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6516 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 68, NO.

8, AUGUST 2021

Multi-objective Optimization Design of


Variable-Saliency-Ratio PM Motor
Considering Driving Cycles
Xue Zhou , Xiaoyong Zhu , Member, IEEE, Wenye Wu , Zixuan Xiang , Yongfeng Liu , and Li Quan

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

the magnetic reluctance barriers along q-axis magnetic field are


purposely added and the magnetic bridges in d-axis magnetic
field are enhanced to realize the characteristic of the saliency
ratio less than 1 (ρ = Lq /Ld < 1), and thus obtaining the ad-
vantages of a low irreversible demagnetization risk and wide
speed range. Yet, the capacity of output torque in high-speed
region is still limited to some extent since the low utilization
of reluctance torque. In general, current researches on drive
motors often focus on satisfying the high efficiency or power
density under single operation condition (normally under the
rated-condition), rather than the diverse requirements under the
Fig. 1. Relationships among standard road conditions, driving cycles
multiple operation conditions. Hence, how to fully meet the high of EVs, and design requirements of motors.
torque capability, wide speed range and high efficiency under
multiple operating conditions and diverse driving cycles is still
a huge challenge.
In this article, by incorporating the new design concept of
the variable-saliency-ratio into a permanent magnet brushless
motor, a new variable-saliency-ratio permanent magnet (VSR-
PM) motor is proposed to satisfy the diverse requirements of
electric vehicles under various operation conditions and driving
cycles. The key new characteristics of the proposed motor are
described that, during the low-speed heavy-load region, the Fig. 2. PM motor design according to the operation requirements.
value of d-axis inductance Ld is larger than q-axis inductance (a) Based on rated operation condition. (b) Based on multiple driving
Lq , namely the characteristic of the saliency ratio ρ less than cycles.
1 (ρ = Lq /Ld < 1) can be innovatively designed to realize
the flux-intensifying effect, thus high output torque and a low normal cruise, and high speed cruise. Theoretically, for the
irreversible demagnetization risk can be obtained. During the design of EV motor, each operation condition often corresponds
high-speed flux-weakening region, the main flux can result to a special requirement, which is far different from the con-
be leaked actively by themselves, thus the characteristic of ventional single design requirement under the rated operation
the saliency ratio ρ larger than 1 (ρ = Lq /Ld > 1) and flux condition.
weakening operation can be synchronously realized. Therefore, For example, to meet the frequent start, frequent acceleration
the advantages of high output torque, wide speed range and or overloaded climbing, high output torque should be given
high efficiency can be achieved successfully. Meanwhile, the precedence in the design procedure of EV motors. And to meet
multiple driving cycles and the new design concept of variable- the operation condition of the high-speed cruise, the wide speed
saliency-ratio are presented in Section II. In Section III, the range is often necessarily required. Based on the earlier analysis,
motor topology and initial design of the proposed motor are the relationships among standard road conditions, driving cycles
introduced. Besides, according to the comprehensive sensitivity of EVs, and design requirements of EV motors are summarized
analysis, some key desirable variables under different typical and presented in Fig. 1.
operation conditions are selected, and a multiobjective opti-
mization considering multiple driving cycles is also presented.
B. Multiple Requirements and Operation Conditions
Then, the electromagnetic performances are analyzed in detail
as well to verify the performances of variable-saliency-ratio in The traditional design method of permanent magnet motor
Section IV. In Section V, the VSR-PM motor is manufactured, is mainly based on single operation region (normally under
and some fundamental experiments are conducted. Finally, the the rated operation condition) as shown in Fig. 2(a), the cor-
conclusions are drawn in Section VI, in which both the theoret- responding dimension equation of the traditional PM motor can
ical analysis and experimental results verify the validity of the be expressed as [13]
motor and the multiobjective optimization approach. 60Pout_rated (1 + η_rated )
D2 s_rated La_rated = (1)
2π 2 K p Kd Ki αi ABς n_rated η_rated
II. MULTIPLE DRIVING CYCLES AND NEW DESIGN CONCEPT
where Ds _rated is stator diameter, La_rated is stack length,
A. Multiple Driving Cycles and Operation Conditions Pout_rated is the rated output power, η_rated is rated efficiency.
Generally, there exists several different standard driving cy- Kp , Kd and Ki denote the back electromotive force (EMF)
cles to test the performances of the vehicles. Among them, the waveform coefficient, winding coefficient and current coeffi-
New European Driving Cycles (NEDC) and Urban Dynamome- cient, respectively. αi is the pole-arc coefficient, A is the line
ter Driving Schedule have been adopted widely to simulate load, Bς represents the peak value of airgap flux density, and
the city or suburban multiple operation conditions [12]. There n_rated is rated speed.
are some similarities between the two driving cycles, including For the EV motor, to satisfy the multiple driving cycles, con-
frequent start, frequent acceleration, climbing with heavy load, ventional design method based on the rated working area can be

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6518 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 68, NO. 8, AUGUST 2021

Fig. 3. Simplified equivalent magnetic circuit model. (a) Traditional PM


motor. (b) PM motor considering driving cycles.

no longer adopted. From Fig. 2(b), multiple operation points of


the motor need to be designed to meet the multiple requirements
at the different representative operation areas. For each typical Fig. 4. Rotor evolution from the conventional interior PM motor to the
or representative operation region, the corresponding dimension VSR-PM motor.
equation can be obtained according to the traditional PM design
method theoretically, and such obtained dimension parameters
According to (2), the variable saliency ratio ρ (id , iq ) under
can only meet the special operation region. However, the final
multiple conditions can be obtained as
manufactured motor can only have a set of determined design
parameters, so how to comprehensively design a reasonable Lq Φσ (id , iq ) × (2Rpm + Rr + Rs + 2Rg )
PM motor and meet such multiple requirements of high torque ρ(id , iq ) = = .
Ld N iq
capability, wide speed range, and high efficiency is still difficult (3)
and full of challenge. Obviously, the saliency ratio ρ (id , iq ) is proportional to the
flux leakage φσ (id , iq ). The total output torque Te is
C. Design Requirements and Saliency Ratio Variation 3
Te = Pr [ψpm iq + Ld (1 − ρ)id iq ] + Tcog (4)
Generally, in PM motors, the inductances of a PM motor, 2
including the d-axis Ld and q-axis inductances Lq , have a where Pr is number of pole-pairs, ψpm is flux linkage of PMs.
close relationship with output torque Te and the flux-weakening During the operation conditions of climbing with heavy load
capability kζ [14]. It means that, the variable design of the and frequent start, the large value of q-axis current iq may result
d-axis inductance Ld and q-axis inductance Lq may contribute to in the saturation of magnetic circuit and large value of Rbr ,
realizing the multiple design requirements or objectives, which In this situation, the leakage flux is transformed into effective
may provide a new perspective to design such type of EV motors. working flux, which contributes to realizing the high utilization
Fig. 3 shows the simplified equivalent magnetic model of PM of the PM magnetic field. Thus, the characteristic of the saliency
motors. Compared with the simplified magnetic circuit model of ratio ρ less than 1 (ρ = Lq /Ld < 1) can be obtained to realize
traditional PM motors shown in Fig. 3(a), a variable resistance the flux-intensifying effect, and the high output torque and a low
unit of Rbr (id , iq ) is newly employed in the magnetic circuit irreversible demagnetization risk can be obtained according to
model and illustrated in Fig. 3(b). By regulating the armature cur- (4). On the other hand, during high-speed cruise condition, the
rent under different operation conditions, the saturation degree small value of q-axis current iq may result in a small value of
of magnetic circuit could be changed accordingly. Therefore, Rbr and a large value of flux leakage, thus such flux weakening
the variable resistance Rbr plays an important role to obtain operation can contribute to realizing the characteristic of the
the variable-flux-leakage Φσ and the variable-saliency-ratio ρ. saliency ratio ρ larger than 1 (ρ = Lq /Ld > 1). Hence, the
To clarify the principle of variable-saliency-ratio design, the advantages of high output torque, wide speed range and high
corresponding simplified d-axis and q-axis equivalent flux path efficiency can be achieved comprehensively.
are also illustrated in Fig. 3(b), where the d-axis and q-axis flux
path are indicated at different rotor position.
D. Evolution of Motor Topology
From Fig. 3, the d-axis inductance Ld , q-axis inductance Lq
and flux leakage φσ (id , iq ) can be expressed as Based on the new design concept of saliency ratio variation
⎧ above, the rotor topology evolution from the conventional in-
⎪ N2
⎨Ld = (2Rpm +Rr +R
⎪ terior PM motor to VSR-PM motor, including the evolution of
s +2Rg )
2 PMs and magnetic barriers are depicted in Fig. 4. It is noted that,
Lq = Rs +Rr +2RNg +Rbr (id ,iq ) (2)

⎪ the variable-flux-leakage magnetic barrier is newly adopted in
⎩Φσ (id , iq ) = N iq
Rr +Rs +2Rg +Rbr (id ,iq ) the rotor and such changes have several advantages.
First, the outer edge of the rotor is purposely set an elliptic
where Rpm is PM reluctance, Rg is air gap reluctance, Rr is magnetic barrier and one layer of arc-shaped magnetic barrier
rotor core reluctance, and Rs is stator core reluctance. along q-axis magnetic field, which provides variable path for

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ZHOU et al.: MULTI-OBJECTIVE OPTIMIZATION DESIGN OF VSR-PM MOTOR CONSIDERING DRIVING CYCLES 6519

Fig. 5. Characteristics of current and voltage constraint circles.

magnetic flux leakage under different operation conditions.


Second, due to the adoption of two groups of three-section
arc-shaped magnetic barriers, q-axis magnetic field is not easily
saturated, which contributes to online accurate estimation of the
inductance. Third, since the elliptic magnetic barrier and multi-
layer arc-shaped magnetic barriers block the downward path of
the q-axis flux in the rotor, the resulting q-axis magnetic path
in the rotor is conducive to controlling the flux leakage. Finally,
V-shaped PMs are replaced by arc-shaped PM to improve the
utilization of PMs. Generally, by the coupling design of stator
armature winding magnetic circuit and flux leakage magnetic Fig. 6. Flowchart of the multiobjective optimization approach.
circuit, a new variable-saliency-ratio design can be achieved
under different driving cycles.
Fig. 5 shows the corresponding current constraint circle and Step 2: Selection of objectives and parameters. Based on the
voltage-constraint circle under diverse operation conditions. It different design requirements under diverse operation con-
can be observed that, due to the characteristic of the saliency ratio ditions, the important optimization objectives under each
ρ less than 1 (ρ = Lq /Ld < 1) during the operation conditions typical operation condition are selected, and the saliency
of climbing with heavy load and frequent start, the voltage ratio ρ is acted as a new optimization objective for the first
constraint locus is a vertical ellipse and the maximum torque time. Meanwhile, the design variables and the corresponding
operation point A1 is located in the first quadrant, indicating constrain are also determined simultaneously. Based on the
that the maximum torque per ampere (MTPA) control method comprehensive sensitivity analysis, the optimal parameters
is suitable for the constant torque operation region. Thus, a are also selected.
positive d-axis current id is required to achieve the maximum Step 3: Optimization under typical operation conditions. Based
torque and the advantage of low irreversible demagnetization on the multiobjective genetic algorithm (MOGA) method,
risk can be obtained. On the other hand, since the characteristic optimization under I-region and II-region, and optimization
of the saliency ratio ρ larger than 1 (ρ = Lq /Ld > 1) is designed under III-region are conducted to determine the candidate
during the operation conditions of normal cruise and high speed optimization values.
cruise, the voltage constraint locus becomes an ellipse with a Step 4: Determination of evaluation criteria. In this step, the
relatively small semiminor axis. Thus, flux-weakening control evaluation function fmin is firstly defined. Then, based on the
method under field-oriented-control is used in constant power evaluation function, the final values can be chosen from the
region. Moreover, via combining the two control methods under candidate optimization values.
the multiple operation conditions, the high efficiency over wide
speed range control method of the motor can be achieved.
A. Motor and Multiple-Operation-Conditions Design
III. MULTI-OBJECTIVE OPTIMIZATION According to the new design concept of saliency ratio varia-
The multiobjective optimization flowchart of the VSR-PM tion, the VSR-PM motor and the parametric geometric structure
motor considering driving cycles is presented in Fig. 6, which of motor are proposed in Fig. 7.
contains the following steps. It could be seen that the pole of magnetic barriers is same as
that of the permanent magnets of the motor, and the main reason
Step 1: Initial design of VSR-PM motor. First, according to is that the consistency of number of rotor magnetic barriers and
the reference drive cycles of NEDC and the plant growth permanent magnets can guarantee the symmetry of the d–q-axis
optimization (PGO) method, typical representative operation magnetic circuit of the motor, thus the efficient utilization of the
points are selected. Then, based on the operation condition of motor magnetic field can be realized. Meanwhile, considering
normal cruise, the initial motor design is carried out. the application demands of electric vehicles, the combination

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6520 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 68, NO. 8, AUGUST 2021

Fig. 7. Proposed VSR-PM motor. (a) Configuration. (b) Parametric


geometric structure of motor. Fig. 8. Selection of representative operation points under different
subregion based on the reference of NEDC.

of 36-slot/8-pole, which is more classical in interior permanent TABLE I


magnet motor, is selected in this article, and this design scheme INITIAL DESIGN SPECIFICATIONS OF VARIABLE SALIENCY RATIO PM MOTOR
has been successfully applied in Toyota Prius drive motor with
large-scale industrial development [3].
In addition, the multilayer magnetic barrier design can usually
effectively alleviate magnetic short-circuit between the adjacent
permanent magnets, which can improve the utilization of the
magnetic field and realize the improvement of the motor torque
density. Moreover, the reasonable multilayer magnetic barrier
design can effectively reduce the core loss of the rotor and
improve the operating efficiency. Based on the existing design and sometimes even fail to converge. Hence, to achieve a rea-
experience and the actual rotor space limitations, the motor sonable and relatively accurate parameters combination during
proposed in this article adopts the four-layer magnetic barrier the design optimization procedure, according to the PGO, a new
design. multiobjective optimization method under the typical operation
As for the shape of flux barrier, among them, for the first layer conditions is proposed, and some typical representative opera-
of magnetic barrier, in order to realize effective control of motor tion points are selected and listed as follows:
flux leakage, the ellipse shape of magnetic barrier is selected.
While for the rest of three-layer magnetic barriers, the same O1 : (0.5nrated , 1.1Tmax ) , O2 : (0.5nrated , 0.7Tmax ) ,
arc-shaped magnetic barrier design is adopted, which cannot
only reduce the motor inductances and weaken the saturation O3 : (1.2nrated , 0.7Tmax ) , O4 : (2.5nrated , 0.3Tmax ) .
degree of the magnetic circuit, but also effectively reduce design
dimensions of the motor parameters and improve the motor To facilitate the design process, the typical operation con-
design efficiency. Consequently, by the combination of spe- dition of normal cruise (NC-region) is selected for the initial
cial design of magnetic barriers and the arc-shaped permanent design of the proposed VSR-PM motor. And the corresponding
magnet, the unique design of “magnetic leakage circuit” and design requirements are given in Table I. The size equation of
“flux concentrated circuit” in the motor can be realized, thus the the VSR-PM motor can be given by [16]
flexible saliency ratio of motor can be obtained. 45(1 + η)Pr [ψf iq + Ld (1 − ρ(id , iq ))id iq ]
According to the reference drive cycles of NEDC shown in D s 2 La = . (5)
9.55 × π 2 Kp Kd Ki αi ABς η
aforementioned Fig. 1, the torque-speed envelope of the motor is
illustrated in Fig. 8. From the figure, nearly all operating points
fall within the specified torque-speed envelope [15]. Moreover, The corresponding d-axis inductance Ld and the PM flux
the motor drive cycles operation is decomposed into four main linkage ψf are expressed as follows:
torque-speed subregions, which is consistent with four opera-
μ 0 α i τ La
tion conditions in Fig. 2. The operation conditions of climbing Ld = N 2 Λ = N 2 × 10−2 (6)
with heavy load, frequent start/stop, normal cruise and high 2δkδ ks
speed cruise are termed as I-region, II-region, NC-region, and ψ f = N B M S = N B M bM L a (7)
III-region, respectively.
From Fig. 8, there are still many operating points even under where μ0 is the air permeability, τ is pole pitch, kδ is the air-
subregion of each typical operation condition. Theoretically, by gap coefficient, ks is the saturation coefficient, BM is the PM
optimizing all working points in these operating regions, the magnetic field intensity, and bM is the effective width of the PM.
relatively accurate optimal solutions can be obtained. However, The corresponding key parameters of VSR-PM motor are given
such multidimensional data often mean long computation times in Table II.

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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

Fig. 9. Pareto front of the MOGA under different operation conditions.


(a) I-region and II-region. (b) III-region.
TABLE III
VARIATION RANGE OF DESIGN VARIABLES
The objective function and constraints are given as follows:


⎪ Function : [Maxf1 (Tout ) , Minf1 (kr ) , Min(ρ)]



⎪ Constraints :

⎨⎧I − region : ρ < 1, k ≤ k ≤ k , 0.8T


⎪ r_l r r_u rated



⎪ ≤ T ≤ T


out peak

⎪ ⎪


⎩⎩ ⎪II − region : ρ < 1, kr_l ≤ kr ≤ kr_u , 0.4Trated

≤ Tout ≤ Trated
(8)
B. Optimization Under Typical Operation Conditions where Tout is the output torque. kr is the coefficient of torque
As shown in aforementioned Fig. 1, the EV motor exists ripple, which is defined as ratio of the ripple torque Tripple to
multiple design requirements and objectives of high power Tout . Besides, Trated is the rated output torque, Tpeak is the peak
density, wide speed range and high efficiency under different op- torque. kr_l and kr_u denote the lower and upper limiting values
erating conditions. Among these multiple design objectives, the of torque ripple coefficient, respectively. As design examples,
importance or priority is different under each typical operation the values of Trated , n, kr_l and kr_u are set as 30 N·m, 600 r/min,
condition. For example, compared with torque ripple, the output 2% and 12%, respectively.
torque is the preferred optimization objective under the typical The MOGA is adopted for conducting optimization to obtain
operation conditions of I-region and II-region. Besides, the out- a group of optimized parameters [17], [18]. In order to realize
put torque, efficiency or loss is also important under NC-region the multi-objective optimization of VSR-PM motor considering
and III-region. In order to meet diverse performance require- driving cycles, commercial finite element analysis (FEA) soft-
ments under multiple operating conditions, multiobjective opti- ware coupled with scripting code is implemented. Specifically,
mization considering driving cycles is proposed in this section. commercial FEA software is employed to obtain the sampling
And considering the relationship between inductance/saliency data which are the geometric parameters of motor and perfor-
ratio and torque/speed range, etc., the saliency ratio ρ is acted mance parameters under different operation conditions, while
as a new optimization objective for the first time. MOGA, which is programmed by us, is utilized to determine the
1) Comprehensive Sensitivity Analysis: Firstly, some de- optimal motor design based on FEA calculation results. Based
sign parameters are chosen as design variables and denoted in on the objective function and constraints in (8), the Pareto front
the geometric model of the proposed motor, which are shown of the MOGA under typical I-region and II-region is shown
in Fig. 7(b). The selected variables and corresponding variation in Fig. 9(a), which obviously meet the design requirements
ranges are given in Table III. mentioned earlier.
Then, a comprehensive analysis method of weighted- 3) Optimization Under Typical III-Region: In III-region,
sensitivity is adopted, which is an efficient approach to determine the performances of the core loss, saliency ratio, and output
how each design variable affects the performances of the PM torque usually need to be paid more attention. Thus, they are
motor. According to the comprehensive sensitivity analysis, the set as the main objectives simultaneously in high speed cruise
design variables of hpm , bf s are the strong-sensitive parameters, condition. The objective function and its constraints are given
thus such strong-sensitive parameters are chosen as examples for as follows:
the following optimization. ⎧

⎨Function : [Minf2 (Pcore ), Maxf2 (T) , Max(ρ)]
2) Optimization Under Typical I-Region and II-Region: In
I-region and II-region, the performances of the output torque, Constraints : ρ > 1, Pcore_l ≤ Pcore ≤ Pcore_u , Tout


torque ripple, and saliency ratio usually need to be paid more at- ≥ 0.2Trated
tention. Thus, they are set as the main objectives simultaneously. (9)

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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

Fig. 10. Distribution of parameters combination under different region.

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).

C. Final Values Determination


Based on the convergence results in Fig. 9, the distribution of
parameters combination under different typical operation con-
ditions are depicted in Fig. 10, in which three candidate designs,
namely A, B, and C, are obtained by taking the intersection of
the different operation conditions.
Considering a compromise among the saliency ratio, output
torque, torque ripple under I-region and II-region and saliency
ratio, output torque, core loss under III-region, the evaluation
function fmin is defined as Fig. 11. No-load characteristics. (a) Back EMF waveforms. (b) Air-gap
  flux density.
Tout_1 λ2 kr λ3 ρ
fmin = + +
λ1 Tout kr_1 ρ_1
   A. Fundamental Electromagnetic Performances
λ 1 Pf e Tout_2 ρ_2
+ +  +  (10)
Pf e_2 λ2 Tout λ 3ρ First, the no-load back EMF and the air-gap flux density of the
initial and the optimal VSR-PM motor at the speed of 1200 r/min
where Tout˙1 , kr˙1 , and ρ˙1 are the initial value of the torque, are simulated and shown in Fig. 11.
torque ripple, and saliency ratio, respectively, under I-region From Fig. 11(a), the optimized no-load back EMF waveform
and II-region, Tout˙2 , kr˙2 , and ρ˙2 are the initial value under is more sinusoidal and the amplitude is also increased. In ad-
III-region, and λ1 , λ2, λ3 , λ1 ’, λ2 ’, and λ3 ’are the weight dition, fast fourier transform (FFT) analysis is applied to the
coefficients. simulated back EMF waveform and the total harmonic distortion
According to the evaluation function in (10), the combination (THD) value of initial and optimal motor are 6.44% and 4.26%,
B is chosen finally. Hence, hpm and bfs are chosen to be 2 and respectively, which means that the optimal motor can obtain the
2 mm. Similarly, all optimal points can be achieved efficiently. less torque ripple. Furthermore, the air-gap flux density of the
The final determined values of the key design variables and the initial and optimal motor are described in Fig. 11(b), it can be
objective performances under different typical regions are given observed that the peak value of the air-gap flux density waveform
in Table IV. It can be observed that, after the optimization, for optimal motor is slightly higher than that for the initial motor,
the performances of the motor are better to satisfy the design indicating that the optimal motor possesses the higher magnetic
requirements. load and higher output torque, which is prefer under the I-region
and II-region.
IV. PERFORMANCES EVALUATION
Second, the flux density distributions and flux lines at the same
To verify the validity of the VSR-PM motor and the opti- rotor position of 0 electrical degree under different operation
mization approach, electromagnetic performances of VSR-PM conditions are simulated and depicted in Fig. 12. On one hand,
motor are investigated in detail by finite-element method. from Fig. 12(a) and (c), under I-region or II-region, the high

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ZHOU et al.: MULTI-OBJECTIVE OPTIMIZATION DESIGN OF VSR-PM MOTOR CONSIDERING DRIVING CYCLES 6523

Fig. 14. Flux leakage Фσ (id , iq ) variation map.


Fig. 12. Flux density distributions and flux lines under different opera-
tion conditions. (a) and (c) I-region and II-region. (b) and (d) III-region.

Fig. 15. Saliency ratio ρ (id , iq ) variation map.

Fig. 13. Torque characteristic of the VSR-PM motor versus current


angles.

value of q-axis armature current is often applied, thus, the


interpolar magnetic bridge would be converted into saturation
situation. In this situation, the leakage flux is transformed into
effective working flux, which contributes to realizing the high
utilization of the PM magnetic field. As a consequence, the
characteristic of the saliency ratio ρ less than 1 (ρ = Lq /Ld <
1) can be obtained to realize the flux-intensifying effect. On the
other hand, From Fig. 12(b) and (d), under the flux-weakening
operation of III-region, the main flux can be leaked actively
by themselves, thus the variable-flux-leakage, the characteristic
Fig. 16. Saliency-ratio-map under different speed and torque.
of the saliency ratio ρ larger than 1 (ρ = Lq /Ld > 1) and flux
weakening can be synchronously realized.
Then, the torque performances of the VSR-PM motor at
During I-region and II-region, the saliency ratio ρ decreases
different current angles with different currents are illustrated in
gradually with the increase of iq when the id is an arbitrary fixed
Fig. 13. Due to the characteristic of the saliency ratio ρ less than
value, which indicates that, with the increasing q-axis current
1 (ρ = Lq /Ld < 1) is designed to realize the flux-intensifying
gradually saturates the inter-pole magnetic bridge, the PM flux
effect under I-region and II-region, the proposed motor can reach
leakage path is blocked and the characteristic of the saliency ratio
the maximum torque at the positive current of d-axis id . As
less than 1 (ρ = Lq /Ld < 1) can be purposely achieved to realize
the armature current increases, the saturation of the interpolar
the flux-intensifying effect. Similarly, during III-region, the
magnetic bridge becomes higher and the saliency ratio is smaller.
saliency ratio decreases gradually with the increase of iq when
So the corresponding reluctance torque is constantly increased
the id is an arbitrary fixed value. The saliency ratio increases
according to (4), which makes the maximum torque points keep
slowly with the increase of d-axis demagnetizing current when
moving to the left.
the iq is a fixed value. Hence, the flux leakage and the flux
weakening are conduced to obtaining the characteristic of the
B. Verifying Characteristic of Variable Saliency Ratio
saliency ratio ρ larger than 1 (ρ = Lq /Ld > 1).
As shown in Fig. 14, the flux leakage Фσ (id , iq ) variation map Finally, Fig. 16 shows the saliency-ratio-map under different
is obtained. Fig. 15 shows the saliency ratio ρ (id , iq ) variation speed and torque. When the motor operates under the I-region
map. As expected, the saliency ratio ρ (id , iq ) variation is and II-region, the q-axis armature current iq blocks the flux
positively correlated with the flux leakage Фσ (id , iq ) variation. leakage path and the characteristic of the saliency ratio ρ less

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6524 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 68, NO. 8, AUGUST 2021

Fig. 17. Torque ripple under different speed and torque.

Fig. 18. Experiment platform of the VSR-PM motor.


than 1 (ρ = Lq /Ld < 1) can be achieved to realize the flux-
intensifying effect, thus high output torque and a low irreversible
demagnetization risk can be obtained. Conversely, when the
motor operates under III-region, the main flux is leaked by
themselves, the variable-flux-leakage, the characteristic of the
saliency ratio ρ larger than 1 (ρ = Lq /Ld > 1) and flux weakening
can be synchronously realized. So, the advantages of high output
torque, wide speed range and high efficiency can be achieved.
Fig. 17 shows the torque ripple under different speed and
torque. It can be seen that, the torque ripple is less than 10%
in the entire driving cycles, indicating that the torque ripple
performance of the motor under different operation conditions
is within a reasonable range. The cogging torque equation can
Fig. 19. Measured no-load back EMF waveform at the speed of
be expressed as below, it can be seen that, the cogging torque 1200 r/min.
is independent of the operation conditions. For a more com-
prehensive presentation, the performances of cogging torque
are also demonstrated under I-region and II-region as well as
III-region. It can be seen that the pk2pk value of cogging torque
under different operation conditions are almost 0.2 N·m, which
indicates that the motor has the great performance of cogging
torque under different operation conditions
 ∞
πzla
Tcog (α) = (R2 2 − R1 2 ) jGj Br jz sin jzα (11)
4μ0 j
2p

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.

Fig. 23. Measured saliency-ratio ρ in the speed range of 0–3000 r/min


under different torque characteristics.

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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Xue Zhou received the B.Sc. degrees in electri-


cal engineering from Jiangsu University, Zhen- Yongfeng Liu received the B.Sc. degrees from
jiang, China, in 2018, where she is currently Jiangsu University, Zhenjiang, China, in 2018,
working toward the Ph.D. degree in electrical where he is currently working towards the Mas-
engineering. ter’s degree, both in electrical engineering.
Her current research interests include de- His current research interests include flux-
sign and analysis of variable-saliency ratio per- weakening controller for interior permanent
manent magnet machines for electric vehicles magnet synchronous motor.
(EVs).

Xiaoyong Zhu (Member, IEEE) received the


B.Sc. and M.Sc. degrees in electrical engineer-
ing from Jiangsu University, Zhenjiang, China,
in 1997 and 2002, respectively, and the Ph.D.
degree in electrical engineering from the School
of Electrical Engineering, Southeast University, Li Quan received the B.Sc. degree in electrical
Nanjing, China, in 2008, mainly focusing on the engineering from Hefei University of technology,
design, analysis, and control of hybrid excited Hefei, China, in 1985, the M.Sc. degree in mo-
permanent magnet machines. tors and electrical specialty from Southeast Uni-
Since 1999, he has been with Jiangsu Univer- versity, Nanjing, China, in 1991, and the Ph.D.
sity, where he is currently a Professor with the degree in power electronics and power trans-
School of Electrical Information Engineering. During 2007–2008, he was mission from Nanjing University of aeronautics
a Research Assistant with the Department of Electrical and Electronic and astronautics, Nanjing, in 2007.
Engineering, University of Hong Kong. From 2012 to 2013, he was Since 1998, he has been with Jiangsu Univer-
a Visiting Professor with the Department of Energy-Funded Graduate sity, where he is currently a Professor with the
Automotive Technology Education Center for Elctric Drive Transporta- School of Electrical and Information Engineer-
tion, University of Michigan, Dearborn, MI, USA. In these areas, he ing. He has authored or co-authored more than 100 technical papers,
has authored and co-authored more than 70 referred technical papers, one textbook, and holds three patents in these areas. His teaching and
and holds 12 patents. His current research interests include design and research interests include high performance permanent magnet motor
drive control of electric machines with wide-speed range, less rare-earth for electric vehicles, double rotor permanent magnet motor for hybrid
permanent magnet motor, and multiport permanent magnet motor. electric vehicles, and motor drives control.

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