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Rapid Prototyping and Implementation of traction motor drive for E- Mobility
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on November 21, 2019 by SAE International in United States
Event: NuGen Summit
Objective / Question: Is it possible to extend the envelope of simulation driven design and its advantages to development of complex dynamic systems viz. traction motor drives? The objective that then follows is how to enable OEM/Tier-1s to reduce wastes in the process of traction motor controller design, development, optimization and implementation. Motor control design to validation process is time consuming and tricky! Additionally, the requirement of software knowledge to write code to implement drive engineer's control ideas. The challenges here are - to name a few - algorithm for real time, addressing memory constraints, debugging, comprehending mathematical overflows, portability & BOM cost. These introduces wastes in parameters like time, cost, performance, efficiency and reliability. Methodology: Developing a new traction motor controller for E Mobility takes 18 - 24 months typically. 2 distinct activities take place in a loop. One is the motor drive engineer who has good understanding of the motor, requirement demands on the motor & digital control of the motor and the second is the software engineer who has a good understanding of the processors where the code must run, how to design and build an efficient and robust code. Given the idea is to control a dynamic system and verify it real time to ensure performance in terms of response and smoothness over a range, efficiency, fault and protections, etc. it becomes important to have a single platform that can handle the 2 distinct activities to reduce errors (wastes) and improve time to completion. Altair - a pioneer in simulation driven design to reduce time to market - has successfully developed a solution to address control of commonly used traction motors for E - Mobility. Speed up comes from compressing the time taken to build the control diagram, develop the code, reduce foot-print and eliminate bugs as the fundamental blocks are correct by design. A sub KiloWatt BLDC motor used in a two-wheeler (e-scooter) was chosen to study the efficacy of the available solution. This was a bench study. Results: It was observed that the first spin-up happened rapidly within a week including motor identification and subsequently the tuning for speed range within few months. Additionally, the real time diagnostics of the electrical and mechanical parameters of the motor along with energy draw was witnessed. Limitation: Real load conditions and drive cycle tests were not conducted at the time of writing this. It is anticipated that the drive cycle evaluations and real load conditions will answer more questions. Questions with respect to how the bench tuning changes in real life, how does it affect the energy efficiency, time taken to complete optimization, etc. Conclusion: It can be concluded that Altair's solutions for motor control (E Mobility application) really helps in not only compressing the cycle time going from model to code to physical but also reduces other wastes involved in the process.