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SELECTION OF MOTOR FOR AN ELECTRIC VEHICLE MINOR PROJECT REPORT

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SELECTION OF MOTOR FOR AN
ELECTRIC VEHICLE

MINOR PROJECT REPORT

Name: Vasanthakumar S
College: Rajalakshmi Engineering College
Department: Mechanical
 1
Abstract:

In this study, six types of drivetrain systems of electrical motor drives for EVs are discussed.
And so, the needs of EVs on motor drives are presented. The comparative investigation on the
efficiency, weight, cost, cooling, maximum speed, and fault-tolerance, safety, and reliability is
administered for switched reluctance motor, induction motor, static magnet brushless dc motor,
and brushed dc motor drives, to seek out the most appropriate motor drives for electric vehicle
applications. Permanent Magnet Brushless DC motors(PM BLDC) will result in less pollution,
DC motors and their drives have low cost, and higher power to volume ratio. IM is appropriate
for controllability and cost, the weight of SRM is low, its reliability is high, it operates
fault-tolerance and according to the acceleration time, its performance is better than IM and
BLDC. Hence, SRM is the most appropriate motor for EV.
 2

TABLE OF CONTENTS

1. Introduction 3

2. Motors Types used in EV 4

2.1. DC motors 4
2.2. Induction motors 5
2.3. Permanent Magnet Synchronous Motor 6
2.4. Permanent Magnet Brushless DC Motor 8
2.5. Switched Reluctance Motor 9

3. Drivetrain Systems of EVs 11

3.1. Conventional type 11
3.2. Transmission-less Type 12
3.3. Cascade type 12
3.4. In-wheel type 13
3.5. In-wheel Direct-drive type 13
3.6. Four-wheel Directed 14

4. Desired and Output characteristics 15

5. Comparative study of Electric motors 16

5.1. Power Density 16
5.2. Energy efficiency 16
5.3. Reliability 17
5.4. Cost Factor 17

6. Analysis and Evaluation 18

7. Conclusion 19

References 19
 3

1. Introduction

Electric vehicles (EVs) are gaining popularity as a green alternative to internal combustion
engines (ICEs), which have been the primary mode of transportation for over a century. EVs are
powered by a battery-driven electric motor. An electric motor, which is an electrical machine,
that transforms electrical energy into mechanical energy. The operation of the electrical motors is
due to the interaction between the motor’s electric field and current windings which generate
force in the rotation form. Using direct current sources (DC) such as from batteries, motor
vehicles, and by alternating current sources (AC) as an influence grid, inverters these electric
motors are often powered. An electrical generator is mechanically similar to that of an electric
motor, but it operates in a reverse direction which accepts mechanical energy and converts that
accepted mechanical energy to electrical energy.

General-purpose motors with standard size and features are used to offer easy mechanical power
for industrial applications. The biggest electric motors, with ratings approaching 100 megawatts,
are utilized for pumped-storage applications, pipeline compression, and ship propulsion. The
term "electric vehicle" refers to a vehicle that uses one or more electric motors for propulsion.
An electric car can be fueled by off-vehicle sources through a collector system by electricity, or it
can be self-contained with a solar panel and a battery to convert fuel to electricity. In the market,
there are a variety of electric vehicles. Different motors are used for different functions in these
vehicles. We will be discussing electric automobiles in this article, and the electric motor
functions will be used to drive the electric car's powertrain.

Many factors must be considered, including power density, energy efficiency, cost factor,
reliability. Depending on the vehicle's intended usage, several types of electric motors are used.
The choice of a motor for an electric vehicle must be made carefully, as motor attributes have an
impact on the vehicle's total performance.
 4

2. Motor Types Used in EV

DC motors are used in the majority of electric vehicles (4 kW and less power). The induction
motor is a well-known type of AC motor which is used in a large number of high-power electric
vehicles (above 5kW). In most cases, a vector drive is used to control torque and acceleration.
Directly, BLDC motor applications can be found in low-power electric vehicles. In an electric
vehicle, the battery is the principal energy storage device. Lately, tremendous works have been
accounted for ion-battery enhancement such as Li-particle, which is now being used by a new
generation of electric vehicles. Different types of motors have different characteristics, thus it's
important to compare motors using certain basic criteria before choosing one for an electric
vehicle. Electric motors used in electric vehicles should have important characteristics such as a
simple design, high energy output, minimal maintenance costs, and excellent control. There are
various types of motors used for EVs. This article looks into the mechanics of electric vehicles
and provides an overview of the most prevalent motor types.

1. DC motors
2. Permanent Magnet Brushless DC motors (PM BLDCs)
3. Induction Motors
4. Permanent Magnet Motors
5. Switched Reluctance Motors (SRM)

2.1. DC motors

One of the motor types used in EV applications is the DC motor which is also known as Direct
Circuit motor. They were extensively employed in variable speed applications before the
advancements in power electronics. They are preferred in EVs because of their ease of use and
durability. Brushed and brushless DC motors are the two types of DC motors available.
Brushless DC motors are preferred for low-power vehicles. The brushed motors are said to be
universal motors, it works by the direct current and it is lightweight. The larger DC motor is
applicable for electric vehicles, drives, mills, and elevators. The multiple turns are provided in
the windings, in case the large motors carry the parallel current paths.
Shunt motors are more controllable than series motors. Due to their decoupled torque and flux
control properties, separately excited DC motors are intrinsically suited for field weakening
operation. Separate field weakening, on the other hand, allows for a wider spectrum of constant
power activities. The commutator is connected through the ends of the wire to energize the coils
and the brushes are provided to connect the coils with the external power supply.
They do, however, have certain disadvantages, including a huge construction, low efficiency,
limited reliability, and high maintenance costs due to the brush and collector construction.
Furthermore, the maximum motor speed is limited by friction between the brush and the
collector.
 5

Fig 1. DC motor

Fig 2. torque-speed characteristic of a DC motor

2.2. Induction Motors (IM)

Three-phase AC Induction motors are commonly used in EV applications because of their simple
structure, reliability, robustness, low maintenance requirements, low cost, and ability to operate
in poor environmental conditions. The elimination of brush friction allows the motors to increase
their maximum speed limit, and the greater speed rating allows these motors to provide high
power. The frequency of voltage is changed to change the speed of induction motors. The
electric current in the rotor required to produce torque is obtained through electromagnetic
induction from the magnetic field of the stator coil.
An induction motor can be built without any electrical connections to the rotor. In an induction
motor, the rotor can be either squirrel-cage or wound. Its magnetic field is established via
induced current. Unidirectional torque is produced by the interaction of a rotating magnetic field
with a field due to induced currents. Vector control methods can be used to segregate torque and
 6
field control. Flux weakening in the constant power zone can widen the speed range.

When compared to permanent magnet motors, IM has disadvantages such as low efficiency,
increased losses at high speeds, and a low power factor. Dual inverters are utilized to provide
constant power and rotor losses are decreased at the design stage to overcome these issues.

Fig 3. Induction motor

Fig 4. torque-speed characteristic of an IM motor

2.3. Permanent Magnet Synchronous Motor (PMSM)

The rotor pivots at synchronous speed in a synchronous motor. The rotor is powered by a DC
source, while the stator is powered by a three-phase AC source. Brushless AC motors are another
name for PMS motors. They are suited for use as traction motors because of their simple
 7
construction, high efficiency, and high power density (common in hybrid vehicles, EVs, and
buses). In comparison to IM motors, PMSM motors are more efficient. Several automobile
manufacturers (including Nissan, Honda, and Toyota) have successfully utilized these engines.

Highly conductive materials with high permeability, such as Samarium-Cobalt and

Neodymium-Iron-Boron, are used in permanent magnets. This is a particularly suitable material
because of its cost-effectiveness and availability. On the rotor core, those magnets can be
observed. The constant power zone of these motors is naturally narrow. The conduction angle of
the power converter can be changed at speeds greater than the base speed to extend the speed
range and efficiency of PMS motors. It is possible to increase the speed range to three or four
times the base speed.
These motors have the disadvantage of being susceptible to demagnetization due to heat or
armature reaction. The disadvantages of this type are high costs, eddy current loss in PMs at high
speeds, and a reliability risk due to the possibility of breaking of magnets.
There are two types of PMSM motors which are surface-mounted permanent magnet (SPM) and
interior permanent magnet (IPM) synchronous motor drives. IPM motors are more efficient than
SPM motors, although they have a more complicated design.

Fig 5. Permanent Magnet Synchronous Motor

 8

Fig 6. torque-speed characteristic of a PMSM motor

2.4. Permanent Magnet Brushless DC Motor (PM BLDC)

Another motor type to consider is the Permanent Magnet Brushless DC motor (PM BLDC).
When compared to brushed DC motors, BLDC motors are more efficient and require less
maintenance. A revolving self-synchronous machine with a permanent magnet rotor and known
rotor shaft positions for electronic commutation is referred to as a BLDC motor. In addition, heat
is efficiently vented to the environment. If a conduction-angle control is utilized on a PM BLDC
motor, the speed range can be expanded three to four times beyond the basic speed.

When compared to other motors with identical apex current and voltage, another advantage of
PM BLDC motors is their ability to provide more torque. Permanent magnet brushless dc motors
have a good chance of being used in the EV propulsion system since they provide a strong power
thickness and a lot more productivity. BLDC motors have a capacity of 85 to 90 percent, whereas
brushed DC motors have a capacity of 75 to 80 percent. The brushless DC motor will solve the
problem that a typical DC motor has. The Lorentz force law, in particular, states that any
current-carrying wire placed in a magnetic field will expose a power.

There are some drawbacks, such as mechanical forces and magnet costs. The increase in
centrifugal forces at higher speeds poses a risk in terms of driving safety due to the chance of
magnets breaking. Magnets are also susceptible to high temperatures. Because of the high
working temperature, the residue flux density decreases, lowering the machine's torque capacity.
Although PM BLDC motors do not have a brush to limit speed, there are still concerns about the
magnet's fixing intensity, which limits the maximum speed if the motors are of the inner-rotor
type. Furthermore, the field weakening capability of this motor is relatively limited. The
presence of the PM field, which can only be diminished by producing a stator field component
that opposes the rotor magnetic field, is the reason for this. Nonetheless, by extending the
commutation angle, extended constant power operation is achievable.
 9
BLDC motors further have two types:

a. In-runner type BLDC Motor

b. Out-runner type BLDC Motor

Fig 7. (a) In-runner type BLDC Motor (b) Out-runner type BLDC Motor

Fig 8. torque-speed characteristic of a BLDC motor

2.5. Switched Reluctance Motor (SRM)

A switching reluctance motor (SRM) is a form of stepper motor that is operated under torque.
SRM drives are gaining popularity and are being recognized as having potential for electric
vehicle applications. The high torque component of SRMs allows them to be used in a variety of
applications, including wind energy, generator starter systems in gas turbine engines, and
high-performance aerospace applications. Their durability, simplicity of control, high efficiency,
large constant power operation area, fault tolerance, and effective torque-speed characteristics
are all advantages in EVs. The efficiency of SRM is about 95% when compared to IM. SRM is
an ideal motor type for EV applications because of these characteristics.
 10
Without any windings, magnets, commutators, or brushes, the rotor structure is incredibly
simple. Because of the absence of magnets, mechanical forces are not a problem, allowing the
motor to run at a high speed. There are no copper losses in the rotor because the motor's
windings are not employed, ensuring that the rotor temperature is lower than other motor types.
SRM motors can continue to run even if one of the phases is disconnected since the phases are
not connected. The motor's fault tolerance is likewise quite high. SRM has exceptionally rapid
acceleration and extremely high-speed operation because of its simple structure and minimal
rotor inertia. SRM is particularly well suited for gearless operation in EV propulsion because of
its large speed range.
When contrasted to other DC motors, the hazardous power is sent to the stator, which is larger
than the rotor. The motor's mechanical design does not require power to move parts because the
electrical design is complex, switching devices are required to give power. A good motor design
allows for a large constant power operation range, which allows for high speeds. SRM is also
relatively easy to cool and insensitive to high temperatures due to the lack of magnetic sources
(i.e., windings or permanent magnets) on the rotor. The latter is particularly useful in automotive
applications that require functioning in severe environments. Using a suitable Control, an
expanded range of 2-3 times the base speed is usually attainable. This motor has many
drawbacks, including high noise, high torque ripple, a unique converter topology, and
electromagnetic interference. SRMs feature a torque/power speed characteristic that is suited for
EV applications.

Fig 9. Switched Reluctance Motor

 11

Fig 10. torque-speed characteristic of a SRM motor

3. Drivetrain Systems of EVs

The output characteristics of electric motors in EVs differ from those of internal combustion
engines. The electric motor, in most cases, eliminates the need for a motor to stay idle while
stopped, allows large torque to be produced at low speeds, and provides a wide range of speed
fluctuations. Using the features of electric motors, it may be able to design lighter, more
compact, and more efficient systems. The choices of drivetrain systems in an EV include
mainly:
1. propulsion mode, such as front-wheel drive, rear-wheel drive, or four-wheel drive;
2. number of electric motors in a vehicle;
3. drive method, such as indirect or direct drive; and
4. a number of transmission gear levels.
As a result, EV drivetrain systems can be configured in the following six ways.

3.1. Conventional type

In EVs, the traditional ICE is replaced with an electric motor for the conventional drivetrain
system. This design does not alter the conventional structure of an ICEVs drivetrain system,
making it simple to build.
 12

Fig. 1. Conventional type of drivetrain system

3.2. Transmission-less Type

The transmission-less drivetrain system in EVs simplifies the conventional drivetrain system by
removing the transmission.

Fig. 2. Transmission-less drivetrain system

3.3. Cascade Type

If the differential gear is eliminated from the transmission-less type, it can be simplified to a
differential-less type. Two motors are fitted on the body side, with joints to send power to the
wheels, resulting in a function equal to the differential. The direct-drive type is another name for
this type.
 13

Fig. 3. Cascade-motors drivetrain system

3.4. In-wheel Type using reduction gears

This type is derived from the simplification of the transmission-less type using Reduction Gears.
To drive the wheels, two motors are fixed to the wheel side with reduction gears.

Fig. 4. In-wheel drivetrain system with reduction gears

3.5. In-wheel Direct-drive Type

Because the rear wheels and motors are integrated, rotations can be caused directly without the
use of gears. This is a sort of in-wheel drivetrain system that uses direct drive.
 14

Fig. 5. In-wheel direct-drive drivetrain system

3.6. Four-wheel Direct-drive Type

The four wheels are driven directly by four in-wheel motors. It's feasible that the EV's direction
will be controlled by electric steering.

Fig. 6. Four-wheel drivetrain system

As research progresses, the drivetrain system shrinks in size and minimizes power transmission
losses. At the same time, the size and weight of the motor and reduction gear must be lowered.
The direct-drive drivetrain technology necessitates a motor that is light and produces a lot of
torque. The drivetrain scheme with the single-level reduction gear is an excellent choice for
taking full advantage of the wide range of output characteristics and small motor size resulting
from high maximum speed for electric motor drives.
 15
4. Desired and Output Characteristics of Motor Drives Used in EV

Torque-speed or power-speed parameters are used to evaluate EV performance. The

torque-speed curve is defined by two major design factors: maximum slope and maximum speed.
For proper grade ability and beginning acceleration, the vehicles must run at constant power. The
motor drive should have high torque at low speeds for acceleration and cruising, as well as high
power at high speeds for cruising and a wide speed range under constant power. Beyond base
speed and up to maximum speed, the motor is run in a constant power region.
The motor type affects the constant power operation. Before achieving maximum speed, some
motor drives switch to constant power and complete the natural operation. The maximum torque
falls proportionally to the square of speed in natural operation. This may also result in a lower
total power requirement.

Fig 1. Desired output characteristics of electric motor drives in EVs

Fig 2. Typical performances of electric motor drives in industrial applications

 16
5. Comparative Study of the Electric Motors

For selecting the appropriate electric vehicle motors basically, we need to determine the most
demanding requirements of the performance, the operating conditions, and the cost associated
with the vehicle. The observation has been made on the specific parameters.

5.1. Power Density

The capability to weigh the proportion of any electric motor is known as power density, and it is
usually calculated using the motor's apex power. Subdividing the apex power yield (in kW) by
mass yields power density for every motor (in kg). The power density measurement unit is
kW/kg. Because of the close proximity of high power density permanent magnets, PM motors
have the highest power density. The PMS machine has the maximum power thickness, allowing
for a powerful machine with minimal substance in a car's motor cell's constrained installation
field. PM Brushless motors are then sought most aggressively by both IM and SRM. DC motors,
once again, have the lowest power density. As this machine has the highest power density, PM is
approved to pick up the distinct characteristics for EV application.

5.2. Energy Efficiency

The relationship between electrical and mechanical yield is provided by electric motor efficiency.
Every electric motor is designed to operate at maximum efficiency at the specified output. The
best energy efficiency (more than 95%) is found in BLDC motors, which are followed by
Induction Motors (greater than 90 percent ). Due to the absence of rotor losses, BLDC Motors
has the highest efficiency. In a specified velocity run, BLDC strives for the highest proficiency.
The PMBLDC motors are the most productive motors in terms of efficiency. The induction
comes next, and the SRMs are essentially indistinguishable in terms of efficacy. DC motors are
the least effective of all the motors used in the EVD design.
 17

5.3 Reliability

Presently comparing based on the fidelity of the Electric Motor that is breakdowns and support
ought to be least, utmost reliable ones are IM and SRM. PM motors are pursuing it. The DC
Motor is the least trustworthy. Along these lines, DC motor brushes and switches enter current in
the armature, making them less decisive and ill-equipped for maintenance-free work. Due to
their dependability, induction motors are the most important competitor.

5.4 Cost Factor

One of the most difficult challenges electric car manufacturers face is offering customers an EV
that is in the same class as a fuel vehicle but at a reasonable price. The IM, which is pursued by
the DC and SRM Motors, is the ultimate to be used here. Most manufacturers accept induction
engines for EV applications because they are cost-effective. DC motors are substantially more
expensive than AC motors of the same capacity as large-capacity motors. A faster speed, lower
torque motor will cost less than a lower speed, greater torque motor when two motors with the
same power capacity are compared. A motor with a greater operating voltage but lower current
needs will be less expensive than one with a lower operating voltage but greater current need.
 18

6. Analysis and Evaluation

1. DC motors are difficult to operate, produce a lot of torque at low speeds, but have a high
support cost, a huge structure, and poor efficiency.
2. Although BLDC motors offer a high power density, great productivity, and small size, their
upkeep, and controller costs are substantial.
3. Three-phase IM boosts productivity by more than 91 percent. They have high fidelity, low
power density, and a large surface area, as well as convenience and average acceleration. Electric
vehicle manufacturers favor BLDC motors and 3-phase IM engines.
4. Synchronous machines are more capable at lower accelerations, allowing for better battery
utilization and propulsive range. Wherever a constant torque is required, a synchronous motor is
preferred.
5. SRMs provide an exceptional solution, with low motor/controller costs, high reliability, high
efficiency, and inbuilt failure capacity adaption.
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7. Conclusion

In this study, electrical motor types and drives were discussed, and their characteristics such as
energy efficiency, cost factor, robustness, and power density were compared. PM In terms of
efficiency, BLDC motors and drives are the most efficient, but using magnets adds to the cost
and maintenance requirements. Brush and collectors on a brushed DC motor require maintenance
as well. Brushless DC motors, on the other hand, do not require maintenance and have a cheap
cost. DC motor drives are also the least expensive. SRMs are the lightest motors on the market.
They also have important characteristics including low cost, easy cooling, robustness, and
fault-tolerance operation.
One of the most important aspects of an electric vehicle is its reliability, and SRM is one of the
most reliable motors available. Also, SRM drives are cost-effective and efficient. To compare all
of these characteristics, the most commonly used motor drives are IM and PM BLDC. IM motors
and drives are less expensive, whereas PM BLDC motors and drives are efficient and have a high
power density. One of the most well-established technologies is DC motor drives. SRM is the
most convenient motor in terms of weight, reliability, and fault-tolerance operation, and it
outperforms IM and BLDC in terms of acceleration time.
For EV, these are the most critical aspects. As a result, SRM is the best motor for electric vehicle
applications.

References

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