Anton Ingemansson och Elias Kambrin, Elektroteknik

​Titel: Comparison of a highly sustainable PMaSynRM with a traditional PMSM 

Welcome to the master thesis presentation  

Comparison of a highly sustainable PMaSynRM with a traditional PMSM  
by  Anton Ingemansson and Elias Kambrin  
conducted at Volvo Car Corporation supervised by Elisabet Jansson   
 
Opponent: Emma Johansson

Abstract
In this thesis, a PMaSynRM with ferrite magnets and aluminium hairpin winding was designed and compared to a reference PMSM with Nd(Dy)FeB magnets and copper round-wire winding, for vehicle application. The design and simulation of the PMaSynRM was done in Ansys Electronics and it consisted of a parametric optimisation of the rotor structure for improved performance. The performance requirements of the vehicle included a top speed of 150 km/h, an acceleration from 0-100 km/h in 10 s, and to complete the WLTP and CADC 150 drive cycles. For this evaluation, a vehicle dynamics model was created based on the parameters for the Volvo C30 electric. Further, a MTPA controller was created in Matlab to find the operating region of the motor and to map the losses through interpolation. A simplified model of the powertrain was created in Simulink to calculate the energy consumption and required torque of the motor for the WLTP and CADC 150 drive cycles. It was found that the PMaSynRM and reference motor had an acceleration from 0-100 km/h in 9.72 s and 9.82 s respectively and that they could both handle the WLTP and CADC 150 drive cycles. The loss of energy for the PMaSynRM and reference motor were compared for the two drive cycles. It was found that the aluminium hairpin winding had lower winding losses than the copper round-wire, despite the frequency dependency of the phase resistance due to eddy current effects in the hairpin winding. Further improvements were seen with lower hysteresis and eddy current losses due to the lower flux density from the ferrite magnets compared to the Nd(Dy)FeB magnets in the reference motor. However, the PMaSynRM has a limited operating region to the risk of demagnetization of the ferrite magnets which reduces the performance.

An environmental and cost analysis was conducted for the two motors to investigate the impact of the different materials. The environmental impact was measured with the EPS system, which aims to preserve the natural capital, and is measured in the economic value of ELU. It was found that the PMaSynRM had a 96.1 % lower total impact in ELU compared to the reference motor. Most notable, the aluminium hairpin winding had a 99.9 % lower environmental impact compared to the copper round-wire winding. Further, the total cost in USD of the PMaSynRM was found to be 60.1 % lower than the PMaSynRM.

Welcome!
Anton, Elias and Torbjörn


Kategori Studentarbete
Plats: Fredrik Lamms room, Chalmers Electric Power Engineering division
Tid: 2022-06-03 10:00
Sluttid: 2022-06-03 11:00

Sidansvarig Publicerad: fr 20 maj 2022.