Imd Ecce23

INTEGRATED MOTOR DRIVES, STATE OF
THE ART, CHALLENGES, AND EMERGING TECHNOLOGIES

Liliana de Lillo1, Xu Deng2, Lee Empringham1, Thomas Jahns3 Dan Kernan4 Barrie Mecrow2
1 University of Nottingham, UK
2 Newcastle University, UK
3 University of Wisconsin - Madison, USA
4 ITT Inc, USA

INTRO
• Introduction to VFD’s and Integrated Drives – Lee Empringham

• Electrical Machines– Barrie Mecrow
• Power Converters and Control - Deng (Daisy) Xu
• Thermal management for integrated motor drives – Liliana de Lillo
• Wide Bandgap Switches and the Future of Integrated Motor Drives – Tom Jahns
• Industrial Manufacturer Perspective – Dan Kernan
• Emerging Technologies and Summary – Lee Empringham
INTEGRATED MOTOR DRIVES, STATE OF THE ART, CHALLENGES, AND EMERGING TECHNOLOGIES
- INTRODUCTION Lee Empringham 2/XX
MOTIVATION FOR VFD’S AND
INTEGRATED DRIVES
• VFD’s – Proven to reduce energy consumption
– Installation costs are often prohibitively high
– IMD’s solve this problem
• Increase power density – reduced weight and volume
• Increase in efficiency
• Reduce costs, both manufacturing and through life
– Can generate conflicting aims in the designers if they create

compact designs in isolation
• PE Designer • Motor Designer

– Elimination of line filters – Increased speed
– Use of WBG semiconductors – High Fill-factor Compressed Windings
INTEGRATED DRIVES
• PE Designer
– Elimination of line filters
• Increase in output EMI /
• Degradation in Bearing lifetime
– Use of WBG semiconductors
• Increased DV/DT – EMI,
• Potential premature insulation breakdown
• Motor Designer
– Increased speed - Greater number of pole pairs
• Requires an increased fundamental electrical frequency
• Increased switching frequency / converter losses / controller
bandwidth
– High Fill-factor Compressed Windings • Unified / systems
• Difficulties with insulation systems
• Probability of Breakdown due to DV/DT increased approach needed!
INTEGRATED DRIVES
Integration reveals opportunities not available to VFD designers
• Partitioning of the problem
– Motor windings – not fixed to classical industrial norms
• Increased number of lower current poles
– Individual motorettes
– Individually driven
– Consider multiple smaller power converters
• Trade off between, efficiency, power density, reliability
– Power converter • Unified / systems
• Consider multiple small power modules vs larger power converters approach needed!
• Thermal Management of PE and Motor as a system
– Challenge – opportunity to share functional and structural parts
- ELECTRICAL MACHINES
Barrie Mecrow1, Sandy Smith2, Tom Jahns3, ….
1 Newcastle University, UK
2 University of Manchester, UK
3 University of Wisconsin - Madison, USA
ELECTRICAL MACHINES FOR
INTEGRATED DRIVES
Topics
✓ Modularity
✓ Materials
✓ Integration of Passives
- ELECTRICAL MACHINES - Barrie Mecrow 2/XX
MODULARITY
Why Modularity?
✓ Close proximity of power electronics and machine

✓ Lower penalty of having more connections between motor and converter
✓ Manufacturing advantages
✓ Many identical units
✓ Fault Tolerance
INTEGRATED DRIVES
Machine types most suitable for Modularisation
Suitable Suitable with Challenges Difficult
Switched Reluctance Permanent Magnet Induction
Synchronous Reluctance
Flux Switching
INTEGRATED DRIVES
Axial Modularity
INTEGRATED DRIVES
Circumferential
Modularity
INTEGRATED DRIVES
Modularity and Fault Tolerance
• How many modules should there be?

• Multiple or single phase modules?
• Isolation between modules
Integrated modular wheel

drive from Protean Electric
INTEGRATED DRIVES
How Many Modules?
• Very dependent upon motivation for modularity

• When fault tolerance is required, need to decide in context of the
incoming number of power supplies
• More lanes require less over-rating to compensate for a failed module
• More modules increase complexity and the likelihood of a failure
• 2 or 3 modules generally chosen in aerospace systems
• Isolation between modules
INTEGRATED DRIVES
Single phase or three phase Modules?
Modularity
INTEGRATED DRIVES
Isolation between Modules

• Electrical Isolation – separate power supplies for each module
• Mechanical Isolation – no overlapping end-windings between modules
• Thermal isolation – the coils of two modules must not share a slot.
• Magnetic Isolation – design to minimize magnetic coupling between modules
INTEGRATED DRIVES
Every coil isolated
INTEGRATED DRIVES
Every Module Isolated
INTEGRATED DRIVES
Can we have modularity with Distributed Windings?
INTEGRATED DRIVES
Modularity
and
distributed
windings
Conventional 6 pole distributed winding 6 pole distributed winding split into 3 lanes
INTEGRATED DRIVES
Modularity
and
distributed
windings
Conventional 6 pole distributed winding 6 pole distributed winding split into 3 lanes
INTEGRATED DRIVES
Conclusions on Modularity
• Good for reducing the number of different components, but more
components in total.
• Works well with integrated drives because of the close proximity of power
electronics and machine
• Modularity allows fault tolerance, though there are many things to consider
when designing a fault tolerant system.
INTEGRATED DRIVES
Use of Wide bandgap devices

✓ SiC and GaN Dvices
✓ Permit very high frequency outputs
✓ Ideal for ultra high speed machines
✓ Very fast switching transitions – as low as a few nSecs
INTEGRATED DRIVES
Over voltage at
machine terminals due
to cable impedance
INTEGRATED DRIVES
Overvoltage reduced
by having short leads.
Integration needed to
reduce lead length
when using ultrafast
switching.
INTEGRATED DRIVES
Integration of Passives
✓ Rationale
✓ Passive components (Land C) needed,
particularly when interfacing to an ac supply
✓ As a motor gets faster, it gets smaller for a
given power
✓ However, the passive components do not.
✓ In very high speed drives the passive
components can be larger than the drive
itself.
INTEGRATED DRIVES
Integration of Passives
✓ Wish to reduce size and space occupied by passives

✓ Shape the capacitors to fit in any voids within the motor
✓ Try and use common magnetic paths for the motor and inductor magnetic flux
✓ Use common cooling paths for motor and inductors
INTEGRATED DRIVES
Specific Example
INTEGRATED DRIVES
INTEGRATED DRIVES
INTEGRATED DRIVES
INTEGRATED DRIVES
85% Reduction in
inductor volume
INTEGRATED DRIVES
The final drive - we

need to do more work
on reducing the
capacitor size!
INTEGRATED DRIVES
Conclusions on Motors for Integrated Drives

• Great for modularity
• Ability to introduce redundancy and fault tolerance
• Fault tolerance introduces a whole new set of challenges.
• Integration reduces stray impedances, which is very advantageous for fast
switching drives
• Ability to integrate passives into the machine can give large space and mass
savings.
INTEGRATED MOTOR DRIVES, STATE OF THE ART, CHALLENGES, AND
EMERGING TECHNOLOGIES
POWER CONVERTER AND CONTROL TECHNIQUES
Dr Xu Deng
NUAcT Fellow: Electrical Power
Newcastle University, UK
Power Converters in IMDs
– Switching Devices
❑ Low inductance motors

❑ High speed motors
❑ High temperature application
- POWER CONVERTER AND CONTROL TECHNIQUES - Dr Xu Deng 2/21
Power Converters in IMDs
– Converter Topologies
3-phase/multiphase VSI
Multiphase H-bridge VSI

Multi-level VSI
Power Converter Integration
- Standard Frame Mounting
Nidec Danfoss DANA Bosch

Commander 3 Decentral drive concept TM4 MOTIVE Electric drive for light
drive mounted to with motor adaptor integrated motor drive commercial vehicles
IMfinity induction plate
motor
-Endplate Mounting
Mitsubishi Electric EV Motor System with built-in silicon carbide

inverter
A 34KW high speed SiC based endplate mounted IMD Tesla Model S triangular frame axial endplate mounted
(A research prototype from Newcastle University) electronic drive
- Radial Stator Mounting
Liquid cooled housing Power electronics
Electric motor
A Multiphase Integrated Modular Motor Drive IMD for aerospace propulsion by H3X (200kW, 20,000rpm)
(A research prototype from Ghent University )
- Converter Modularity
ProteanDrive in-wheel motor system

including the integrated inverter
- Passive Filter Integration
❑ Decoupled magnetic
paths
❑ Shared cooling paths
❑ The total volume of the
87.6% smaller integrated filters is
87.6% smaller than the
total volume of the
conventional discrete
LCL filter inductors.
Sensors
- Current and Position Sensing Technology
Shunt Resistor Current Transformer Hall-effect Current Sensor
Magnetic Sensors: Hall-

Resolver Optical Encoder
effect Position Sensor
Control Methods
- Torque and Speed Control
Nested control loops
Control Methods
- Torque and Speed Control
Integrated low power actuation drives High performance, integrated, robotic drives
❑ hobby radio-controlled (RC) vehicles ❑ trapezoidal BLDC or sinusoidal BLAC machines
❑ valve actuation ❑ built-in resolver or encoder position feedback
❑ robotics ❑ high bandwidth data link
(a) (b) (c)

Integrated RC drive (a) gearbox, (b) power electronics, Copyright © DHL International GmbH
(c) motor with covers removed
Control Methods
- Dynamic Torque Control
Field Oriented Control (FOC)
❑ torque is controlled via stator currents
❑ Clarke/Park Transform
❑ simplified the machine equations
Field Oriented Control (FOC)
Control Methods
- Dynamic Torque Control
Direct Torque Control (DTC)
❑ choose a switch combination that keeps the flux magnitude constant
❑ advance the rate of rotation of the flux to increase torque or decrease it to reduce torque
Direct Torque Control (DTC)
Control Methods
- Multiphase Control
❑ The torque control in the d-q
sets is identical to the three-
phase machine
❑ Additional control is required

to force the current to zero in
the additional x-y sets
FOC extension to multiphase drives
Control Methods
- Voltage Synthesis and Interleaving
❑ Space Vector PWM is complex in

multiphase machines and Sine-
triangle PWM has a wider adoption
❑ Phase shift between triangle

waveforms increases the effective
switching frequency
❑ Oversampling followed by digital

filtering is recommended
Effect of interleaving on d.c. current ripple

(resistor-inductor load of 80 kW, power factor of 0.85, 650 V ideal d.c.
voltage source, 600 Hz output frequency and 25 kHz carrier frequency)
Control Hardware
- Control Platforms
Description Peripherals Communications Libraries Numerics Code
Micro-controller Micro-processor QEI, PWM, SPI, I2C, CAN, Park, Clarke, Fixed point, C, C++,
with dedicated ADC, DIO, Timers, USB, USART Modulation, Floating point Mbed, Arduino
hardware Interrupts Control, in software
peripherals so slow
Digital Signal Micro-processor Maths coprocessor. USART, USB, SPI, Park, Clarke, Fast C, C++
Processor (DSP) optimised for fast Other peripherals others, but Modulation, hardware
maths as above, but fewer channels Control, floating point
fewer channels Optimization,
Filters
Field Logic array DIO, Can be Low level, for Fixed point, VHDL
Programmable Specialist configured using peripherals,
Gate Array (FPGA) peripherals can be libraries telecoms, filters
configured using
libraries
System on a chip Logic array with Full range, but Full range, but Park, Clarke, Fixed point, VHDL with C++,
(SoC) integrated micro- quantity limited by quantity limited Modulation, Floating point Mbed,
processor number of pins by number of Control in software Arduino
pins so slow
Control Hardware
- Peripherals
Information flow between the circuit and the control hardware
Control Hardware
- Prototyping systems
❑ Automatic code generation ❑ Control Hardware-in-the-loop
Embedded Controller
❑ Power Hardware-in-the-loop
Control Hardware
- Distributed architectures and data networking
A 9-phase IMD, configured as 3 x 3phase sub-machines

(Research prototype from Nottingham University)
Control architecture of the 9-phase IMD
Summary
❑ The main benefits of converter integration
are modularity, short connections and
simplification of external wiring
❑ The benefits of the integrated controller are

the close coupling of the machine, converter
and drive, which allows accurate parameter
mapping
❑ Prototyping becomes more complicated, with

no direct access to internal measurements
❑ Additional consideration must be given to

environmental protection and EMI
- THERMAL MANAGEMENT FOR
INTEGRATED DRIVES Liliana de Lillo
INTRO
• Background and importance of thermal management

• VFD’s and Motors w.r.t. IMD’s
• Thermal management for Electrical machines
• Power converters
• Power module components and construction
• Thermal management techniques
• Conclusions
- THERMAL MANAGEMENT FOR INTEGRATED DRIVES Liliana de Lillo 2/XX
INTRO
Thermal
• Power electronic drive systems generate a range Management
Heat
of engineering challenges – Heat management
and reliability is key
– Aim is to remove generated heat losses to the ambient in an
effective manner
– VFD’s and Electrical machines are hard enough to cool as
separate entities
– Higher levels of integration and more compact form factors
increase the complexity of the problem Reliability
– Smaller surface area – higher heat flux Mechanical Stress
INTRO
Thermal
• Heat resulting from losses in components / windings / Management
gear trains
Heat
– Limits lifetime of electrical and mechanical parts
– Effective removal of waste heat is essential due to high heat flux
and reduced surface areas
– Buried conductors, poor heat flow paths limit maximum
performance
• Mechanical stresses generated by thermal cycling
– Wear-out of components and interconnections internally
– Deterioration of external connections, thermal and mechanical Reliability
interfaces Mechanical Stress
– Power Converter components
THERMAL MANAGEMENT OF
INTEGRATED MOTOR DRIVES
System Architectures Classification of cooling methodologies
INTEGRATED ELECTRICAL MACHINES
System Architecture Examples – Passively cooled - Air
• Main route for heat to ambient through stator housing

– All losses conducted through casing and motor parts
– Thermal design and simulation critical
System Architecture Examples – Actively cooled - Liquid
• Liquid cooled traction drive – Borg Warner

– 125kW 16,600 RPM
– Liquid jacket around stator
– Separate motor and power converter sections
– Bolted together
System Architecture Examples – Actively cooled – Liquid – Series arrangement
• Integrated liquid cooled system

– 125kW 13,500 RPM
– Integrated thermal path
– Serial system used
• PE then Motor
– PE cooled as priority
– Rotor cooling used
• Depending on motor
– Parallel paths can be
difficult to design
– Serial paths ensure fluid
flow is consistent
THERMAL MANAGEMENT OF POWER
CONVERTERS
• Electrical motors are constructed using relatively high temperature
capable materials
– Steel stator laminations – Copper or Aluminium conductors
– Insulation materials
– Permanent magnets
• All typically more robust than the Power Electronic materials
• Power Electronic Modules
– Power semiconductor devices – Si, SiC, GaN – (<200C)
– Power device interconnect – Solder (<150C) – Silver Sinter - <175C
– Control Electronics (<125C) – cost driven
– High heat flux in small interfaces is a challenge
– Small sizes desirable for IMD’s – compounds thermal management problems
CONVERTERS
• Different functional layers are required
in order to provide suitable electrical,
mechanical and thermal connections
• Different arrangements require varying
number of thermal interfaces
• Conductive layers
• Isolation layers
• Interconnection layers
– Die bonding
– Top side connections
• CTE matching important for reliability
CONVERTERS - SUBSTRATES
• Insulation materials –
– Polymeric – Polyamide, Polyester – various compositions – Low Cost – High thermal resistance
– Ceramic – AlO, Si3N4, AlN – High thermal conductivity – High Cost
• Insulated Metal Substrate • Direct Bonded Copper

– Aluminium or copper core – Copper and ceramic layers co-fired at high
– Polymer isolation layer temperatures
– Copper conductors – Cu features etched using PCB techniques
– Cost effective PCB – Cost effective
production processes – CTE match for Cu
– Limited to low power baseplates
CONVERTERS - SUBSTRATES
• Insulation materials –
– Polymeric – Polyamide, Polyester – various compositions – Low Cost – High thermal resistance
– Ceramic – AlO, SiN4, AlN – High thermal conductivity – High Cost
• Direct Plated Copper • Active Metal Brazed

– Alternative to DBC – Used for ceramics which cannot accept Cu
– No co-firing needed – Ti layer typically used as ‘glue’
– PCB processes – Cu features pre-cut before firing – thicker Cu possible
– Thinner Cu but higher feature – Less feature resolution
resolution – vias easily achievable – High reliability
– Higher cost
– Good CTE match for
AlSiC baseplates
CONVERTERS – DIE BONDING
Three main technologies used commercially
• Soldering • Silver Sintering – Pressure-less • Silver Sintering – Pressure-
– Industry standard – Silver nano particles – coalesce assisted
process under temperature – Silver nano particles – coalesce
– Wide variety of – Higher reliability under temperature and pressure
materials – Higher thermal conductivity – V.High Reliability
– Highly scalable – Material cost – V.High thermal conductivity
– Cost effective – Potential for voiding within – Higher bond line density
– Reduced reliability bond line – Material cost
• Thermal cycling – Process time – not scalable
• Temperature capability
CONVERTERS – ELECTRICAL INTERCONNECT
Three main technologies used commercially
• Aluminium Wire bonding • Copper wire bonding • Sintered Flex
• Aluminium wire – Higher current carrying capability – High reliability
ultrasonically bonded to – Higher reliability – Potential for using vertical
top surface of die – Surface oxidation space above devices
– Many devices incompatible – CTE complicates design
• Cost effective – rapid • Bond energy needed is too high – Manufacturing capacity
• Reduced power cycling • Need to prepare surface – sintering Cu
reliability blocks ot thick Cu deposition
CONVERTERS – COOLING ARRANGEMENTS
Forced air or liquid cooling are typically the only viable solution
• Forced air • Cold-plate
• Cost effective where suitable • Cost effective – simple
IMD arrangement exists manufacturing process
• Highest mass of liquid cooing
systems
• Pin-Fin • Turbulator
• Cost effective where suitable IMD • Direct substrate cooling
arrangement exists • Cost effective injection moulded cooler
• high thermal mass for transient • High heat transfer coefficient (lower
performance pumping power needed)
• Poor transient overload
performance
• Jet impingement • Cooling techniques have varying

• High velocity targeted substrate characteristics
cooling
• Highest HTC – lowest mass and
pumping power
• 3D printed structures required
THERMAL MANAGEMENT OF IMD’S
CONCLUSIONS
• Compact size and structural and functional integration results in
– reduced material usage
– Reduced weight
• Thermal management is a key challenge for Integrated Motor Drive
implementation – but no one system fits all
• Reduced size implies an increased heat flux density
– Higher temperature capability is desirable
– Limitations on existing power circuit implementation technologies
• substrates, die, interconnect etc
– Thermal cycling and power cycling problems can be exacerbated
• Concurrent thermal mechanical and electrical design is essential
INTEGRATED MOTOR DRIVES:
STATE OF THE ART, CHALLENGES, AND EMERGING TECHNOLOGIES
Wide Bandgap Switches and the
Future of Integrated Motor Drives
Dr. Thomas Jahns
Grainger Emeritus Professor
University of Wisconsin - Madison
Vision of Future
Integrated Motor Drives
2
Future Integrated Motor Drives
Wireless Control
Inverter
• Power electronic integrated into
machine housing with minimal impact
on original machine dimensions
• Controls implemented without need
for additional fragile control wiring
ECCE’23 IMD Tutorial October 29, 2023 3
Integrated Power Electronics
Key Technical Challenges
• Lower Cost Power Electronics

• Higher Power Density à Lower Mass & Volume
• Higher Temperature Power & Control Electronics
(200ºC ambient)
• Vibration-Tolerant Power Electronics
• Higher Power Electronics Reliability
The New Era of Wide Bandgap
Power Semiconductors
• Many devices are
Si
lic pushing Si boundary
on
100M C ar
• Wide Bandgap
bid Materials Significantly
10M
Thyristors
GTOs
e /G
Expand Limits
all
1M IGCTs
ium
Power (VA)
100K
BIPOLAR
Ni
10K TRANSISTOR
MODULES trid
e
IGBT MOSFET
Si
1K MODULES Modules
lic
100
on
DISCRETE
MOSFET
10
10 100 1K 10K 100K 1M
Operation Frequency (Hz) Modified from an Application Note
of Powerex, Inc. Youngwood, PA.
Impact of WBG Technology
• Wide bandgap (WBG) power semiconductors are launching a
technology revolution in power electronics
Ø Much higher switching speeds à high power density
Ø Higher operating temperatures à Tj(max) = 175ºC or higher
Ø Other special characteristics Si SiC
400 kW Traction Inverters

ECCE’23 IMD Tutorial October 29, 2023 Source: John Deere 6
Impact of WBG Technology
• Wide bandgap (WBG) power semiconductors are launching a
technology revolution in power electronics
Ø Much higher switching speeds à high power density
Ø Higher operating temperatures à Tj(max) = 175ºC or higher
Ø Other special characteristics
• Treating WBG power switches as drop-in replacements for today’s
silicon power switches will not take full advantage of their capabilities
How do we extract maximum

value from new WBG switches?
Problems Caused by Drop-In
Replacement of WBG Switches in VSIs
Voltage-Source Inverter
(VSI) Motor Terminal
Over-Voltage
Efficiency
EMI
The natural inclination to replace the silicon power switches with

SiC or GaN switches in VSIs creates complications
Combining WBG Switches and
Current-Source Inverters in IMDs
3 kW and 100 kW CSI-IMD Development
9
WBG-Enabled Current-Source
Inverters for Integrated PM Motor Drives
PM Motor Drive
Next-Generation CSI-IMD Project Overview
Integrated Motor
Drive (IMD) Develop innovative integrated
motor drives (IMDs) using current-
source inverter (CSI) topology and
WBG Switches
WBG power switches to disruptively
increase the penetration of
adjustable-speed drives.
CSI-IMD Performance Metrics
Current-Source
Inverter (CSI) State-of-the- Proposed Improve-
Metric Art VSI CSI-IMD ment
Lbus
Inverter Power density @
1.6 kW/L >5 kW/L >3.1x
3 kW, 230V-3ph
Cf
Specific Power @ 3 kW 2.72 kW/kg >8 kW/kg >2.9x
10
Appealing Features of CSIs vs. VSIs
Topology DC Link Output Voltage Common-Mode EMI
105℃
VSI
Fragile and High dv/dt, creating High Common Mode (CM)

temperature-limited motor insulation stress EMI and bearing current risk
CSI
11
200℃
Rugged and capable of Low-THD sinusoidal voltage Integral LC filter provides
high temperature and current waveforms appealing EMI roll-off
WBG-based Current-Source Inverter (CSI) overcomes many of the VSI limitations by significantly
lowering output dv/dt stress, CM EMI emissions, bearing current risks, and temperature limitations
Prototype 3 kW
Assembled CSI-IMD
Current-Source Inverter
Integrated Motor Drive
l Back-to-back CSR-CSI has been
integrated into machine
l 3 printed circuit boards include
End Chamber Assembly controller card
Ventilation
Slots Controller l Power consumption of cooling fan
Card
has been reduced to 3 W
Power electronics all fits

within original machine housing
12
Year 3 Prototype CSI Integrated Motor Drive
• Prototype CSI-IMD unit was successfully tested on a WEMPEC dynamometer

Year 3 Prototype Unit Performance
Measured Current and Voltage Waveforms
with Rated 3 kW Motor Load Year 3 Prototype Unit
Current (A)
Year 2 Benchtop Unit

THD < 1.5%
Voltage (V)
• Prototype CSI units met all project

performance requirements
• Measured current THD < 1.5% is
well within max. limit of 8%
Time (ms) • Measured full-load efficiency >98%

fsw = 100 kHz in at full load
Integrated Motor Drive for Traction Applications
Surface PM Synch. Machine Project Objectives
Integrated Motor Pursue an aggressive research program to merge
high-torque-density traction machines and
Drive (IMD) high-efficiency inverters into state-of-the-art
integrated motor drive (IMD) packaged inside
combined housing that will exceed existing
traction drive performance metrics in key
WBG Switches categories, as follows:
Performance Metric Targets

Metric Motor Pwr Electr.
Power Density (kW/L) ≥ 50 ≥ 100
Current Source Inverter (CSI) Cost ($/kW) ≤ 3.3 ≤ 2.7

System Peak Power
100 100
Rating (kW)
Project aims to develop advanced IMD technology for

achieving major performance improvements at lower cost
IMD Configuration and Fabricated Components
Stator Inner Housing
DC Link Inductor w/ Cooling Jacket
Exploded View of the Integrated Machine and
Power Electronics
Assembled Machine IMD Unit during Initial Tests
IMD integrates power electronics and motor into a single

unit with minimum total volume 16
1 MW Integrated Modular Motor
Drive (IMMD) Development
17
Electric Aircraft Propulsion
Ampaire
Lilium
City Airbus
Beta
GE Joby Aviation
Electrified aircraft propulsion is experiencing an explosion of innovation

18
Power Conversion System
Power Density Requirements
Jet Engines
11 to 19 kW/kg
Machine + PCU
14
kW Power Conversion
/kg
Electric Machine Specific

12 System
Power Density (W/kg)

kW
/kg Specific Power
Density (kW/kg)
5.4 kW/kg
Power Conditioning Unit (PCU)

Specific Power Density (W/kg)
ARPA-E
To match SOA turbofan power density, electric propulsion system
power density must reach at least 12 kW/kg
NASA ULI Project: 1 MW Machine Drive Development
Modular Windings with Modular Winding Excitation Scheme 1 MW IMD Configuration
Six 3-Phase Winding Sets
Stage III
6 5
1 4
Stage I Stage II
2 3
• Stator configured as modular six 3-phase wye-connected winding sets

• Winding sets are excited in pairs, and 3 modules are connected in series across 2 kV dc source
Ø Each winding set excited from 667 Vdc bus, reducing partial discharge risk
Configuration chosen to offer opportunities for high power density and fault tolerance
Modular 18-Phase SiC Inverter Details
Exploded View of 20 krpm PM Machine Assembled PM Machine Submodule Pair View
Key Components
Prof. Jin Wang / OSU
• Surface PM machine selected as best topology to meet requirements
DC-Link Cap DC-Link Cap
• Stator cooled using PAO (synthetic oil) and rotor uses forced air
Ø Litz windings immersed in PAO flowing through all stator slots
Every machine
Snubber
Gate Drive and
phase winding is
• Each power electronics submodule excites two stator phase windings excited by a
43.5 mm
Current Cap Power Supply

Transduce
Ø Total of 9 submodules
r to excite 18 coils (6 x 3-phase) dedicated phase-leg
41 mm Power Module
• Submodule houses two SiC phase-leg modules, rated at 450 A, 1200 V
1 MW Integrated Motor Drive Configuration
IMD Rendered Drawing IMD Electrical Excitation
Stage III
Total IMD Physical Metrics

Stage I 575 mm dia. X 286 mm long
Stage II Vol. Power Density = 13.5 kW/L
Est. Total IMD Mass = 111 kg
Est. Mass. Power Density = 9.0 kW/kg
Significant Step Toward Demonstrating both Power Density & Modularity

Assembled 1 MW Integrated Modular Motor Drive
Sample of Module Phase Currents & Vdc Waveforms
Vdc = 350 Vdc
Iph = 165.9 A rms
Test Conditions: 4000 rpm, 274.5 Nm, 115 kW

• Tests conducted at UW and NASA NEAT facility
Ø Full IMD functionality demonstrated
Assembled 1 MW IMD Ø Tested up to ~60% Te-rated , 100% nrated
• Dyno limitations prevented full power operation
All key design concepts successfully demonstrated 23

Future IMD Directions and
Conclusions
24
Commercial IMD Prototypes and Products
BorgWarner H3X
MAGicALL
BMW
WBG-based IMD development efforts are more active then ever before 25
The Road to Embedded Power Electronics
200ºC, 3D
Power Embedded Power Controls
Electronics Electronics
Thermal
Materials
Mechanical
Manufacturing Processes: Electromagnetics/

Additive/Composite/IC/Packaging
EMI
Future power electronics will required intense cross-disciplinary research

26
Conclusions
• Future integrated motor drives will progressively move towards complete
integration of complete motor drive electronics inside machine housing
• WBG power semiconductors will have a major impact in enabling and

accelerating the development and adoption of future integrated motor drives
• Future advances in IMD power density and reliability depends on addressing

multi-disciplinary challenges involving materials, thermal, mechanical, mfg.
• Embedded power electronics will become increasingly pervasive, playing a

playing a major role in electrifying the world and reducing GHG emissions
Get ready for accelerating adoption of IMDs!

Thank you!
For more information, contact:
Dr. Thomas Jahns

Bucky jahns@engr.wisc.edu
Badger
- INDUSTRIAL MANUFACTURER PERSPECTIVE
Dan Kernan, ITT Inc.
ITT AT A GLANCE
MOTION INDUSTRIAL CONNECT & CONTROL

Diversified, leading TECHNOLOGIES PROCESS TECHNOLOGIES
manufacturing of highly
engineered critical
components and
customized technology
solutions.
| $3B ANNUAL REVENUES
| 49 MANUFACTURING LOCATIONS
| 1,250+ ENGINEERS
| 1,500+ ACTIVE PATENTS
© ITT
INDUSTRIAL MARKETS & USES
PULP & PAPER CHEMICAL OIL & GAS MINING PHARMACEUTICAL
Ability to Control Fluids Touches Everyday Life 3
© ITT
INDUSTRIAL FLOW MACHINES EXAMPLES
INDUSTRIAL INDUSTRIAL
PUMPS FANS & BLOWERS
Millions of Industrial Flow Machines with Electric Motors Installed 4
© ITT
INDUSTRIAL PUMP & FAN ENERGY CONSUMPTION
GLOBAL ELECTRICITY INDUSTRIAL PUMP &
PRODUCTION FAN ENERGY
2,500 TWh
27,000 TWh
Distribution &
Transmission Losses
Energy consumption
Other
Electronics
Global Electricity Global Electricity

Heat
~10%
Production Consumption
Light Global Electricity
Residential
Commercial
Motors
Industrial
Mechanical Movement
Compressors
Fans
2,500 TWh
~$300B
Pumps Global Electricity Costs
Production Consumption Application Market Equipment
Source(s): 5
[1] International Energy Agency, Energy-Efficiency Policy Opportunities for Electric Motor-Drive Systems, 2011
© ITT [2] International Energy Agency, 2019 Global Electricity Consumption; https://www.iea.org/reports/electricity-information-overview/electricity-consumption
[3] Average Global Business Electricity Costs of $0.127 per kWh, https://www.electricrate.com/data-center/electricity-prices-by-country/
THE CURRENT STATE
INDUSTRIAL FLOW MECHANICAL ADJUSTABLE SPEED
MACHINES CONTROLS CONTROLS
| $300B annual spend on electricity | Electric motor runs the machine at 100% | Variable Frequency Drive (VFD) regulates the
fixed speed while a control valve throttles voltage and frequency to the motor to adjust the
| 85% of industrial flow machine operate with the flow speed
no control or mechanical controls
+ Proven method of control, small footprint + Lower energy, improved equipment reliability
| Low adoption of digital adjustable speed
controls − 30-70% wasted energy, lower equipment − Large footprint, high installation cost and
reliability complexity
Source(s):
[1] ITT research Adjustable Speed Control – Great Benefits, Low Adoption 6
© ITT
CASE STUDY | UPGRADE TO ADJUSTABLE SPEED
UPGRADED 37KW INDUSTRIAL

pump CENTRIFUGAL PUMP TO ADJUSTABLE
SPEED CONTROL AT PULP & PAPER PLANT
EMD
55% energy saving

motor
80 tons CO2e emissions reduced per year
50% increase in equipment life
$86,000 10-year life cycle cost savings
Source(s):
[1] ITT research
7
© ITT
THE OPPORTUNITY
INDUSTRIAL FLOW MACHINES INDUSTRIAL FLOW MACHINE
ADJUSTABLE SPEED ADOPTION ADJUSTABLE SPEED POTENTIAL
Requires fixed
speed
15%
Has adjustable
speed $60 Billion
Electricity Costs Savings Potential
37%
Industrial
Pumps
And
500 TWh 370,000

Fans
48% Electricity Consumption Avoided ~ Football Fields of Solar Panels

Fixed speed that
could benefit from
adjustable speed
218 Million
Tons of CO2e Avoided
~ 70 Million
Vehicles Converted from ICE to EV
Source(s):
[1] ITT Internal Research
[2] Average Global Business Electricity Costs of $0.127 per kWh, https://www.electricrate.com/ 8
Definitions:
[3] EV Savings of 225 grams CO2e per mile, average miles per year 13,500, Are electric vehicles definitely better for the climate than gas-powered cars? | MIT Climate Portal
© ITT ICE: Internal Combustible Engine
[4] 436 grams CO2e per kWh, Carbon intensity of electricity, 2000 to 2022 (ourworldindata.org)
EV: Electric Vehicle
[5] 1,362,795 kWh annual electricity generated by one football field covered with solar PV, Green Power Equivalency Calculator - Calculations and References | US EPA
ADJUSTABLE SPEED (VFD) ADOPTION BARRIERS
| VFDs require clean environmentally

controlled environment, not easily available
in existing industrial plants
| Footprint – VFDs are typically 3-5x the

footprint of typical motor contactor
| Complex installation to ensure reliable motor

operation – VFD shielded cable, inverter
duty motor insulation, dV/dt filters
| Power quality - increasing demand of non-

linear loads will require power conditioning
Earthrings
Beldon
VFD High Installation Cost and Complexity Limits Adoption Definitions:

VFD: Variable Frequency Drive
9
© ITT
THE SOLUTION
INTEGRATED MOTOR DRIVE
Integrated motor drives enables a EXAMPLES
direct replacement to the fixed speed

electric motor
| Replace mechanical controls with digital adjustable

speed controls
| Lower total installed cost than VFD alternatives
| Reduce complexity of implementation
| Improved efficiencies with optimized pairing of

power electronics and synchronous motor
technology
10
Definitions:
© ITT
VFD: Variable Frequency Drive
THE CHALLENGES
EASILY ROBUST & SCALABE &

RETROFITABLE RELIABLE COST EFFECTIVE
| High power density – dimensionally | +10 year life span | Scalable to +150kW, most commercially
equivalent to fixed speed motor available IMD are less than 15kW
| Withstand outdoor, wet, hot environments
| No special cooling – air cooled preferred | Economic benefits must outweigh
| Contend with corrosive and potentially upfront costs
| High power quality – IEEE 519-2022 explosive gases and dust
compliance
Keep it Simple and Make it Easy 11
© ITT Definitions:
IMD: Integrated Motor Drive

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INTEGRATED MOTOR DRIVES, STATE OF

THE ART, CHALLENGES, AND EMERGING TECHNOLOGIES

3 University of Wisconsin - Madison, USA

4 ITT Inc, USA

• Introduction to VFD’s and Integrated Drives – Lee Empringham

– Can generate conflicting aims in the designers if they create

• PE Designer • Motor Designer

✓ Close proximity of power electronics and machine

Machine types most suitable for Modularisation

Suitable Suitable with Challenges Difficult

Switched Reluctance Permanent Magnet Induction

Modularity and Fault Tolerance

• How many modules should there be?

Integrated modular wheel

• Very dependent upon motivation for modularity

Isolation between Modules

Every coil isolated

Can we have modularity with Distributed Windings?

Use of Wide bandgap devices

✓ Wish to reduce size and space occupied by passives

The final drive - we

Conclusions on Motors for Integrated Drives

❑ Low inductance motors

Multiphase H-bridge VSI

Nidec Danfoss DANA Bosch

Mitsubishi Electric EV Motor System with built-in silicon carbide

ProteanDrive in-wheel motor system

Shunt Resistor Current Transformer Hall-effect Current Sensor

Magnetic Sensors: Hall-

Nested control loops

(a) (b) (c)

Field Oriented Control (FOC)

Direct Torque Control (DTC)

❑ Additional control is required

FOC extension to multiphase drives

❑ Space Vector PWM is complex in

❑ Phase shift between triangle

❑ Oversampling followed by digital

Effect of interleaving on d.c. current ripple

A 9-phase IMD, configured as 3 x 3phase sub-machines

❑ The benefits of the integrated controller are

❑ Prototyping becomes more complicated, with

❑ Additional consideration must be given to

• Background and importance of thermal management

• Main route for heat to ambient through stator housing

• Liquid cooled traction drive – Borg Warner

• Integrated liquid cooled system

• Insulated Metal Substrate • Direct Bonded Copper

• Direct Plated Copper • Active Metal Brazed

• Jet impingement • Cooling techniques have varying

• Lower Cost Power Electronics

400 kW Traction Inverters

How do we extract maximum

The natural inclination to replace the silicon power switches with

Fragile and High dv/dt, creating High Common Mode (CM)

Power electronics all fits

• Prototype CSI-IMD unit was successfully tested on a WEMPEC dynamometer

Year 2 Benchtop Unit

• Prototype CSI units met all project

Time (ms) • Measured full-load efficiency >98%

Performance Metric Targets

Current Source Inverter (CSI) Cost ($/kW) ≤ 3.3 ≤ 2.7