Simulation Based Performance

Characterization of an Electric
Drive Train System

Authors: Zed (Zhangjun) Tang, Wendy Lei

Presenter: Scott Stanton

Ansoft LLC

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Electric Drive Train Configuration

Electrical Grid Traction Motor

Energy Storage Unit Power Electronics

Drive Cycle
Control Unit
Generator

ICE Engine

ICE: Internal Combustion Engine

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Electric Drive Train Example

Full-Size SUV 2-Mode Hybrid

Power Electronics
Traction Motor

Controller 300 Volt Battery Pack

2-Mode Transmission

ICE
Chevrolet
Tahoe
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Electric Drive Train Applications

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Contents

• Efficiency Map of Traction Motor

• Equivalent Circuit Model Extraction
• Vector Controller
• Conclusions
• Future Work

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Basis for Research – 2004 Toyota Prius

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Contents

• Efficiency Map of Traction Motor

• Equivalent Circuit Model Extraction
• Vector Controller

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Efficiency Map of Traction Motor

Q Axis D Axis

Synchronous Motor
Phasor Diagram

Synchronous Motor
Losses

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Use Transient with Motion for Accurate Losses
Calculation
Transient with Motion

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Eddy Losses on Permanent Magnets

Assign zero current to the

permanent magnets:
Jtot = 0
Apply boundary condition to each
magnet

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Extract the Capability Curve of IPM
Output Torque

Constant
Torque

Constant
Power

Motor Speed
Idealized Torque vs. Speed Curve Comparing with Capability Curve

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Optimal Torque Output at Different Currents

Ansoft Corporation Torque vs. Load Angle @ Currents Maxwell2DDesign1

400.00
Curv

350.00

300.00

250.00
Y1

200.00

150.00

100.00

50.00

0.00
0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00
Primary Sweep

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Efficiency Map of Traction Motor
Output Torque (N*m)

Efficiency (%)
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Speed (RPM) Ansoft, LLC Proprietary
Contents

• Efficiency Map of Traction Motor

• Equivalent Circuit Model Extraction
• Vector Controller

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ECE Method

Goal: Create a state space type equivalent circuit

extracted (ECE) model from magnetostatic FEA
parametric solution for use in a system simulation

Input Variables IB

Output Parameters
IC - λa, λ b, λ c
Θ - Torque
IA

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System Representation

Current
Inputs:
Ia, Ib, Ic Torque
Ia, Ib, Ic, Theta
Back EMF

Outputs:
EMF: Va, Vb, Vc
Torque
Theta

Where: λT = LI + λm
d
V= T
λ
dt
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Solution Method

• Assume Wye connected winding

• IA = Im * cos(Θ * PolePairs - β )
• IB = Im * cos(Θ * PolePairs - β – 120)
• IC = Im * cos(Θ * PolePairs - β – 240)
• Let phi = Θ * PolePairs - β
• Independent • Dependent
Iy
IB

IA Ix

IC

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Input Parameter Variations

• Im from 0 to Imax : 9 steps

• Beta from 0 to 330 deg: 30 steps
• Rotor angle: 0 to 60 electrical deg: 10 steps
• Total number of solutions:
• 9 * 30 * 10 = 2700 independent solutions

Good for rapid design using

Distributed Solve Option (DSO)

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DSO – Distributed Solve Option

Host

Nodes …

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User Defined Simplorer® Models

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Simplorer® ECE Circuit

Iyb GAIN
Coordinate transformation realized using VHDL-AMS
n
Iyc GAIN GAIN

Ixb GAIN
ATAN2 GAIN

Ixc GAIN

ω +
RA
A
+

IA L1
GAIN Φ
e1 D
Beta_IN Im_IN Theta_IN
GAIN
RB
A

IB L2
e2 D GAIN

RC
A
GAIN ECE - LINK
IC L3
e3 D

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Verify ECE Model Against FEA Transient

• Open Circuit Back EMF

Ansoft Corporation Back EMF OC_EMF
300.00
Curve Info
Ansoft Corporation Back EMF
InducedVoltage(PhA)
OC_EMF

Setup1 : Transient
240.00
InducedVoltage(PhB)
Setup1 : Transient Curve Info avg
200.00 InducedVoltage(PhC) InducedVoltage(PhA)
225.0685
Setup1 : Transient Setup1 : Transient

Y Component 1 InducedVoltage(PhB)
-105.5390
Imported Setup1 : Transient
230.00 InducedVoltage(PhC)
Y Component 2 -102.5586
Imported Setup1 : Transient
100.00
Y Component 3 Y Component 1
224.6388
Imported Imported
Y Component 2
-105.1177
Imported
220.00 Y Component 3
-102.3206
Y1

0.00 Imported
Y1

210.00
-100.00

-200.00 200.00

-300.00
190.00
0.000 0.002 0.004 0.006 0.008 0.010 0.012
Primary Sweep

0.0005 0.0010 0.0015 0.0020 0.0025 0.0030

Primary Sweep

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Verify ECE Model Against FEA Transient

• Unbalanced Phase Currents

Ansoft Corporation XY Plot 2 Test_tran
0.50
Curve Info
Ansoft Corporation Flux Linkage FluxLinkage(PhA)
Test_tran1
0.50 Setup1 : Transient
0.40
Ansoft Corporation Flux Linkage
FluxLinkage(PhB)
Curve Info Test_tran
FluxLinkage(PhA)
0.30 Setup1 : Transient
Setup1 : Transient Curve Info
0.40 FluxLinkage(PhC)
FluxLinkage(PhB) FluxLinkage(PhA)
Setup1 : Transient
Setup1 : Transient Setup1 : Transient
0.30 Y Component 1
FluxLinkage(PhC) FluxLinkage(PhB)
Imported
0.30 Setup1 : Transient Setup1 : Transient
Y Component 2
0.20 Y Component 1 FluxLinkage(PhC)
Imported
0.20 Imported
Setup1 : Transient
Y Component 3
0.20 Y Component 2
Imported Y Component 1
Imported
Imported
Y Component 3
0.10 Y Component 2
Imported
0.10 Imported
0.10
Y1

Y Component 3
Imported
0.00
Y1

0.00
Y1

-0.10 0.00
-0.10

-0.20 -0.20

-0.10
-0.30
-0.30

-0.40
-0.40
-0.20
0.000 0.002 0.004 0.006 0.008 0.010 0.012
Primary Sweep
-0.50
0.000 0.002 0.004 0.006 0.008 0.010 0.012
Primary Sweep

-0.30
0.000 0.002 0.004 0.006 0.008 0.010 0.012
Primary Sweep
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Contents

• Efficiency Map of Traction Motor

• Equivalent Circuit Model Extraction
• Vector Controller
• Energy Storage Sub-system
• System Integration

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Vector Control with Step Load

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Vector Control with Step Load

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Vector Control with Step Load

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Vector Control with Ramp Load, Mfg. IGBT and
Deadtime Control

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Vector Control with Ramp Load, Mfg. IGBT and
Deadtime Control

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Maximum Torque per Ampere (MTPA) and Field
Weakening Control

Voltage and Current Limitation Equations

is = i + i ≤ I lim 2
d
2
q

u s = ωe ( Ld id +ψ f ) + ( Lq iq ) ≤ U lim
2 2

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Maximum Torque per Ampere (MTPA) and Field
Weakening Control

id, iq calculation equations for field

weakening control

ψf
2 2
⎛ U lim ⎞ ⎛ Lq iq ⎞
id = − + ⎜⎜ ⎟⎟ − ⎜⎜ ⎟⎟
Ld ⎝ Ld ωe ⎠ ⎝ Ld ⎠
iq = I 2
lim −i
2
d

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Maximum Torque per Ampere (MTPA) and Field
Weakening Control
2
⎛ U lim ⎞
Lqψ f − (Lqψ f ) + 8⎜⎜ ⎟⎟ (Lq − Ld )
2 2

ψf ⎝ ωe ⎠
id = − +
Ld 4(Lq − Ld )Ld
2
⎛ U lim ⎞
⎜⎜ ⎟⎟ − (Ld id +ψ f )2
⎝ ωe ⎠
iq =
Lq
For this IPM exported from RMxprt: ψ f / L d > I lim
So, there is no such control phase with maximal
constant output power
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Maximum Torque per Ampere (MTPA) and Field
Weakening Control

MTPA Control

Field Weakening
Control

ψf/Ld>Ili
Stable:ψ f / Ld > I lim

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Maximum Torque per Ampere (MTPA) and Field
Weakening Control

From the calculation equation of ideal maximal speed:

U lim
Ω max =
P * (ψ f − Ld * I lim )
We can get the maximal speed is 5475 rpm,
which coincides with the simulation result.

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Maximum Torque per Ampere (MTPA) and Field
Weakening Control

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Future Work

• Field-weakening that includes accurate FEA

model
• Energy Storage Sub-system
• System Integration

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Maximum Torque per Ampere (MTPA) and Field
Weakening Control

Too steep because the Ld, Lq and ψ f calculated by

RMxprt are not precise enough for FWC. FEA
model is recommended.

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Conclusion

• Efficiency Map of Traction Motor

– Calculated Using Transient FEA
• Equivalent Circuit Model
– Extracted Based on Static FEA
• Torque-Speed Capability
– Implemented Using Vector Control
• Field-weakening Controller
– Implemented to Enhance the Vector Control

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References

•Report on Toyota/Prius Motor Torque Capability, Torque Property, No-

Load Back EMF, and Mechanical Losses, J. S. Hsu, Ph.D., C. W.
Ayers, C. L. Coomer, R. H. Wiles, Oak Ridge National Laboratory

•Report on Toyota/Prius Motor Design and manufacturing Assessment,

J. S. Hsu, C. W. Ayers, C. L. Coomer, Oak Ridge National Laboratory

•Evaluation of 2004 Toyota Prius Hybrid Electric Drive System Interim

Report, C. W. Ayers, J. S. Hsu, L. D. Marlino, C. W. Miller,G. W. Ott,
Jr.,C. B. Oland, Oak Ridge National Laboratory

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