MOTORS AND MOTOR DRIVERS
Contents
DC motors ..................................................................................................................................................4
BLDC (Brush Less DC motor) ................................................................................................................4
Permanent Magnet Synchronous Motors (PMSMs)......................................................................... 5
Three Phase AC Induction Motors .......................................................................................................6
Switched Reluctance Motors ................................................................................................................. 7
Motor Controller ...................................................................................................................................... 8
Communication between Motor Controller and EVCU ..................................................................9
Simulation and Testing tools ............................................................................................................... 10
Table of Figures
Figure 1: Brush and coil arrangement........................................................................................................... 4
Figure 2: Stator and rotor arrangement ....................................................................................................... 4
Figure 3: In runner and outrunner motor comparison ................................................................................. 5
Figure 4: PMSM arrangement ....................................................................................................................... 6
Figure 5: PMSM working principle ................................................................................................................ 6
Figure 6: 3 phase AC induction motor arrangement .................................................................................... 7
Figure 7: Switched reluctance motors .......................................................................................................... 8
Figure 8: Configuration of switched reluctance motor................................................................................. 8
Figure 9: Motor controller in EV ................................................................................................................... 9
Figure 10: EVCU of a car.............................................................................................................................. 10
DC motors
A majority of DC motors run on voltages between 96 and 192 and generate more torque
which leads to cost-cutting. There are three types of DC motors: brushed DC motor, BLDC
(brushless DC motor), and stepper. Brushed DC motors are widely used for electrically-powered
side windows but tend to wear quickly and require frequent maintenance. BLDC motors are more
efficient, reliable, and have advantages like higher speed ranges, better speed vs. torque
characteristics, and higher torque to size ratio making them suitable for electric vehicles.
However, they do require regulated power supplies and sophisticated control electronics.
Figure 1: Brush and coil arrangement
Figure 2: Stator and rotor arrangement
BLDC (Brush Less DC motor)
Brushless DC (BLDC) motors are a type of DC motor that are commonly used in electric
vehicles (EVs) due to their high efficiency and reliability. Unlike brushed DC motors, BLDC motors
do not have brushes and use an electronic commutator instead, which eliminates the source of
power and wear loss. This results in a more efficient and reliable motor that has several
advantages over other motor types. There are two types of BLDC motors.
i. Out-runner type BLDC Motor
ii. In-runner type BLDC Motor
Figure 3: In runner and outrunner motor comparison
Permanent Magnet Synchronous Motors (PMSMs)
Permanent Magnet Synchronous Motors (PMSMs) are a popular choice in the
design of electric vehicles (EVs) due to their high efficiency and superior performance
characteristics. PMSMs are a type of synchronous electric motor that uses permanent magnets
to generate the magnetic field required for operation. In EVs, PMSMs are used as the main
traction motor and provide the driving force to the wheels. Their high efficiency level results in
longer driving ranges and less energy consumption, making them a desirable choice for EVs.
PMSMs also have a high power-to-weight ratio, which is critical for EVs where weight reduction
is important for improved performance and energy efficiency. Additionally, PMSMs operate
smoothly and quietly, providing a comfortable driving experience. Furthermore, their fast torque
response time makes them ideal for electric vehicles that require quick changes in speed and
torque. PMSMs are also well-suited for use in EVs with regenerative braking systems, which can
recover energy that would otherwise be lost during braking. The combination of these
advantages makes PMSMs a popular choice in the design of EVs, and their use is likely to continue
to grow as the demand for electric vehicles increases.
Figure 4: PMSM arrangement
Figure 5: PMSM working principle
Three Phase AC Induction Motors
The induction motors do not have a high starting toque like DC series motors under fixed
voltage and fixed frequency operation. But this characteristic can be altered by using various
control techniques like FOC or v/f methods. By using these control methods, the maximum
torque is made available at the starting of the motor which is suitable for traction application.
Squirrel cage induction motors have a long life due to less maintenance. Induction motors can be
designed up to an efficiency of 92-95%. The drawback of an induction motor is that it requires
complex inverter circuit and control of the motor is difficult.
Figure 6: 3 phase AC induction motor arrangement
Switched Reluctance Motors
Switched Reluctance Motors (SRMs) are a type of electric motor that are used in some
electric vehicles (EVs). They operate on the principle of magnetic reluctance and use switching
elements to create the required magnetic field. In EVs, SRMs can provide an efficient and cost-
effective solution for the main traction motor. They have a simple construction, with no
permanent magnets, which makes them less expensive than other motor types. Additionally,
SRMs are robust and have a high power density, making them suitable for use in harsh
environments and for applications that require high power in a compact package. They also have
good power-to-weight ratio and fast torque response, making them a good choice for electric
vehicles that require quick changes in speed and torque. While SRMs are still not as widely used
in EVs as other motor types, their low cost and simple construction make them an attractive
option for certain applications, and their use is likely to grow in the future as the demand for
electric vehicles increases. The biggest drawback of the SRM is the complexity in control and
increase in the switching circuit. It also has some noise issues. Once SRM enters the commercial
market, it can replace the PMSM and Induction motors in the future.
Figure 7: Switched reluctance motors
Figure 8: Configuration of switched reluctance motor
Motor Controller
A motor controller is an essential component of an electric vehicle (EV) that is responsible
for controlling the speed and torque of the electric motor. The controller works by converting
the DC voltage from the battery into AC voltage that is required to drive the electric motor. It
also monitors the position and speed of the motor and adjusts the power output accordingly to
maintain the desired speed and torque.
The motor controller typically consists of three main parts: the power electronics, the
microcontroller, and the user interface. The power electronics include the inverter, which
converts the DC voltage from the battery into AC voltage for the motor, and the power transistors
that switch the voltage on and off to control the power output.
The microcontroller is responsible for controlling the power electronics and monitoring
the speed and position of the motor. It uses a variety of sensors such as encoders and Hall-effect
sensors to measure the motor speed and position, and it adjusts the power output accordingly
to maintain the desired speed and torque.
The user interface provides a way for the driver to interact with the motor controller. This
can include a display that shows the speed and battery level, as well as controls for adjusting the
speed and torque.
Figure 9: Motor controller in EV
Communication between Motor Controller and EVCU
In an electric vehicle (EV), the motor controller communicates with the Electric Vehicle
Control Unit (EVCU) through a variety of communication protocols, such as Controller Area
Network (CAN) or Local Interconnect Network (LIN).
The EVCU is responsible for monitoring and controlling various aspects of the EV,
including the battery management system, charging system, and powertrain system. It receives
data from sensors and other components in the vehicle, including the motor controller, and it
uses this data to make decisions about how to operate the vehicle.
The motor controller communicates with the EVCU through the CAN or LIN bus, which
allows for the exchange of data and control signals between the two components. For example,
the motor controller can send information about the speed and torque of the electric motor to
the EVCU, which can then use this data to optimize the vehicle's performance and energy
efficiency.
Likewise, the EVCU can send commands to the motor controller to adjust the speed or
torque of the motor, or to limit the power output to protect the battery or other components in
the vehicle. This two-way communication between the motor controller and EVCU is critical for
the safe and efficient operation of the electric vehicle, and it enables the driver to have a smooth
and responsive driving experience.
Figure 10: EVCU of a car
Simulation and Testing tools
There are several motor design and simulation tools available that can help engineers
design and optimize electric motors for various applications. Here are some of the most popular
tools used in industry and academia:
• ANSYS Motor-CAD: This is a comprehensive motor design and analysis software
that can be used to design and optimize motors for different applications. It
includes advanced electromagnetic, thermal, and mechanical modeling
capabilities, and it can simulate the entire design process from conception to
manufacture.
• JMAG: This is another popular motor design and simulation software that uses
finite element analysis (FEA) to model and optimize electromagnetic and thermal
performance of electric machines.
• MATLAB/Simulink: This is a popular software tool for control system design and
simulation that includes tools for motor and power electronics modeling and
simulation.
