [8], [9], where
Quan are with the School of Electrical and Information Engineering, the different magnetization of PMs can be online tunable by
Jiangsu University, Zhenjiang 212013, China. (e-mail: zx2543582320@ only injecting a d-axis current pulse temporarily. And yet, the
163.com; zxyff@ujs.edu.cn; zxxiang@ujs.edu.cn; 2211807005@stmail.
ujs.edu.cn; quanli@ujs.edu.cn).
additional magnetization windings will occupy the limited inner
Wenye Wu is with the School of Automotive Engineering, room of the motor and the corresponding control system need
Changshu Institute of Technology, Suzhou 215000, China. (e-mail: the extra control and drive circuits, thus inevitably increasing
wwyzhshsh0308@163.com).
Color versions of one or more of the figures in this article are available
the cost and reducing motor reliability.
online at https://ieeexplore.ieee.org. To alleviate the complexity of motor structure, a new type of
Digital Object Identifier 10.1109/TIE.2020.3007106 flux-intensifying motor is presented in [10] and [11], in which
0278-0046 © 2020 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See https://www.ieee.org/publications/rights/index.html for more information.
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ZHOU et al.: MULTI-OBJECTIVE OPTIMIZATION DESIGN OF VSR-PM MOTOR CONSIDERING DRIVING CYCLES 6517
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6518 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 68, NO. 8, AUGUST 2021
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ZHOU et al.: MULTI-OBJECTIVE OPTIMIZATION DESIGN OF VSR-PM MOTOR CONSIDERING DRIVING CYCLES 6519
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6520 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 68, NO. 8, AUGUST 2021
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ZHOU et al.: MULTI-OBJECTIVE OPTIMIZATION DESIGN OF VSR-PM MOTOR CONSIDERING DRIVING CYCLES 6521
TABLE II
KEY PARAMETERS OF THE VARIABLE SALIENCY RATIO PM MOTOR
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6522 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 68, NO. 8, AUGUST 2021
TABLE IV
OPTIMAL RESULTS UNDER DIFFERENT TYPICAL OPERATION REGIONS
where Pcore is core loss, Pcore_l and Pcore˙u denote the lower
and upper limiting values of core loss, respectively. The values
of Pcore˙l , Pcore˙u and n as design examples are given as 5 W,
40 W, and 3000 r/min, respectively.
Similarly, according to the objective function and constraints
in (9), the Pareto front of the MOGA under III-region is shown
in Fig. 9(b).
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ZHOU et al.: MULTI-OBJECTIVE OPTIMIZATION DESIGN OF VSR-PM MOTOR CONSIDERING DRIVING CYCLES 6523
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6524 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 68, NO. 8, AUGUST 2021
where la is stack length, R1 and R2 are armature outer radius and Fig. 20. Measured waveforms. (a) I-region and II-region. (b) III-region.
stator yoke inner radius, respectively. j is an integer that makes
jz/2p an integer.
from the manufacturer of Mitsubishi Electric, where the specific
type is PM300RL1A060.
V. EXPERIMENT VALIDATION Some fundamental experiments of the VSR-PM motor are
In order to validate the theoretical analysis, the VSR-PM mo- carried out. First, Fig. 19 shows the measured three-phase
tor is manufactured according to the optimization results. Fig. 18 no-load back EMF waveforms at rated speed of 1200 r/min.
shows the corresponding silicon steel sheet, the assembled motor It can be observed that the variation trends of measured back
and experimental platform. A high-performance driving con- EMF waveforms are in agreement with the simulation result
troller of dSPACE 1103 is employed to control the armature cur- aforementioned in Fig. 11, which exhibits the characteristics of
rent. Besides, an 8-kVA three-phase full-bridge voltage-source sinusoid and symmetry.
inverter is used to power and control the VSR-PM motor in the In addition, the driving characteristics under the regions of
experimental part. It is noted that the inverter capacity is selected I, II, and III are tested for the VSR-PM motor, where the
relatively large to meet the various test demands, considering dc-bus voltage is selected as 250 V based on the experimental
that the test platform is general for measuring various prototype requirements. Then, the measured waveforms under I-region and
motors. Actually, the inverter is designed and assembled by II-region are depicted in Fig. 20(a). It can be observed that, as
ourselves. For instance, intelligent power module is purchased example, when the load change from 8 to 16 N·m and back to
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ZHOU et al.: MULTI-OBJECTIVE OPTIMIZATION DESIGN OF VSR-PM MOTOR CONSIDERING DRIVING CYCLES 6525
Fig. 21. Continuous variable load of the proposed motor. (a) I-region
and II-region. (b) III-region.
VI. CONCLUSION
In this article, to satisfy the diverse requirements of elec-
tric vehicles under various operation conditions and driving
cycles, a new VSR-PM motor was proposed and investigated.
By adopting the PGO and MOGA method in the selection of
Fig. 22. Steady torque and current waveforms of the proposed motor.
representative operation points and multiobjective optimization,
(a) id = 0 method. (b) MTPA method with positive id . respectively, the motor was successfully designed, simulated,
optimized, and experimentally verified. Under climbing with
heavy load and frequent start/stop, through the optimization,
12 N·m under the operation conditions of climbing, frequent the saliency ratio and torque ripple were reduced by 1.37% and
acceleration or deacceleration, the current of armature winding 33.5%, respectively, while the output torque is raised by 7.84%;
responds swiftly, and the speed of the motor can maintain Under the high-speed cruise, by optimizing, the saliency ratio
a nearly constant speed with small fluctuation. Similarly, the and output torque are grown by 0.88% and 3.6%, respectively,
measured waveforms of III-region under high-speed cruise are and the core loss dropped by 42.6%. Therefore, the validity
investigated in Fig. 20(b). From Fig. 20(b), the speed response of the new VSR-PM motor for the multicondition driving field
exhibits a better characteristic when the given speed is changed was verified and a new perspective to motor design considering
from 1000 to 2000 r/min and back to 1500 r/min, which evi- driving cycles was provided. Also, the proposed optimization
dent that a better speed closed-loop control and rapid dynamic design method can improve the driving performances under
response capability of control system can be realized. different operation conditions.
Fig. 21 shows the continuous variable-load waveforms of
the proposed motor under different operation conditions. From
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