Professional Documents
Culture Documents
net/publication/3172195
Application of Direct-Drive Wheel Motor for Fuel Cell Electric and Hybrid
Electric Vehicle Propulsion System
CITATIONS READS
190 2,774
6 authors, including:
Some of the authors of this publication are also working on these related projects:
Newly-conceived on-board electrical generating systems for automotive applications View project
All content following this page was uploaded by Fabio Crescimbini on 06 December 2013.
Abstract—This paper presents a gearless wheel motor drive torque low-speed application. In this regard, this paper presents
system specifically designed for fuel cell electric and hybrid elec- a gearless wheel motor drive system.
tric vehicle propulsion application. The system includes a liquid- Gearless wheel motor drive systems for fuel cell electric or
cooled axial flux permanent-magnet machine designed to meet
the direct-drive requirements. The machine design implements hybrid vehicles have advantages over the classical construction
techniques to increase the machine inductance in order to improve with one central machine. Mounting the motors directly to the
machine constant power range and high-speed efficiency. The im- wheels simplifies the mechanical layout. The gearless wheel
plemented technique reduces machine spin loss to further improve motor drive system will reduce the drive line components, thus
efficiency. The machine design also optimizes the placement of improving the overall reliability and efficiency. This option will
magnets in the rotor to reduce cogging and ripple torque. An
original cooling system arrangement based on the use of high ther- also reduce the drive line weight since mechanical differential
mal conductivity epoxy joining machine stator and liquid-cooled and gear reduction are not used. However, due to the elimina-
aluminum casing allows the very effective removal of machine tion of gears, the machine needs to produce the total torque
power loss. Design details and experimental results are presented. directly into the wheel shaft. Hence, the size and the weight
Index Terms—Axial flux, component, direct drive, wheel motor. of the machine tend to grow. Therefore, the major challenge
in a gearless system is to keep the size and the weight of
the machine low for direct in-wheel mounting. Unsprung mass
I. I NTRODUCTION should be carefully evaluated when designing wheel motors.
There should be a tradeoff between the size, power, and weight
T HE ELECTRIC traction system is an important com-
ponent of fuel cell electric and hybrid electric vehicle
propulsion systems. Generally, in most propulsion applications,
of the machine.
Compared to conventional designs, the axial flux permanent-
an ac machine is connected to the wheels by reduction gears and magnet (AFPM) machine has favorable characteristics con-
mechanical differential. In some vehicle drive arrangements, cerning efficiency and specific torque. For this reason, it is
high-speed low-torque wheel motors requiring gear reduction especially suited for direct-drive applications [1]–[5]. This pa-
are used, and in these cases, either a gear motor assembly is per presents a wheel direct-drive system with an axial flux ma-
mounted inside the wheel or a chassis-mounted motor is con- chine targeted for fuel cell electric and hybrid electric vehicle
nected to the wheel through gear reduction. Further simplifica- propulsion systems. The axial flux machine in this system is
tion of the vehicle drive arrangement results in the elimination directly coupled with the wheel without gear reduction. The
of the gear being interposed between motor and wheel, and machine has been designed, built, and tested in the dyno and
this calls for the use of wheel motors being designed for high- also in a mule vehicle. This paper presents the design of a
gearless wheel motor drive system and the dyno test data to
validate the drive system performance.
Paper IPCSD-06-029, presented at the 2004 Industry Applications Society
Annual Meeting, Seattle, WA, October 3–7, and approved for publication
in the IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS by the Elec- II. R EVIEW OF AFPM M ACHINES
tric Machines Committee of the IEEE Industry Applications Society. Man-
uscript submitted for review November 1, 2004 and released for publication Flux in an axial flux machine flows axial to the direction
June 1, 2006.
K. M. Rahman is with General Motors Hybrid Power Train Engineering,
of rotation. The AFPM machine is basically equivalent to
Troy, MI 48083 USA (e-mail: khwaja.rahman@gm.com). the conventional radial flux surface-mount permanent-magnet
N. R. Patel, T. G. Ward, and J. M. Nagashima are with the Advanced Tech- (SMPM) machine geometry. Therefore, they suffer from the
nology Center, General Motors, Torrance, CA 90505 USA (e-mail: nitinkumar.
patel@gm.com; james.nagashima@gm.com).
well-known low-inductance problem. However, this problem
F. Caricchi is with the Department of Electrical Engineering, Univer- can be substantially mitigated as discussed in the following.
sity of Rome “La Sapienza,” 00184 Rome, Italy (e-mail: Fred@elettrica. High torque density and good efficiency of the AFPM machines
ing.uniroma1.it).
F. Crescimbini is with the Department of Mechanical and Industrial Engi- have been verified theoretically [6]. It has been shown that an
neering, University of Rome “Tre,” 00146 Rome, Italy (e-mail: crescimbini@ improvement of two times the density of an induction machine
ieee.org). is possible even with ferrite magnets. The gain in density can
Color versions of Figs. 1, 3, 4, 7, 8, and 10–13 are available online at
http://ieeexplore.ieee.org. exceed three times if high-energy magnets are used. The AFPM
Digital Object Identifier 10.1109/TIA.2006.880886 machine has favorable geometry for in-wheel mounting and
0093-9994/$20.00 © 2006 IEEE
1186 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 42, NO. 5, SEPTEMBER/OCTOBER 2006
with several magnets mounted on the disk and one stator disk
sandwiched by the two rotor disks. In a Torus geometry, the
magnet in the two opposite rotor disks may be placed on N–N
or N–S arrangements, depending on whether the winding has
a cored or coreless arrangement. Fig. 1(b) shows the flux plot
of a Torus-type geometry with N–N rotor magnet placement.
Core losses in a cored geometry mostly happen in this stator
core, therefore, it needs to be laminated, while the rotor back
iron only carries the dc flux, hence can be a solid ferromagnetic
disk. In a slotted geometry, cogging and ripple torque will be
present due to the slotting effect. A nonslotted core is therefore
sometimes preferred to eliminate cogging and ripple torque.
However, a nonslotted geometry increases the eddy loss in the
winding.
The coreless axial flux machine is sometimes used for several
apparent advantages [7]. The coreless geometry eliminates the
core loss and the cogging torque. The machine torque density is
very high due to the very light weight of the coreless geometry.
However, the coreless geometry also poses challenges mostly
due to the use of a winding being placed in the air gap and
directly exposed to the magnet flux. As a consequence, the
coreless geometry is characterized by extremely low machine
inductance and thereby hardly has any constant power range.
To overcome this problem, the machine inverter needs to be
oversized. The coreless geometry, although does not have any
core loss, may have significant copper loss due to the eddy-
induced current in the winding. A coreless machine designed
for high-speed operation may, therefore, require a Litz wire to
overcome this problem. Either cored or coreless topologies used
in AFPM are strong candidates for direct-drive applications.
Fig. 5. (a) Flux in the rotor back iron showing the area of low flux concen-
tration. (b) Area of low flux concentration removed from the back iron to
reduce mass.
TABLE I
MACHINE DATA
calculated flux linkages of Fig. 8(b) and (c), where the flux
linkages are used to calculate the torque and later compared
with the measured torque.
Once the machine model is developed using the machine
characteristic data in Fig. 8, the machine model is used to cal-
culate the machine optimal control parameters. Fig. 9 shows the
search algorithm for calculating the optimal control parameters.
Fig. 10 shows the optimal control parameters of the devel-
oped wheel motor calculated using the method described in Fig. 8. Machine characteristic data as a function of control angle and phase
Fig. 9. Fig. 10(a) shows the q-axis optimal control parameters, current. (a) Measured and calculated (using the flux linkage data) torque.
(b) Measured (calculated from measured voltage and current) d-axis flux
and Fig. 10(b) shows the d-axis optimal control parameters. The linkages. (c) Measured q-axis flux linkages.
d-axis control parameters are zero at low speed since no field
weakening is needed at low speed. measured torque speed profile of the developed wheel mo-
Once the optimal control parameters are calculated, they are tor controlled using the optimal control parameters calculated
added in the controller as lookup tables. Fig. 11 shows the above. As seen in the figure for a bus voltage of 250 V, the
1190 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 42, NO. 5, SEPTEMBER/OCTOBER 2006
Fig. 12. Comparison of no-load loss in wheel motor with and without mag-
netic wedges in the stator slot.
VI. C ONCLUSION
This paper presents the design and performance data of
an AFPM machine for the direct-drive propulsion system of
fuel cell electric and hybrid electric vehicle. The machine
has been specifically designed to meet the requirements of
low cogging torque and long constant power field weaken-
ing region. The presented test results show excellent cogging
performance as evidenced by the nearly sinusoidal back EMF
with little slotting effects. A constant power range of two
times or more has been achieved by adding magnetic wedges
in the stator slots. Magnetic wedges have also reduced the
core loss and thus improved the machine efficiency espe-
cially during high-speed operation. Special attention is given
to minimize the mass of the machine active parts and thereby
reduce the wheel motor unsprung mass. Additionally, an ef-
fective cooling system has been conceived and patented to
improve the machine thermal performance. The engineering
S10 mule vehicle has been driven over 1000 miles on test
drives by automotive news reporters during GM’s technology
tours around the world. The wheel motors installed on the
S10 mule have demonstrated excellent performance during the
test drives.
The measured performances of the wheel motor drive dis-
cussed throughout this paper met or exceed the design specifi-
cations set forth by the system requirements, thus confirming
that AFPM machines should be regarded as strong candidates
for direct-drive automotive applications.
R EFERENCES
[1] F. Caricchi, F. Crescimbini, and A. Di Napoli, “Prototype of electric vehicle
drive with twin water-cooled wheel direct drive motors,” in Proc. IEEE
Fig. 13. System efficiency of direct-drive wheel motor (a) with and PESC, 1996, pp. 23–26.
(b) without magnetic wedges. DC-bus voltage of 250 V. [2] ——, “Prototype of innovative wheel direct water-cooled axial-flux PM
motor for electric vehicle application,” in Proc. IEEE APEC, 1996,
pp. 764–770.
[3] F. Caricchi, F. Crescimbini, O. Honorati, A. Di Napoli, and E. Santini,
“Compact wheel direct drive for EVs,” IEEE Ind. Appl. Mag., vol. 2, no. 6,
the slotting effect between the stator slot and the rotor. This pp. 25–32, Nov./Dec. 1996.
reduces air gap flux harmonics. It is clear that the machine with [4] F. Caricchi, F. Crescimbini, F. Mezzetti, and E. Santini, “Multistage axial-
magnetic wedges has significantly less spin loss compared to flux PM machine for wheel direct drive,” IEEE Trans. Ind. Appl., vol. 32,
no. 4, pp. 882–888, Jul./Aug. 1996.
the machine without magnetic wedges. [5] F. Caricchi, F. Crescimbini, E. Fedeli, and G. Noioa, “Design
The low spin loss and the necessity of lower field weakening and construction of a wheel-directly-coupled axial-flux PM motor
current at high speed (higher inductance) improve the efficiency prototype for EVs,” in Proc. IEEE-IAS Annu. Meeting, 1994,
pp. 254–261.
of the machine with magnetic wedges. This is illustrated in [6] S. Huang, J. Luo, F. Leornardi, and T. Lipo, “A comparison of power
Fig. 13 by comparing the measured system efficiency of two density for axial flux machines based on general purpose sizing equations,”
machines of Fig. 12. IEEE Trans. Energy Convers., vol. 14, no. 2, pp. 185–192, Jun. 1999.
[7] F. Caricchi, F. Crescimbini, O. Honorati, G. Bianco, and E. Santini, “Per-
Fig. 13(a) shows the measured system efficiency for a ma- formance of coreless-winding axial-flux permanent-magnet generator with
chine with magnetic wedges, while Fig. 13(b) shows the system power output at 400 Hz, 3000 r/min,” IEEE Trans. Ind. Appl., vol. 34, no. 6,
efficiency of a machine without magnetic wedges. It is clear pp. 1263–1269, Nov./Dec. 1998.
[8] F. Caricchi, F. Capponi, F. Crescimbini, and L. Solero, “Experimental study
from the figure that the machine with magnetic wedges is ex- on reducing clogging torque and core power loss in axial-flux permanent-
hibiting superior efficiency than the machine without magnetic magnet machines with slotted winding,” in Proc. IEEE-IAS Annu. Meeting,
wedges. The maximum efficiency of the machine with magnetic 2002, pp. 1295–1302.
[9] K. Rahman and S. Hiti, “Identification of the machine parameters of syn-
wedges is about 3% better than the machine without wedges. chronous motor,” in Proc. IEEE-IAS Annu. Meeting, Salt Lake City, UT,
More importantly, in the medium-speed to high-speed low- 2003, pp. 409–415.
1192 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 42, NO. 5, SEPTEMBER/OCTOBER 2006
Khwaja M. Rahman (S’93–M’99) received the James M. Nagashima (M’98) was born in Chicago,
B.Sc. and M.Sc. degrees from Bangladesh University IL, in 1946. He received the B.S. degree in electrical
of Engineering and Technology (BUET), Dhaka, in engineering and the M.B.A. degree from California
1987 and 1990, respectively, and the M.S. and Ph.D. State University, Long Beach, in 1969 and 1983,
degrees from Texas A&M University, College Sta- respectively.
tion, in 1992 and 1998, respectively, all in electrical He is currently a Manager with the Advanced
engineering. Technology Center, General Motors, Torrance, CA,
From 1987 to 1990, he was a Lecturer with the where he is responsible for developing new power
Electrical Engineering Department, BUET. In 1998, electronics, motor drives, and controls for GM’s
he joined the Advanced Technology Center, General electric, hybrid, and fuel-cell vehicles. His past work
Motors, Torrance, CA, as a Research Engineer. He is includes the GM EV-1 electric vehicle, autonomy
currently a Technical Specialist with the General Motors Hybrid Power Train fuel-cell concept vehicle, Precept 90 mpg concept demonstrator for PNGV,
Division, Troy, MI, where his responsibilities include the design of electric and the recently announced Sequel fuel-cell concept vehicle. He holds 16
machines and control of electric drives for hybrid electric vehicle propulsion patents in the field of power electronics and electric machines. He has published
systems. He is also a coinventor of several U.S. patents in these areas. several papers on advanced motor drives and electronics. He represents General
Dr. Rahman was the recipient of the First Prize Paper Award from the IEEE Motors on several academic and government committees. His interests include
Industry Applications Society. automotive power electronics, electric machine design, and advanced motor
controls.
Mr. Nagashima is a member of the Society of Automotive Engineers. He was
awarded two GM innovation awards in 2003 and 2004 for his work on electric
wheel hub motors and hybrid permanent-magnet machines.
Nitin R. Patel (S’96–M’97) was born in Gujarat,
India. He received the B.S. degree in instrumentation
and control from the University of Poona, Maharash-
Federico Caricchi (M’90) received the electrical
tra, India, in 1991, the M.S. degree in electrical engi-
engineering and Ph.D. degrees from the University
neering from the University of Tennessee, Knoxville,
of Rome “La Sapienza,” Rome, Italy, in 1988 and
in 1996, and the M.S. degree in mechanical engi-
1994, respectively.
neering from the University of Wisconsin, Madison,
Since 1991, he has been with the Department
in 2004.
of Electrical Engineering, University of Rome “La
He was with Dover Elevator as a Research Engi-
Sapienza,” where he is currently a Full Professor.
neer. In 1997, he joined the Advanced Technology
His research interests include analysis and design of
Center, General Motors, Torrance, CA, where he is
unconventional electric machines, power electronic
currently a Control Engineer involved in the development of ac drives control
equipment, and permanent-magnet motor drives.
for propulsion systems for FCEV/HEV application. He has authored several
Prof. Caricchi is a member of the Italian Associ-
publications in IEEE conferences. He holds 13 U.S. patents with 11 pending.
ation of Electrical and Electronic Engineers, the Italian Association for Naval
His research interests include fuzzy logic and neural network applications to
Techniques, and the IEEE Industry Applications Society.
power electronics, drives, and sensorless machine control.
Mr. Patel is an active member of the IEEE Industry Applications Society
Industrial Drives Committee. He was awarded the 2003 General Motors Vice
President’s Award (Charles L. McCuen award) for his contribution to wheel Fabio Crescimbini (M’90) received the degree in
hub motor technology. electrical engineering and the Ph.D. degree from the
University of Rome “La Sapienza,” Rome, Italy, in
1982 and 1987, respectively.
From 1989 to 1998, he was the Director of the
Electrical Machines and Drives Laboratory, Depart-
Terence G. Ward received the B.S.M.E. degree ment of Electrical Engineering, University of Rome
from the University of Nebraska, Lincoln, and the “La Sapienza.” In 1998, he joined the Department of
M.S.M.E. degree from the University of Southern Mechanical and Industrial Engineering, University
California, Los Angeles. Roma Tre, Rome, Italy, where he is currently a
He has 21 years of engineering experience in Full Professor of electrical machines and drives. His
aerospace and automotive power electronic packag- research interests include the design of newly conceived permanent-magnet
ing and electric motor design. He is currently a Staff machine drives and power converter topologies for emerging applications such
Engineer with the Advanced Technology Center, as electric and hybrid vehicles and renewable energy generating systems.
General Motors, Torrance, CA. Prof. Crescimbini is an active member of the IEEE Industry Applications
Mr. Ward is a recipient of the Hughes Aircraft Society (IAS), the IEEE Power Electronics Society, and the IEEE Vehicular
Company Fellowship. He is a Registered Profes- Technology Society. From 2001 to 2005, he was a member of the IEEE IAS
sional Engineer in the State of California. Executive Board.