Browse Topic: Electric motors

Items (1,979)
Surface Permanent Magnet Synchronous Motors (SPMSMs) have gained significant attention in modern industrial, automotive, and aerospace applications due to their high efficiency, power density, and superior dynamic performance. This paper explores the fundamental principles, control strategies, and optimization techniques for SPMSMs. The study focuses on advanced vector control methods, i.e., Field-Oriented Control (FOC), to achieve precise torque and speed regulation. Additionally, to ensure the safety and reliability of EV motors. Active discharge strategies used in EV motor drives focus on circuit topologies, control techniques, and implementation challenges. The paper also discusses a comparison of Sinusoidal Pulse Width Modulation (SPWM) and Space Vector Pulse Width Modulation (SVPWM) techniques, where the maximum speed of the motor is achieved. The findings highlight the potential of SPMSMs in high-performance applications, emphasizing future research directions in energy
Munnur, SwathiGandhi, NikitaTendulkar, SwatiMasand, DeepikaMurty, V. ShirishPeruka, Mahesh
This paper presents the virtual prototyping of traction motor in commercial EV to make an early prediction of the performance parameters of the machine without spending an enormous cost in building a physical structure. A 48/8 slot-pole configuration of IPMSM is used to demonstrate the electromagnetic and thermal co-simulation in ANSYS MotorCad. The core dimensions were determined using permanent-magnet field theory. From those, a two-dimensional finite-element (2D FEM) model of the interior permanent magnet (IPM) motor was simulated using Ansys Motor-CAD electromagnetic simulation tool. The influence of geometrical parameters on the performances of traction motor are evaluated based on FEM. The temperature distribution have been analyzed under steady and transient operating conditions. Alongside, the effects of saturation, demagnetization analysis, and the impact of PM flux linkage on inductances are also considered in this paper. At last, the simulation and analytical results of the
Murty, V. ShirishRathod, SagarkumarGandhi, NikitaTendulkar, SwatiKumar, KundanThakar, DhruvSethy, Amanraj
Electric vehicles are becoming more popular due to the low-cost investment for individual daily usage, such as traveling to nearby places, offices, and schools. There are environmental benefits that make them green and produce less pollution compared to traditional vehicles. Two-wheeler electric vehicles (EVs) have more electronic components compared to two-wheeler internal combustion engine (ICE) vehicles. The major components in two-wheeler EVs are the motor and battery. The traction motor is driven by the battery, Battery is a primary energy source in 2Wheeler electric vehicle. An electric vehicle comprises different major electronic components such as the battery management system (BMS), motor control unit (MCU), human-machine interface (HMI), and, in some cases, a vehicle control unit (VCU) as well. Considering a 48V architecture or less than 60V provides advantages of low system cost as it requires less effort for safety measures. Furthermore, this paper explores diverse
Karunakar, PraveenK R, Amogh
As the trend shifts from Internal Combustion Engine (ICE) vehicles to Electric Vehicles (EVs), the operating speeds of prime movers have significantly increased. Commercial EV manufacturers prefer high-speed, low-torque motors coupled with transmissions over low-speed, high-torque motors due to higher efficiency and power density. This combination of high-speed, low-torque motors coupled with transmission is essential for achieving the required gradeability and enhances operational efficiency. However, the increased operating speeds of these EV transmissions have inherently increased the risk of ‘bearing creep’ [8]. The “bearing creep” is the phenomenon where unintended relative motion occurs between bearing races and their mounting surfaces, leading to premature wear of mounting surfaces [3]. This issue can lead to a series of failure modes such as increased gear mesh misalignment, bearing damage, seal damage, etc. These problems result into elevated transmission vibrations eventually
Bagad, Sachin SunilKanase, AshishHiremath, SatalingayyaNevarekar, Sandip
Electric vehicle (EV) transmissions play a vital role in powering EVs by channeling energy from the electric motor to the wheels. Recently, the focus has shifted to multi-speed transmissions in the EV sector due to their potential to improve efficiency and performance. By utilizing various gear ratios, these transmissions enable the motor to function within its most efficient range across different speeds. Most of these transmissions need electric control unit (ECU) with software for optimal functionality and smoother gear shifting. These controllers incorporate controller area network (CAN) communication protocol to operate along with other ECUs. Thus validation of these transmissions is a challenge as they are clutch less, motor has to be controlled for speed matching and have electro mechanical systems replacing conventional systems for operation. This paper proposes a methodology to validate multispeed EV transmissions on a test bench. The validation setup consists of electric
Thambala, PrashanthPatel, HiralSoor, Debasis
Traction motors technology has, driving the EV industry forward with more efficient, lightweight, and durable solutions. However, despite these advancements, noise testing at the end of the production line remains a critical stage for identifying manufacturing defects in traction motors. Hence early fault detection in traction motors is crucial to ensure safety and reliability of EV. This research contributes a solution that predicts early-fault detection, supporting improved reliability, reduced material cost and minimizing process time in the series production line. To identify the root cause of this problem, historical quality data has been acquired from manufacturing plants to enable efficient analysis. Feature selection was then carried out using embedded and wrapper methods to identify the most important features. These selected features were subsequently used as input for ML models. The best accuracy was achieved using SVC model for early-stage motor failure prediction.
Gaikwad, PoojaNangare, KapilrajSuryawanshi, Chaitanya
Electric Vehicles and Plug-in Hybrids alleviate the energy crisis but pose a unique challenge for vehicle dynamics. Though significant developments in motor control strategy and energy density management are evolving, we face significant challenges in torque management, with several ADAS features being an integral part of the EVs/xHEVs. It demands high-fidelity physical and control model exchanges between electric chassis, ride-handling, tire modelling, steering assist, powertrain, and validation using a 0D–1D platform. This paper explicates a unified strategy for improving overall vehicle performance by intelligently distributing and coordinating drive torque to enhance traction, stability, and drivability across diverse operating conditions through co-simulation. The co-simulation platform includes physical models in AMESIM, and control strategies integrated in MATLAB/Simulink. The platform features comprehensive representations of digital vehicles that require detailed modelling of
Eruva, PatrickxavierSarapalli Ramachandran, RaghuveeranChougule, SourabhNatanamani-Pillai, Siva SubramanianScheider, ClementLeclerc, CedricNatarajasundaram, Balasubramanian
Hydrogen Fuel Cell Electric Vehicles (FCEVs) represent a significant trajectory in vehicular decarbonization, harnessing the inherently high energy density of diatomic hydrogen within electrochemical conversion systems. When sourced via renewable pathways, such hydrogen facilitates propulsion architectures characterized by zero tailpipe emissions, enhanced energy efficiency, and extended operational range profiles. Realizing peak systemic efficacy necessitates the synergistic orchestration of high-fidelity fuel cell stack design, resilient compressed gas storage modalities, and nuanced energy governance protocols. To reduce transient stressors and guarantee long-term electrochemical stability, employing multi-scale modeling and predictive simulation, combined with constraint-aware architectural synthesis, is crucial in handling stochastic driving conditions spectra. This study develops a high-fidelity mathematical plant model of a hydrogen Proton Exchange Membrane (PEM) fuel cell
Mulik, Rakesh VilasraoE, PorpathamSenthilkumar, Arumugam
With the increasing tonnage of electric heavy commercial vehicles, there is a growing demand for higher power and torque-rated traction motors. As motor ratings increase, efficient cooling of the EV powertrain system becomes critical to maintaining optimal performance. Higher heat loads from traction motors and inverters pose significant challenges, necessitating an innovative cooling strategy to enhance system efficiency, sustainability, and reliability. Battery-electric heavy commercial vehicles face substantial cooling challenges due to the high-pressure drop characteristics of conventional traction system cooling architectures. These limitations restrict coolant flow through key powertrain components and the radiator, reducing heat dissipation efficiency and constraining the operating ambient temperature range. Inefficient cooling also leads to increased energy consumption, impacting the overall sustainability of electric mobility solutions. This paper presents a novel approach of
Dixit, SameerPatil, BhushanGhosh, Sandeep
The growing demand for Electric Vehicles (EVs) has highlighted the importance of efficient and accurate simulation tools for design and performance optimization. The architecture of electric vehicles is distinct from that of internal combustion engine vehicles. It consists of on-board charger, DC-DC converter, Lithium ion battery pack, Inverter, electric motor, controllers and transmission. The battery pack supplies electric current to the traction motor, which then converts this electrical energy into mechanical energy, resulting in the rotational motion needed to drive the vehicle. Wide range of Multi-physics is involved in the simulation which involves Power electronics, Electromagnetics, Fluid Mechanics, Thermal engineering. This paper presents an integrated simulation and range prediction methodology for Electric Vehicles (EVs) using the Reduced Order Model (ROM) approach. The methodology includes simulation in both 3D and 1D domain. CFD simulation is performed to understand the
Shandilya, AnandKumar, Vivek
Over the last few years, notable progress has occurred in electric vehicle (EV) technology. Inverters are key components for electric vehicles (EV). Various PWM strategies have been implemented by OEMs over past years. For most of PWM scheme timing calculation & Lengthy algorithm increases complexity. The proposed a novel Pulse Width Modulation (PWM) control technique for generating inverter lag switching times in multi-level inverters. The proposed Space Vector PWM (SVPWM) method eliminates the need for sector and region identification by utilizing sampled values of reference phase voltages, thereby reducing computational efforts and complexities. The scheme can generate N-level PWM signals and offers flexibility to operate with fewer levels, including operation in the overmodulation range. The sampled magnitudes reference phase voltages are converted into timing signals that are subsequently processed by an algorithm to modify modulating signals. These modulating signals are
Bhanabhagvanwala, Prem Kiritkumar
The noise generated by pure electric vehicles (EVs) has become a significant area of research, particularly due to the increasing adoption of electrified propulsion systems aimed at meeting OEM fleet CO₂ reduction targets. Unlike internal combustion engines, which mask many drivetrain noises, EVs expose new challenges due to the quieter operation of electric motors. In this context, the transmission system and gear structures have emerged as primary contributors to noise, vibration, and harshness (NVH) in EVs. The present study provides an NVH study that focuses on the gear whine noise issue that is seen at the vehicle level and cascades to the powertrain level. Comprehensive root cause identification, focusing on the transmission system's structural and dynamic behavior. The research emphasizes modifications to both the gearbox housing and gear structures to reduce noise level, and model validation was all part of the study, which was accompanied by physical test results. Using MBS
Baviskar, ShreyasKamble, PranitGhale, GuruprasadBendre, ParagPrabhakar, ShantanuKunde, SagarThakur, SunilWagh, Sachin
As the electric mobility landscape evolves, there is a growing emphasis on addressing the Noise, Vibration, and Harshness (NVH) challenges associated with electric drivetrains. The absence of an IC engine in EVs shifts the focus to other noise contributors such as gear meshing, electric machine operation, and structural vibrations. Despite the known influence of micro-geometry on gear dynamics, current optimization practices often rely on empirical adjustments or standard guidelines without fully utilizing advanced computational methods to predict and optimize NVH performance. There exists a pressing need for a systematic approach to analyze and optimize gear micro-geometry to reduce noise and vibration in high-speed e-axle applications. This research aims to bridge that gap by investigating the relationship between micro-geometry optimization and NVH characteristics of an e-axle. Through detailed modelling and optimization techniques, this research aims to identify optimal gear micro
Ankit, PriyadarshiKulkarni, KrishnaMomin, Vaseem
Agricultural operations in hilly, uneven & slopy terrains demands high levels of operator focus, effort and skill. However, todays farming ecosystem across the globe is affected by 2 major scenarios: the aging workforce in the agricultural sector and the ever-growing problem of distraction due to mobile device and social media use. These issues compromise safety during operations such as start stop maneuvers, parking on slopes, and maneuvering in confined & narrow areas. Stringent emission norms are also being mandated across developed and developing countries as a measure to reduce Global Greenhouse house gas emissions. These measures are indeed necessary for sustainability but has increased overall tractor purchase and operating costs without improving safety & operator comfort. There has been a trend seen around the world in terms of poor sales post Emission implementation. Registration of Older tractors without these stringent emission norms were also witnessed in Developed
M, RojerT, GanesanP, VelusamyNatarajan, SaravananV, Mathankumartripathi, ShankarNarni, KiranHaldorai, RajanDevakumar, Kiran
Predictive maintenance is critical to improving reliability, safety and operational efficiency of connected vehicles. However, classic supervised learning methods for fault prediction rely heavily on large-scale labeled data of failures, which are difficult to obtain and maintain a manually built dataset of failure events in real automotives settings. In this paper, we present a novel self-supervised anomaly detection model that makes predictions on the faults without the need for labeled failures by using only the operational data when the systems or robots are healthy. The method relies on self-supervised pretext tasks, like masked signal reconstruction and future telemetry prediction, to extract nominal multi-sensor dynamics (i.e., temperature, pressure, current, vibration) while jointly minimizing the deviation between encoded/decoded signals and normal patterns in the latent space. A unsupervised anomaly detection model is then used to detect when the learned patterns are violated
Kumar, PankajDeole, KaushikHivarkar, Umesh
The automotive industry is undergoing a transformational shift with the addition of Virtual ECU in the development of software and validation. The Level 3 Virtual ECU concept will lead to the transformation in the SDLC process, as early detection of defects will have a significant impact on cost and effort reduction. This paper explains the application of a Level 3 virtual ECU which can enable to perform testing in initial period considering the Shift Left Strategy, which will significantly reduce development time. This paper demonstrates various development and validation strategies of virtual ECU and how it can impact project timeline.
Bhopi, AmeySengar, Bhan
Electric vehicle (EV) transmission efficiency is crucial for optimizing energy use and enhancing performance. It minimizes power losses during energy transfer from the motor to the wheels, directly impacting the vehicle's range and battery life. High efficiency ensures smoother acceleration and better driving dynamics, improving the overall user experience. Unlike internal combustion engine (ICE) transmissions, EV transmissions often employ simpler, single-speed systems, reducing complexity and energy loss. Efficient transmissions help reduce energy usage, lower costs, and minimize environmental impact. As a result, transmission efficiency plays a vital role in ensuring the sustainability and reliability of EV designs. This paper proposes a simulation model based methodology to estimate EV transmission efficiency based on modelica models developed on simulation X. A single speed EV model is developed which contains whole transmission layout discretized into simple components which
Sutar, SureshThambala, PrashanthPatel, Hiral
Modern automotive systems are becoming increasingly complex, comprising tightly integrated hardware and software components with varying safety implications. As the demand for ISO 26262 compliance grows, performing efficient and consistent Hazard Analysis and Risk Assessment (HARA) across these layers presents both methodological and practical challenges. Traditional approaches often involve performing HARA for an item (where item maybe a system or a combination of systems), which can lead to update of HARA for every new feature addition in an item, which in turn may lead to analysis of same functions in multiple HARAs leading to inconsistent risk categorization, redundancy, or even conflicting safety goals. Therefore, this paper proposes a unique HARA methodology which consolidates the list of functions from various systems and performs the HARA for the grouped functions (hereby referred to as Cluster HARAs). For example, Electrical power steering, Electric pump powered hydraulic
Somasundaram, ManickamVijayakumar, Melvin
High power and torque density electric motor is finding increasing demands in modern-day electric and hybrid vehicles because of compact and light-weight designs. These high-performance requirements are achieved by increasing the current flow, strengthening the magnetic field as well as downsizing the motor dimensions and hence can lead to multiple failure modes if not designed properly. Higher current flow results in increased magnitude of losses within the motor components such as ohmic loss, iron loss, hysteresis loss and mechanical losses. All these localized losses contribute to higher operating temperature and temperature gradient that can act as a catalyst to several modes of failure. Hence, accurate prediction of temperature distribution across the motor components is very crucial to come up with a robust and durable motor design. A common approach of predicting component temperature is by assuming bulk losses for lamination stack, hairpin and magnets. This approach might be
Munshi, Irshad AhmedElango, GokulKarmakar, NilankanPrasad, Praveen
Born Electric SUVs is gaining immense popularity due to enhanced ride and handling characteristics, advanced tech features elevating both performance and customer experience to an elite standard. Due to the platform constraints, the vehicle adopts a Front Wheel Drive (FWD) layout with a rear twist beam configuration, housing the electric motor at the front to deliver drive torque directly to the front wheels. Torque steer is a phenomenon often found in FWD cars, which is unsettling to driver where the steering wheel could be pulled hard to one side when there is aggressive throttle input potentially leading to deviation of the vehicle from its desired path. In contrast to internal combustion engines (ICEs), electric motors provide an instantaneous torque, something that can worsen torque steer if not well addressed. However, torque steer remains a key concern, with high torque output of electric motors especially for a front wheel drive vehicle. This paper introduces a methodology to
Prabhakara Rao, VageeshWankhade, KrishnaThakur, PragyeshRasal, ShraddheshAsthana, Shivam
The transition to electric vehicles (EVs) has brought about significant advancements in automotive technology, with inverters playing a crucial role in converting DC power from the battery to AC power for the electric motor. Ensuring the functional safety of these inverters is paramount, as any failure can have severe implications for vehicle performance and passenger safety. This case study explores the successful implementation of ISO 26262 standards in the development and validation of EV traction inverters. This paper begins by outlining the functional requirements and safety goals specific to EV inverters, followed by a detailed analysis of the potential hazards and risks associated with their operation. Using ISO 26262 as a framework, we describe the systematic approach taken to identify, assess, and mitigate these risks. Key methodologies such as Hazard Analysis and Risk Assessment (HARA), Failure Mode and Effects Analysis (FMEA), and Fault Tree Analysis (FTA) are employed to
Ramachandra, ShwethaV, Sushmitha
In driving, steering serves as the input mechanism to control the vehicle's direction. The driver adjusts the steering input to guide the vehicle along the desired path. During manoeuvres such as parking or U-turns, the steering wheel is often turned fully from lock to lock and then released. It is expected that the steering wheel quickly returns to its original position. Steering returnability is defined as the ratio of the difference between the steering wheel position at lock to lock and the steering wheel angle after 3 seconds of release, to the steering wheel angle at the lock position, under steady-state cornering conditions at 10 km/h. Industry standards dictate that the steering system should achieve 75% returnability under these conditions within 3 seconds. Achieving proper steering returnability characteristics is a critical aspect of vehicle design. Vehicles equipped with Electric Power-Assisted Steering (EPS) systems can more easily meet returnability targets since the
Singh, Ram Krishnanahire, ManojJAIN, PRIYAVellandi, VikramanSUNDARAM, RAGHUPATHIPaua, Ketan
Electric Vehicles (EV) are embedded with increased software algorithms coupled with several physical systems. It demands the efficacy of components which are linked together to build a system. The digital models reviewed in this paper are at system-level and full vehicle-level, comprising many components and control design, analysis, and optimization. Systems pertaining to each functionality such as, A/C (Air Conditioning) loop, E-Powertrain (Electric Powertrain), HEVC (Hybrid Electric Vehicle Controller), Cooling system, Battery Management System (BMS), Vehicle control system etc. together make an ‘Integrated Digital Vehicle.’ Fidelity of Intersystem co-simulation [AMESIM + SIMULINK] is key to validating thermal and energy strategies. This paper elucidates the correlation of Digital Vehicle compared to Test for Thermal Strategy in different driving scenarios and Energy management. Validation of Digital vehicle with 52kWh, 40kWh High Voltage Battery for Intercity Travel of Customer
Sarapalli Ramachandran, RaghuveeranSrinivasan, RangarajanSaravanan, VivekDutta, SouhamPichon, MartinLeclerc, CedricGuemene, Alexis-Scott
With growing significance of electric vehicles (EVs), their powertrains – while naturally quieter than internal combustion engine (ICE) powertrains – pose new NVH (Noise, Vibration, Harshness) challenges. These are triggered mainly from high-frequency disturbances caused by electric motors and gear interactions. Isolation of such excitations is essential for securing cabin refinement and customer expectations for acoustic comfort. This paper offers a simulation-based approach to optimal placement of the electric drive unit (EDU), which houses the electric motor and gearbox, with the objective of reducing vibration transfer to the chassis of the vehicle. The methodology explores the effect of spatial mount repositioning under actual dynamic load conditions through multibody dynamics (MBD) modeling and integrated optimizer using advanced multibody dynamics simulation software – Virtual Dynamics. The suggested workflow helps in effective investigation of mount positioning within packaging
Shah, SwapnilMane, PrashantBack, ArthurEmran, Ashraf
As the brain and the core of the electric powertrain, the traction inverter is an essential part of electric vehicles (EVs). It controls the power conversion from DC to AC between the electric motor and the high-voltage battery to enable effective propulsion and regenerative braking. Strong and scalable inverter testing solutions are becoming more essential as EV adoption rises, particularly in developing nations like India. In India, traditional testing techniques that use actual batteries and e-motors present several difficulties, such as significant safety hazards, inadequate infrastructure, expensive battery prices, and a shortage of prototype-grade parts. This paper presents a comprehensive approach for traction inverter validation using the AVL Inverter TS™ system incorporating an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology. It enables safe, efficient, and reliable testing eradicating the need for actual batteries or mechanical
Mehrotra, SoumyaChhabra, Rishabh
This paper elucidates the implementation of software-controlled synchronous rectification and dead time configuration for bi-directional controlled DC motors. These motors are extensively utilized in applications such as robotics and automotive systems to prolong their operational lifespan. Synchronous rectification mitigates large current spikes in the H-bridge, reducing conduction losses and improving efficiency [1]. Dead time configuration prevents shoot-through conditions, enhancing motor efficiency and longevity. Experimental results demonstrate significant improvements in motor performance, including reduced thermal stress, decreased power consumption, and increased reliability [2]. The reduction in power consumption helps to minimize thermal stress, thereby enhancing the overall efficiency and longevity of the motor.
Patil, VinodKulkarni, MalharSoni, Asheesh Kumar
The technology in the automotive industry is evolving rapidly in recent times. An electric vehicle is a complex and dynamic system consisting of numerous components interacting with each other. With increase in number of EVs on Indian roads, EV makers to produce innovative and pragmatic concept of electric vehicle features. This electrification in automobile has brought new dimension to Electro Magnetic Compatibility (EMC). Considering all these, EMC Testing of all power train components with real case scenarios is utmost important. This paper will put a light on applicability of various EMC tests for EV components like Traction Battery, Traction Motor and Inverter, DC to DC Converter, 3 in 1 Unit, 4 in Unit, BTMS unit, HVAC system, On Board Charger etc. With ICE vehicles, all components were connected to only 12V battery but with the EV era, Components are getting connected to HV battery or LV battery or sometimes both. With this change, all ISO and CISPR standards were undergone with
Yeola, MayurMulay, Abhijit BSwaminathan, Ganeshan
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