University of Tennessee, Knoxville TRACE: Tennessee Research and Creative Exchange Masters Theses Graduate School 8-2006 Vector Control and Experimental Evaluation of Permanent Magnet Synchronous Motors for HEVs Timothy Adam Burress University of Tennessee - Knoxville Follow this and additional works at: https://trace.tennessee.edu/utk_gradthes Part of the Electrical and Computer Engineering Commons Recommended Citation Burress, Timothy Adam, "Vector Control and Experimental Evaluation of Permanent Magnet Synchronous Motors for HEVs. " Master's Thesis, University of Tennessee, 2006. https://trace.tennessee.edu/utk_gradthes/1517 This Thesis is brought to you for free and open access by the Graduate School at TRACE: Tennessee Research and Creative Exchange. It has been accepted for inclusion in Masters Theses by an authorized administrator of TRACE: Tennessee Research and Creative Exchange. For more information, please contact [email protected]. To the Graduate Council: I am submitting herewith a thesis written by Timothy Adam Burress entitled "Vector Control and Experimental Evaluation of Permanent Magnet Synchronous Motors for HEVs." I have examined the final electronic copy of this thesis for form and content and recommend that it be accepted in partial fulfillment of the equirr ements for the degree of Master of Science, with a major in Electrical Engineering. Leon Tolbert, Major Professor We have read this thesis and recommend its acceptance: Jack Lawler, Fangxing Li Accepted for the Council: Carolyn R. Hodges Vice Provost and Dean of the Graduate School (Original signatures are on file with official studentecor r ds.) To the Graduate Council: I am submitting herewith a thesis written by Timothy Adam Burress entitled “Vector Control and Experimental Evaluation of Permanent Magnet Synchronous Motors for HEVs.” I have examined the final electronic copy of this thesis for form and content and recommend that it be accepted in partial fulfillment of the requirements for the degree of Master of Science, with a major in Electrical Engineering. Leon Tolbert Major Professor We have read this thesis and recommend its acceptance: Jack Lawler Fangxing Li Accepted for the Council: Anne Mayhew Vice Chancellor and Dean of Graduate Studies (Original signatures are on file with official student records.) Vector Control and Experimental Evaluation of Permanent Magnet Synchronous Motors for HEVs A Thesis Presented For the Master of Science Degree The University of Tennessee, Knoxville Timothy Adam Burress August 2006 Copyright © by Timothy A. Burress All Rights Reserved ii Dedication In Memory of Chris Tolbert iii Acknowledgements Many people contributed in addition to my efforts to help complete this thesis. I especially want to thank Dr. Leon Tolbert for his efforts in providing assistance and knowledge to a vast amount of students, and without him, I would not have made developments herein. The knowledge and experience of Dr. John Chiasson, Dr. Jack Lawler, John McKeever, Pedro Otuday, Dr. Milton Bailey, Dr. Burak Ozpineci, Dr. John Hsu, and George Ott was essential in helping me to understand concepts related to motor modeling, system control, and implementation. I need to thank Curt Ayers, Chester Coomer, and Cliff White for their ability to handle numerous questions and responsibilities while maintaining an enjoyable attitude. I would also like to thank Don Adams, Laura Marlino, Kathy Gambrell, Mitch Olszewski, Pam Olszewski, and especially Bob Staunton, whom I have worked closely with on this project. Those mentioned above and many other folks at the NTRC make work much more pleasant through simple conversations and acquaintanceships. I must also thank my parents, brothers, sisters, and friends for their prayers and support throughout the years. iv Abstract The 2004 Toyota Prius exceeded sales expectations and led the automotive industry to realize that there is a healthy market for hybrid electric vehicles (HEVs). The Prius uses two interior permanent magnet motors to manipulate power flow throughout the drive system. Permanent magnet synchronous motors (PMSMs) are most suitable for HEVs and full electric vehicles due to their high efficiency, high power density, and fast dynamic response. This thesis will present vector control theory for PMSMs, with focus on interior permanent magnet motors. The primary 50kW drive motor and inverter of the 2004 Toyota Prius Synergy drive system was removed for an intensive thermal, electrical, and mechanical evaluation in a dynamometer test cell at Oak Ridge National Laboratory. These evaluations include locked rotor, back-EMF, and motoring operation region tests. The resulting data is presented to reveal characteristics such as torque capabilities, thermal limitations, and motor efficiencies for all toque-speed operation points. One of the most challenging tasks of the evaluation was to solve problems related to electromagnetic interference (EMI). The pulse width modulation (PWM) driven high voltage converter/inverter is a large source of electromagnetic field radiation and nearby low level signals, including control circuitry for the hybrid system, will experience EMI if proper countermeasures are not taken. Methods to reduce electromagnetic field radiation and practices to prevent EMI are discussed. v Table of Contents Chapter 1 ........................................................................................................1 Introduction ................................................................................................1 1.1 Advantages of HEVs............................................................................................ 2 1.2 Disadvantages of HEVs ....................................................................................... 6 1.3 System Efficiencies.............................................................................................. 7 1.4 Thesis Outline .................................................................................................... 11 1.5 Chapter Outlines ................................................................................................ 11 Chapter 2 ......................................................................................................12 HEV Drive Systems..................................................................................12 2.1 The 2004 Toyota Prius Synergy Drive System.................................................. 13 2.2 Variable DC Bus Voltage Using Boost Converter............................................. 20 2.3 Summary ............................................................................................................ 22 Chapter 3 ......................................................................................................23 Modeling and Control of PM Motors.....................................................23 3.1 PM Machine Classifications .............................................................................. 24 3.2 A Three-Phase Model of the Non-Salient PM Machine.................................... 30 3.3 The d-q Transformation ..................................................................................... 35 3.4 A d-q Model of the Non-Salient PM Machine................................................... 39 3.5 A d-q Model of the Salient PM Machine........................................................... 44 3.6 Field Oriented Control of the Salient PM Machine........................................... 48 3.7 Summary ............................................................................................................ 59 Chapter 4 ......................................................................................................60 Experimental Evaluation.........................................................................60 4.1 Experimental Setup............................................................................................ 60 4.1.1 Parameter Identification and Impact of Ideal Assumptions ..............................61 4.1.2 Controller Implementation ................................................................................64 4.1.3 Causes and Countermeasures of EMI................................................................68 4.1.4 Laboratory Setup ...............................................................................................69 4.2 Experimental Results ......................................................................................... 72 4.2.1 Back-EMF Test Results.....................................................................................73 4.2.2 Locked Rotor Tests............................................................................................74 4.2.3 Boost Converter Efficiency Tests......................................................................77 4.2.4 Motor and Inverter Efficiency Mappings ..........................................................78 4.3 Summary ............................................................................................................ 83 vi Chapter 5 ......................................................................................................85 Conclusion and Future Work .................................................................85 5.1 Conclusion ......................................................................................................... 85 5.2 Future Work ....................................................................................................... 89 List of References.........................................................................................90