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ARMEVA Project – From vehicle

requirements to electric motor assessment

Rémi Mongellaz – Siemens Industry Software SAS

Frei verwendbar © Siemens AG 2017

2017-10-17 Siemens PLM Software

ARMEVA Project overview –

Introduction

Punch Powertrain N.V. Belgium

Siemens SISW Belgium

Technische Universiteit

EindhovenNetherlands

Prodrive B.V. Netherlands

TeKshift GmbH Germany

Universitatea Tehnica din

Cluj-NapocaRomania

Siemens SISW France

Purpose: develop a new rare-earth-material free

generation of advanced reluctance motors




Electric motor studied

• Motor class studied: Reluctance Motors

• Advantages:

• magnet-free

• high efficiency

• high power density

• low manufacturing costs

• Drawbacks:

• NVH due to radial forces

• torque ripple

• complexity of control

• Three different types of motors are designedSRM DCEFSMSynchRM




Description of work

• WP1: Determine the motor requirements and high level specifications starting from vehicle requirements

and operational conditions for typical EV passenger cars.

• WP2: Comparative assessment of the different types of reluctance motors, and different reluctance based

motor concepts.

• WP3: Realization of the specified motor design. Mechanical, electrical and thermal design suitable for

production of the motor and definition of the necessary dismantling process.

• WP4: The development of the power electronics for reluctance motor control including:

• packaging and cooling of the power electronics;

• control software for the control of the power electronics and motor.

• WP5: Test the actual performance of the complete electric drive system on test bench level and vehicle

level.



Vehicle

Requirements

Motor

Specifications

3 Motor Designs

Assessment of

3 Motors

Workflow of the ARMEVA Project



From vehicle requirements to motor specifications –

2 vehicles: EV and PHEV, 3 architectures

LMS

Imagine.Lab

Amesim

• 3 vehicle

architectures:

• PHEV

• EV

• EV2Gr




LMS Amesim sketch – Multiphysic model of EV

Quasi-static model

of battery

Driver

Vehicle Control Unit Longitudinal

model of vehicle

Reducer

Tabulated model

of motor reading

loss map




Link between vehicle performance requirements and motor parameters




Motor sizing – Step 1: Design of exploration

Test: acceleration 80 to 120 km/hTest: acceleration 0 to 50 km/h

• Design of exploration on motor

parameters to match requirements

DOE on gradeability test




Motor sizing – Step 2: Adding a gearbox

𝑇𝑤ℎ𝑒𝑒𝑙[N.m]

𝜔𝑤ℎ𝑒𝑒𝑙[rpm]

𝑇𝑚𝑜𝑡𝑜𝑟[N.m]

𝜔𝑚𝑜𝑡𝑜𝑟 [rpm]

Gearbox ratios

constraints



Operation

points

Operation

points with GB


Gearbox shift strategy implementation

Gearshift

strategy

• Gearbox strategy by Punch

Powertrain

• Optimization of:

• Efficiency

• Comfort

• Performance

• Implemented in Statechart • 3 to 4% of efficiency growth

expected



Tmotor[N.m]

ωmotor[rpm]


Output given to the motor designers

Vehicle

Requirements

Motor

Specifications

3 Motor Designs

Assessment of

3 Motors

• Gr:

• PHEV: 11.25

• EV: 15.6

• EV2Gr: 14 and 7



Vehicle

Requirements

Motor

Specifications

3 Motor Designs

Assessment of

3 Motors

Workflow of the ARMEVA Project



From motors designs to assessment –

Efficiency maps from the motor designers

SRM

DCEFSM

SynchRM




Motors assessments – Evaluation on drive cycles

NEDC WLTC Cl3

MOLAGB10 (from Punch) Fleet (from Punch)

• Evaluation on drive cycles

• 2 tests:

• Thermal (ok / not ok)

• Efficiency (grades)≈ 46’000 km




Thermal model of motor – LMS Amesim sketch updated

• Geometrical equivalent

approach

• Forced cooling

• Tabulated motor:

• Multiple loss maps read

(here iron and copper)

• Temperature dependency




Thermal tests on drive cycles

Temperature in coil during

3 WLTC drive cycles

• Not 1 but 2 loss maps per motor:

for copper and iron

Iron

losses

Copper

losses

• Test with 40 s peak and

drive cycles

• Temperatures below 180°for the

3 vehicle architectures with the 3

motors

Thermal test passed




Efficiency test on drive cycles

• Efficiency = Emecha

Eelec

• Simulations: efficiency of 3 motors × 3 EV architectures × 4 drive cycles

• Grade calculation: average with same weight factors for all vehicles and drive cycles

SRM DCEFSM SynchRM

#3 #2 #1

Efficiency grades – Results




Final assessment and next steps of the project

• Final assessment:

• Remaining tasks:

• Detailed acoustic analysis and optimization of the entire motor and invertor design.

• Design and realization of power electronics hardware

• Optimization of the thermal design and cooling system of the machine

• Development of the control software

• Prototype production, measurements, vehicle integration

• LMS Amesim models available and ready to be improved / tested / compared

SRM DCEFSM SynchRM

#1 #3 #2

Motor which will be built




Conclusion – LMS Imagine.Lab Amesim use in ARMEVA

• Motor

specifications

Vehicle

Requirements

Motor

Specifications

3 Motor Designs

Assessment of

3 Motors

Inp

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• Comparison

of efficiency

of motors

• Motors loss maps

• Vehicle

parameters

and

requirements

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